I second Peter's idea of the mortising chisel, especially if you don't
need to go the full depth of the slot. Another option is a
reciprocating saw with a blade that will not bottom out in the hole. If
you want more control and a slower cut, use a pruning saw. Then use a
file to smooth the edge. Put some tape on the side edges of the file so
only the side will cut so the slot stays looking nice.
Brian
On 11/24/2011 9:33 AM, Peter J. Thomas wrote:
> On 11/24/2011 10:19 AM, eric at megageek.com wrote:
>> I'm not sure if a wood working question is appropriate here, so let me
>> know if I'm stepping outside the allowed content.
>>
>> I'm sure someone here has an answer however.
>>
>> OK, I have a nice knife block with knife set. One of the knives was
>> replaced with a better one. The problem is that the new knife
>> doesn't fit
>> in the slot on the block.
>>
>> Does anyone know how to cut/expand one of those slots in a block of
>> wood.
>> I need to go about 7" deep?
>>
>> Failing any other solution, I was thinking of cutting the block in half
>> with a bandsaw, routing the slot, then gluing it together. This is
>> not my
>> first choice however.
>>
>> Thanks guys and have a happy thanksgiving!
> Your approach is probably the easiest and the way the block was made
> in the first place. Only issue I see it the kerf of the saw blade
> will make the block narrower; don't know if this is an issue for you.
>
> Only other approach is to use a mortising chisel. Not the power
> mortising kind that like a drill press, but the old fashioned hammer
> and chisel.
> http://www.highlandwoodworking.com/sorby18sashmortisechisel.aspx
>
> 1/8 inch is the narrowest I've seen. That might be too thick? If you
> have a piece of bar stock the right thickness and a bench grinder you
> could make your own. Grind a 45 degree bevel on the end and sharpen
> with oil stones or emery cloth. A mortising chisel is different form
> other chisels. If you lay the mortising chisel down the bevel is on
> the right or left side, not parallel to the table like other chisels.
> The idea is to widen the slot a fraction of an inch at a time by
> pounding the chisel in. You can also deepen the slot with this kind
> of chisel.
>
> Peter T.
>>
>> Eric P
>> "Be as beneficent as the sun or the sea, but if your rights as a
>> rational
>> being are trenched on, die on the first inch of your territory." Ralph
>> Waldo Emerson
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