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A quick word, in passing, to acknowledge the carpenter's Butt Joint.
This is most likely responsible for the vast majority of garden gates
in existence today. Fastened with nails or screws, we have an
assembly that is also often accompanied by a wood, or cable, diagonal
brace in a losing effort to forestall the certainy of a sagging assembly.
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The Half-Lap joint. Originally, our gates utilized this joint
on all gates, illustrated thoroughly in an article for Fine Homebuilding
in the Spring of 1997. But in time we came to realize the limitations
of the half-lap.
Advantages:
1) A fairly simple joint to fabricate, providing a large mating area,
or what might be called the 'glue-mass.'
Disadvantages
1) Wood breathes with the seasons. The red arrows indicates
in what direction the wood will breath, expanding and contracting in
wet and dry weather. This breathing occurs perpendicular to the
direction of the wood grain. The stile, which is the vertical stock
of the gate, breathes left and right, or horizontally. This is
why there is a 3/8" clearance configured between the net width
of you gate and the post or jamb. Now . . .the rails, which are
the horizontal stock between the stiles, is going to breath vertically,
or perpendicular to the horizontal rail. In direct contrast to
the stile's movement.
------In furniture design, this is a principle that cannot be slighted,
as the result can often lead to a tug of war that results in one of
the two members suffering the severe damage of checks and fissures.
Why? Because one of the two members is trying desperately to simply
breath, which is it's organic right, and yet it is being held in check
by the half-lap of the corresponding member. The result, again,
is stress. Stress is bad. Stress is at the root of not only
schizophrenia and paranoia and a whole bevy of nervous disorders, but
it can also result in this half-lap joint opening, loosening, and the
opposing member checking and cracking just as a seemingly sane soul
begins to slip from sanity.
2) The second issue that arises with the half-lap joint is how
the top of the joint is essentially exposed to the rainfall. This
in itself is not the most favorable scenario in that a golden rule in
exterior carpentry and woodwork is to avoid allowing end-grain to ever
be exposed to the vertical fall of the weather, such as rain and snow
and the heat of sunlight.
3) The third issue is that the top of the exposed half-lap joint
has nothing to thwart it's placement beyond the strength of the adhesives.
As we see in the far right illustration, above, is how once the joint
opens from the exposure to direct weather, then checks and cracks from
the opposing grain directions, the rail begins to crack and check under
the stress and drops, or sags, with nothing to prevent the lure of
a beckoning gravity.
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We
next turn to the through tenon. Here we double the glue mass,
or mating surface, by having each side of the tenon, or male segment,
mating to the inside surfaces of the milled stile. Double glue
mass is good. Particularly when assuming the adhesives are determined
with a good sense of separating the hierarchy of the available choices
in today's exterior glues.
Advantages:
1) Double the mating surface--an improvement over the half-lap.
Disadvantages:
1) We have already covered the issues with grain direction and
seasonal breathing, and this joint is not exempt from the faults discussed
in the above example.
2) We have also covered the issue of nothing between the top of
the two joint seams and the falling weather.
3) And finally, the right side illustration resulting in our gate giving
way, once again, to the madness of gravity.
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The traditional Blind Mortise and Tenon joint. Here we have a
male tenon milled from the same stock of the horizontal rail.
The tenon consequently mates to a corresponding mortise milled into
the vertical stile. Assuming a good tight fit has been fabricated,
this is a reliable and long-standing favorite among woodworkers and
furniture-makers.
Advantages:
1) The top of the joint is concealed from the falling weather.
2) There is what we call a 'shoulder' above the tenon, preventing,
by a matter of simple physics, from the tenon dropping to the ravages
of gravity.
Disadvantages:
1) We are still wrestling with the issue of breathing in opposing
directions. Not so dramatically as our first two examples, but
nevertheless we have a tenon that is an extension of the horizontal
rail and this tenon is going to expand and contract in a direction that
is perpendicular to that of the stile.
3) The strength of our joint between the rail and the stile is
now resting solely on the properties of the tenon, or western cedar.
Western cedar is not a dense wood, nor particularly suited for the stress
loads of harder woods. It is conceivable that the tenon could
break, or snap.
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For obvious reasons, the CPW joint is not illustrated. It might be as
simple as bands of single and two-sided high-strength band-aids with
colorful little actions figures, or as schematically advanced as one
of the examples shown below. Whatever our methods, the long-term
structural integrity of the gate begins with the joinery.
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Because Charles has written a number of articles over
the years on the art of joinery for such publications as Fine Woodworking,
Fine Homebuilding, Old House Journal, This Old House, and Woodwork Magazine,
among others, it seems only appropriate to carry our discussion a step
further, skipping ahead to a few advanced examples in an effort to illustrate
not just the shere perplexity of this procedure, but the alluring
temptation of the joint as a work of art in itself.
Below is a look at an interlocking dovetail with stepped haunches, or
shoulders. A spline, essentially, that might, to the layman, more
closely resemble aRubic's schematic but to the careful and discerning
woodworker it becomes closer to performance art.
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Below, a look at the glue-less joint, where the interlocking planes
and wedges are such that the joint is self sustaining. The example
here is often utilized in Japanese temples for joining the rafter tails
to cross-beams. Take notice of this on your next trip to a Japanese
Tea Garden.

And then, below, an assortment of variations on the traditional mortise
and tenon.

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