Help me fix my screw up!!

[myxpykalix]

Ok here is what i did. David Bushbaum helped me with the dogbone boxjoint and all i did was delete the flat lines from the sides and inserted the boxjoint.
I cut it with a .25 endmill. The wings are just a hair under .50 in length HOWEVER the material is .75 thick so it isn't going to fit with a proper boxjoint. One side will be .25 too shallow.
I have not cut the side pieces yet so my thought was rather than cut them like the sides of the back piece was to take and just cut corresponding pockets that the wings would fit into only i'm not sure if this is the best thing or how to manually place the pockets.

As i was wtriting another thought occurred to me was to make a .25 deep dado along the edge of the side pieces then cut the corresponding piece as normal?

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[beacon14]

The 1/4" dado should work, or I can stretch the joint to 3/4" deep if you want to re-cut the part.

BTW I have no problem with you sharing the file if you want.

[myxpykalix]

hello David,

I cut this in a $40 piece of plywood so i don't want to recut it. As I have thought about it, it seems to me the easiest solution would be to cut the side pieces and the corresponding wings then draw a box around the wings and do a pocket creating a dado and shaving it down .25".
That then lets the joint fit correctly and i only lose .25 on each side but the way its built does not impact on that.
I just wanted to make sure there was not something else i had not foreseen that would be a problem if i did it that way.


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[magic]

4 other longshots for ideas

1. Recut the wood unless you don't you have any extra?

2. Is there another shop near you that has a scrap piece?

3. If you're painting the finished piece, Bondo the mistake and recut.

4. go back to where you purchased the wood and see if they have a scrap piece.

Hope one of those helps.