The answer is both yes and no.
In some cases, a slightly imperfect mortise can still accommodate a correctly cut tenon if the misalignment is minimal. Mild irregularities, such as slight sloping or a slightly oversized cavity, may not impact the ability of the joint to function properly. In such cases, glue or other adhesives can fill the small gaps, ensuring a reasonably strong joint.
However, if the mortise is severely misshapen or has significant inaccuracies, it is unlikely that a correctly cut tenon will fit properly. Large gaps, irregular shapes, or misalignment can compromise the structural integrity of the joint, resulting in a weak connection.
Addressing a badly shaped mortise
If you find yourself facing a badly shaped mortise, here are a few potential solutions:
- Adjust the tenon: Instead of recutting the mortise, you can modify the tenon to better fit the existing cavity. This can be done by paring down the sides, adjusting the thickness, or reshaping the tenon to match the mortise.
- Fill gaps with adhesive: If the misalignment is minimal, you can use wood glue or epoxy to fill the gaps between the mortise and tenon. Apply the adhesive generously and clamp the joint until the glue sets to create a strong bond.
- Refashion the mortise: In some cases, it may be necessary to recut or reshape the mortise to ensure a proper fit. This can be achieved by using chisels, routers, or other appropriate tools to remove excess material, square the cavity, or correct any irregularities.
A badly shaped mortise is unlikely to provide a perfect fit for a correctly cut tenon. While minor irregularities can be compensated for with adhesives or adjustments, significant misalignments or inaccuracies can compromise the integrity of the joint. It is essential to ensure precise workmanship when creating a mortise and tenon joint to achieve a strong, durable connection in woodworking projects.