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A quick word, in passing, to acknowledge the carpenter's Butt Joint.
This is most likely responsible for the vast majority of garden gates
in existence today. Fastened with nails or screws, we have an
assembly that is also often accompanied by a wood, or cable, diagonal
brace in a struggling effort to forestall the certainy of gravity.
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The Half-Lap joint. Early on, more or less still in test mode,
our gates utilized this joint on all gates, illustrated thoroughly
in an article for Fine Homebuilding magazine. But
we came to realize the limitations of the half-lap.
Advantages:
1) A fairly simple joint to fabricate, providing a large mating area,
or what might be called the 'glue-mass.'
Disadvantages
1) Wood breathes with the seasons. The red arrows indicates
in what direction the wood will breath, expanding and contracting in
wet and dry weather. This breathing occurs perpendicular to the
direction of the wood grain. The stile, which is the vertical stock
of the gate, breathes left and right, or horizontally. This is
why there is a 3/8" clearance configured between the net width
of you gate and the post or jamb. Now . . .the rails, which are
the horizontal stock between the stiles, is going to breath vertically,
or perpendicular to the horizontal rail. In direct contrast to
the stile's movement.
------In furniture design, this is a principle that cannot be slighted,
as the result can often lead to a tug of war that results in one of
the two members suffering the severe damage of checks and fissures.
Why? Because one of the two members is trying desperately to simply
breath, which is it's organic right, and yet it is being held in check
by the half-lap of the corresponding member. The result, again,
is stress. Stress is bad. Stress is at the root of not only
schizophrenia and paranoia and a whole bevy of nervous disorders, but
it can also result in this half-lap joint opening, loosening, and the
opposing member checking and cracking just as a seemingly sane soul
begins to slip from sanity.
2) The second issue that arises with the half-lap joint is how
the top of the joint is essentially exposed to the rainfall. This
in itself is not the most favorable scenario in that a golden rule in
exterior carpentry and woodwork is to avoid allowing end-grain to ever
be exposed to the vertical fall of the weather, such as rain and snow
and the heat of sunlight.
3) The third issue is that the top of the exposed half-lap joint
has nothing to thwart it's placement beyond the strength of the adhesives.
As we see in the far right illustration, above, is how once the joint
opens from the exposure to direct weather, then checks and cracks from
the opposing grain directions, the rail begins to crack and check under
the stress and drops, or sags, with nothing to prevent the lure of
a beckoning gravity.
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We
next turn to the Through Tenon. Here we double the glue mass,
or mating surface, by having each side of the tenon, or male segment,
mating to the inside surfaces of the milled stile. Double glue
mass is good. Particularly when assuming the adhesives are
determined with a good sense of separating the hierarchy of the
available choices in today's exterior glues.
Advantages:
1) Double the mating surface--an improvement over the half-lap.
2) Easy to fabricate.
Disadvantages:
1) We have already covered the issues with grain direction and
seasonal breathing, and this joint is not exempt from the faults discussed
in the above example. Like furniture-making, dimensional changes
are not pervasive, but if you are in the business of creating high-end
work, you avoid techniques that allow even the slightest margin of
error. The Through Tenon joint is the sort of joint
you'll see from carpenters and cabinetmaker who have not met the rigors
of a proper woodworker's apprenticeship.
2) We have also covered the issue of nothing between the top
of the two joint seams and the falling weather.
3) And finally, the right side illustration resulting in our gate giving
way, once again, to the madness of gravity. The Through
Tenon has no top shoulder, which is a major component
of a joint that weighs against the omnipresence of gravity.
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The traditional furnituremaker's Blind Mortise and Tenon joint. Here
we have a male tenon milled from the same stock of the horizontal
rail.
The tenon consequently mates to a corresponding mortise milled into
the vertical stile. Assuming a good tight fit has been fabricated,
this is a reliable and long-standing favorite among woodworkers and
furniture-makers, as well as traditional timber frame homes.
Advantages:
1) The top of the joint is concealed from the falling weather.
2) The top of the joint has what we call a 'shoulder' above
the tenon, preventing, by a matter of simple physics, the tenon
dropping to the ravages of gravity.
3) No exposed joints or wood seams. If you're going to expose
a joint, be sure it's a world-class joint.
Disadvantages:
1) We are still wrestling with the issue of breathing in opposing
directions. Not so dramatically as our first two examples, but
nevertheless we have a tenon that is an extension of the horizontal
rail and this tenon is going to expand and contract in a direction
that is perpendicular to that of the stile. To many who have
not lived and breathed wood principles since childhood, this is dealt
with by a shrug and a raised eyebrow. It is relative, in that
there are trades, and then crafts, and them artistry. The tolerances
tighten with each hierarchy, and the graduations from one to another
does not come overnight, nor without proper tutelage.
3) The strength of our joint between the rail and the stile is
now resting solely on the properties of the tenon, which may commonly
be redwood or cedar.
These are not exactly species exhibiting dense properties.
It is conceivable that the tenon could break, or snap.
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The CPW joint is not illustrated. It might be as
simple as bands of single and two-sided high-strength band-aids with
colorful little actions figures, or as schematically advanced
as one of the examples shown below. Whatever our methods,
they were learned from Grandpa, furthered by Dad, and then Charles,
and now Ben, who at 20 is in his 12 year of apprenticeship.
Prior to CPW's development in 1992, there was virtually no joined
exterior assemblies. Workmanship consisted of applied layers
screwed together, or notched and screwed. The build-up effect
existed in everything from Wood Gate to Pergolas to Garden Benches
and tables. When Charles turned his attention to this, and in particular
the Gate, it was 2-1/2 years in development before arriving at the breakthrough
that would stand up to the test of time and usage. The seemingly inconsequential
developments that determined both the functional integrity as well as a
longevity that will outlive us all.
The difference, beyond the aesthetics of a trained and practiced eye
for subtle design, is a Garden Gate that lasts, well . . .that lasts
a few decades beyond the product of a lesser trained, less patient
approach.
These methods and techniques have traveled from the Gate
to become utilized within the full suite of CPW products born from
the efforts to develop and hone the inherent drive to innovate.
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Because Charles has written a number of articles
over the years on the art of joinery for such publications as Fine
Woodworking, Fine Homebuilding, Old House Journal, This Old House,
and Woodwork Magazine, among others, it seems only appropriate to
carry our discussion a step further, skipping ahead to a few advanced
examples in an effort to illustrate not just the sheer perplexity
of this procedure, But the alluring
temptation of the joint as a work of art in itself.
Below is a look at an interlocking dovetail with stepped haunches,
or shoulders. A spline, essentially, that might, to the layman,
more closely resemble a Rubic's schematic but to the careful and discerning
woodworker, it becomes closer to performance art.
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Below, a look at the glue-less joint, where the interlocking planes
and wedges are such that the joint is self sustaining. The
example here is often utilized in Japanese temples for joining
the rafter tails to cross-beams. Take notice of this on your
next trip to a Japanese Tea Garden. Perhaps this is what
CPW uses. It's an extraordinnry joint, relying soley on the
execution of Jointer's steady hand and without the aid of glues
and sticky stuff.

And then, below, an assortment of variations on the traditional mortise
and tenon.

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