Thanks, guys. 5" it will be.
I grabbed a quick hour before work this morning to try some mortises in the maple and man... it's a lot tougher than wallwood. Maple is freakin hard.
Check out this slopfest. This scrap piece will look like swiss cheese before I start hacking away at the actual legs.
Looks ok when the pieces are in though.
Pretty dang close to centered. I like how the cross pieces are just a little thinner than the legs. Should look nice when it's together.
I used the drill press to try and get the bulk of the mortise out. Then I tried to rig up my something on my sad table router. And finally just chiseled it out. I'm going to try and make a jig for the handheld router or something to try and make this a cleaner. And to top things off, the new router table will be here by the end of the day and I start vacation tomorrow. That lined up perfectly.
The project is complete and the fair is over. We did go with the ground bark and epoxy. Really happy how it turned out. She got Grand Champion on her project and the piece will be going to Indy to complete there.