Repairing a Broken Tenon

This posed something of a problem: what do you do when a pinned tenon breaks? The joint was too broken just to glue, neither surface was flat, and the dowels were in the way. In the end I decided to dowel it with three dowls, to leave as much of the broken tenon intact as possible. Dowled joints are easy on flat, square workpeices. On jagged tapering workpeices, now… With a quarter-inch chisel I cut flats to mark on and marked the three holes on both mortice and tenon. Then I made a jig to make drilling square a bit easier. This wood—generic African hardwood—is like fibreboard. The lip and spur bit just spun on the surface:

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Then the mortice was drilled out on the pillar drill, drilling the two top holes, pinning the jig in place, and using it to drill the bottom, as that landed on so much jagged break:

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Top hole is a little close for comfort. Reassamble the other legs first, so the chair can pull itself square:

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And then ‘walk’ it in with a clamp (don’t whack it in with a mallet). All told, not too bad:

It’s not given out yet this week…