[Shawn C]

Awesome, Bill! Love the tutorial, and clever ideas on doing the inlay. Do you ever install ferrels at the bottom, or do you keep it open for cutting to length options?

 

[Shawn C]

Personally, I would rasp, file and then sand it to shape, but something like this may work:

http://www.woodcraft.com/product/2061600/22016/lumberjack-tools-industrial-tenon-cutters-60-degree-2.

 

[Shawn C]

Bill's right; I forgot to mention the epoxy. That is actually what I typically do. I sometimes use copper conversion fittings.