Joining Scrap Balsa

[hsilio]

I just received approximately 1 cubic yard of 3/4x7"x8" finished balsa. I would like to incorporate these into a current project I am working on, a wooden, chambered surfboard. I would like to join these blocks to create 3/4" x7"x 8' planks. I am thinking of using my table saw and cutting tenons and mortises. The only problem I have with the that method is the open ends on the mortise will give a weaker joint. I am thinking quite possibly create the tenons on the table saw and then set up a jig with stops on the router table for a mortise to solve the open end issue. Any thoughts on a faster and or stronger method?

[JohnT.]

You're gonna be fiberglassing the board in the end, I assume? If so, it'll be more than strong enough. Having a good glue joint in endgrain balsa is a must too.

John

[Bridger]

if you're going to glass the board, wouldn't the balsa be more or less nonstructural filler in any case?

look into scarf joints.

[hsilio]

You're right. And not to mention I will be staggering the planks

Thought about it, but the waste would be more than tenoning. What I did consider was finger jointing, but the cost of the blades is more than I am willing to accept for this project.

[Wood Butcher]

That sounds like too much effort to me. How about gluing your blocks together in a running bond pattern

~2/3 the way down) and ripping your desired plank out of this? You'll need to incorporate

1 longitudinal glue line in the plank. This is a lot faster and should be more than strong enuf until you get the glass on it.

Art

[hsilio]

Yep it sure is. And frankly, the only reason I was doing it was because the material was there for free. But after visitng a few other forums, some one suggested I just laminate the wood on it's face. Since I only need about 8" of width by 8' of length, this method prevented the problem I was trying to avoid, weak joints. Thanks, Herb

[Wood Butcher]

Won't that will give you 2X your desired thickness?

[John Crea]

Would instead use a router table and a finger joint bit(s)

John