Author: clarnibass
Date: 2019-03-14 07:14
>> Is one method better than another? <<
Yes, an overlap joint is better. A butt joint can be ok but is weaker, there can be a slighty "sharp" edge that can more easily peel and there's a chance that it will leak.
There is no reason to do a butt joint other than to save time.
>> Do you do something like 45 degree clean cut or bevel it for 4-6 mm? <<
It's not very important. I use a little less than 45 degrees usually (or more, depending on how you look at it). Probably ending with about a +/-3.5mm overlap (from memory... just guesstimating... didn't even look at one to check).
>> I have 1/16 and 3/32 corks. Should I use the 1/16 and shave it down? <<
What do you mean? If you use 3/32" you'd need to save/sand even more.
Measure the old cork for a rough estimate of the feel of that thickness (considering it's compressed).
What I usually do is measure the socket and the tenon, subtract the tenon from the former, then divide by 2. This gives you the gap between the socket diameter and tenon diameter. Then I know what thickness cork to use based on that (just experience). This can also depend on the type of tenon (flat, thin grooves, thick grooves, waves).
The most common thicknesses are 1.2mm (3/64") and 1.6mm (1/16"). It's about half and half, so gambling and just choosing the 1.2mm might end up too thin. Using 1.6mm might mean a lot of unnecessary sanding you could have saved by using 1.2mm, but at least you won't need to redo it. Very occasionally corks need to be thinner or thicker than those.
The bell tenon specifically more often needs 1.2mm. It is longer and doesn't need the stability of the other tenons.
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