2015 08 August Demo – Bow Tie Inlay by Richard Winchester
Butterfly Keys.
Butterfly keys are both artistic and structural and are used to reinforce checks in boards for table tops and other furniture. By making the hand made keys first and then using them as a template insures they fit into the mortice even if the BF is not perfect. Start by choosing a straight grain hardwood of contrasting color. Draw a template out of thin plastic and cut out the shape and then mark the BF board. The length should be less than 3″ to control shrinkage of the BF. The shape I use is from G. Nakashima’s tables. Do not make the ends too wide. The thickness can be 3/8′ or more commonly about 5/8″ to 3/4″, depending on the cracked board. Sometimes a 2nd BF is needed underneath the top BF to reinforce the crack.
The keys are cut on both table saws and bandsaws. All the edges are about 2 1/2 Deg. slope in from the top. They can also be cut with a hand saw. All the edges are cleaned up with a sharp chisel or carefully with a small vertical belt sander. Use the prepared BF as a marker over the cracked board. Use double backed tape to hold in place. With a sharp knife trace the pencil mark slightly on the inside of the line. On the bottom edge of the BF cut off a small amount all around to help the BF to go in the recess with a knife after marking the cracked board. A small router is used to remove the mortice which is about 3/16 to 1/4″ less than the BF’s thickness. Us a 3/16″ straight bit to cut out the waste. Cut out in 2 passes for the deeper recess. Without a plunge router use a 1/4″ Forsner bit to make a starter hole or cut out as much wood as possible with the drill carefully inside the knife cut. Clean out all the wood inside the cut line- vertically. Carefully cut out the corners with a small beveled chisel.
Start to test fit the BF in the hole and then pare the edges of the BF or hole to insure a good fit. Be careful not to stick the BF in the hole and carefully pry it out when testing. Finally, when there is a good fit, almost going all the way to the bottom of the mortice, apply glue all around and hammer in using a scrap board for safety on the top to the BF. After the glue is set plane flush with the top and sand smooth.
Richard Winchester
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