Mini Moravian Bench Build Process

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Well, I think I'm beginning to get an idea of what's going on. I still haven't got my head round why, let alone what to do about it, but at least it's a step in the right direction.

I started by putting a straight edge across the face of the leg and using a small combination square to check the mortices:

They look pretty square to me:

I then put the straight edge flat on the leg and put a digital angle gauge on it. I could then zero the angle gauge so the leg face became a reference:

The straight edge then got shoved in the mortice and I could use the angle gauge to check the angle:

I would consider 89.80° close enough to square!

It then felt like a good idea to try using the real stretchers, so I clamped them to the very end of the bench and again zeroed the angle gauge:

Unfortunately, when I tried to fit the stretchers, they hit the gutter: the leg frames aren't sticking out of the garage enough:

To sort that out, I used one of the pieces that will eventually become the top of the bench to extend the bench out further:

I could then measure the angle on the side of the stretcher:

I don't think anyone could argue with 89.95°!

However, if they're square, why are they wonky?

As another test, I clamped the straight edge to the leg face and used a combination square to check the angle of the stretcher. Bizarrely, it showed the stretcher leaning outwards:

I then had a moment of inspiration and leant the combination square forward so that its rule is parallel with the angled stretcher. Lo and behold...

... that makes it look like its leaning in.

I think I'm suffering from some sort of compound angle complication. I haven't got my head round it, but I thought it would be a good idea to ask Solidworks what it thought the angle between the two faces should be:

If you recall my last post, I said the stretchers were leaning it at about 2°. The CAD model says they should be at 92.14°, so if they're at 90° that would explain the 2° error I think.

I still don't really understand it, but at least things are starting to tally with each other, so that's something.

At the moment, the only thing I can think of to do about it is to open up the mortices (and ruin the lovely finish I got from the router plane). That'll leave a very sloppy mortice, although I could potentially fit some wedges to close the gap up again.

It's time for a commiserating pint of Timothy Taylor's Dark Landlord I think.

I am a hobbyist metalworker and woodworker. I work as an electronic design engineer and spend most of my working days in front of a computer so I enjoy having the opportunity to use my hands and make things in my spare time. I particularly enjoy making tools as I can then use them on other projects. This website showcases some of the things I've made.

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