Wow! Harder than I imagined

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On Sat, 08 Jan 2005 04:05:47 -0500, Silvan

I actually have had pretty fair results "tuning" my box joints with a fine cut metal file.
Tim Douglass
http://www.DouglassClan.com
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Tim Douglass wrote:

I use 10" flat bastard files (more coarse than mill bastard) for knocking corners off things.
It is a trick I picked up from an old timer who did a lot of refacing work.
He would break the sharp edge of a laminate with a file.
HTH
Lew
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So now I have a dilemma:
The new jig is so accurate in terms of dimensions and spacing that the joints are VERY tight and difficult to assemble. The tolerances are so close that there is little, if any, room for glue and they tend to splinter or chip out if I tap too hard on them.
I either have to work all the pins over with an abrasive every time I make a drawer (time consuming), or make the sockets just a hair wider than the pins while assuring that the pins are centered in the openings.
Which is the best approach? Wouldn't the second approach put me back in the realm of accumulated error?

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jig to close the gap doesn't bother me a bit, because I have flexibility of setting throughout.
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Use a piece of paper for a shim on your dado stack and leave everything else alone. That will widen each cut by about .003.
If that is still too snug, use 2 pieces of paper.
--

Roger Shoaf

About the time I had mastered getting the toothpaste back in the tube, then
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