Need to make a mortise, of sorts...

[scooter]

Hello All,

I need to make a slot in a carving, to accept a mating piece. It has to be an inch long, at least an inch deep, and 1/8" wide. Yes, very narrow. The method I was thinking of is to drill a line of 1/8" holes, and then go back with a thin chisel and clean it up as best I could. Another method would be to use a Rotozip, but I hear that they tend to 'skate' (Plus, I'd have to buy one. I'm not adverse to buying another tool but don't want to if it won't do the job.). I don't think a router could be used for it, as the piece is an awkward shape; definitely not flat. I'd like to make this slot as clean as possible, as it's in a prominent place on the carving and is integral to the piece on the whole. Any 'slop' would show.

Who's got the "A-ha!" idea I'm looking for? Anyone?

Thanks in advance!

S~

[jwd]

make an outline of the mortise on the piece with a fine tipped pencil. scribe the outline with a detail knife, then continue deepening the cuts til the needed depth has been reached. it may also be helpful to put a slight bevel on the tenon portion of the insert piece. the center part of the mortise should be easy to remove with a narrow chisel at this point. this method has worked for me quite well in the past. good luck with your project

[Claude]

I'd suggest a router with a 1/8 inch bit and a good fence/guide. I'd cut no more than 1/4 inch deep each pass - maybe less. If you wanted to make sure you didn't exceed the 1/8 width, then I'd use a 3/64 wide router bit, and after it was all done down to the 1 inch depth, use a 1/8 bit to finish the cut.

Claude

[davidinsarasota]

I agree with Claude, as usual, and would add be sure to get a spiral upcut bit. It lifts the sawdust out of the slot.

[brian-bailey]

If it was my carving, I would use jwd's method.