>I forgot to mention, You first cut off the old knuckle flush with a bandsaw >leaving the old core in place. Maybe that was obvious. > >David Love >davidlovepianos@earthlink.net Actually, David, this is the part of the process I don't get. I can't imagine that you can get a nice clean cut up to the shank with a bandsaw. I would think that most of the time you'd be leaving a little bit of knuckle and core or you'd be taking off a little bit of shank. Maybe I just have a ham-handed bandsaw technique. I'd be more inclined to cut the knuckles off on the bandsaw deliberately leaving a little bit of knuckle and core. And then use your jig first to run the shank over a dado bit (wider than the knuckle diameter) on the router to clean them up (I also wonder if you couldn't just do this to begin with, and skip the bandsaw step - sounds a little scary - might be worth a try though). Then use your jig as described. Phil Ford
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