Thanks for the help gentleman. The repair was done by a pro stockmaker. He mortised out a slot under the triggerguard, and accraglassed a piece of walnut about 3/16ths" wide by 1" long and 5/8ths" high between the two pieces. The joint was solid. I think what caused the latest break was the hole drilled thru the wrist for the tang bolt was damn near the thickness of the tenon, and it broke right there.
If I mill the mortise out just under the width of the triggerguard inletting, I can get a slot just under 3/8ths" wide. I am planning on making the mortise about 2.5" long this time. I will take the mortise deep enough so that the there is only about 3/16ths" of wood left above the new tenon at the top of the tang. This should give me a tenon roughly 3/8ths" X 2.5" X1"
I am wondering if I should use a wood tenon, or machine one out of steel, alluminum, or brass to gain more strength. The hole required for the tang bolt is the weak spot. Would using a metal tenon cause any unforseen problems?
Last edited by RGS022; 02/17/09 11:19 PM.