I'm working on some large-scale model railway carriages and need to create a groove in the edge of 1x1/2" wood for windows. The groove has to be 1/16" wide and 1/8" deep, as per my 1909 instructions, which suggest that these parts might have been pre-machined. I don't have access to a table saw or a powered router, so I'm looking for advice on how to achieve this groove with only hand tools. Any suggestions?
3 Answers
You could definitely use a narrow inlay chisel for this! If you're looking at straight cuts, a backsaw might work too. Just check this image to see how it could look! If you don’t have a specialized saw, even stacking a couple of hacksaw blades could help you get that perfect width. A kerning plane would work wonders here as well; it's like an old saw blade fixed in a plane that lets you create those neat kerfs along a reference edge.
For something this thin, using a saw kerf is definitely doable. If you need extra width, stacking some hacksaw blades would give you the needed 1/16". Just make sure to go slow and steady!
I think you should reconsider using a groove for glass because if the glass breaks, you'll have a tough time replacing it without disassembling the wood. Instead, consider using a rabbet joint to hold the glass – it makes replacements much easier. Just a heads-up, a 1/16" kerf might not be suitable for available glass thickness. The thinnest standard window glass is usually 3/32" thick, especially since even back in 1909 glass was generally thicker than 1/16". Go with rabbet joints and use some putty or wooden stops to secure the glass!