Router Tenon Cutting

■ Here's an alternative to cutting stub tenons on a table saw (as shown on page 15). For this method, you'll need a router, a V-f or 3/V'-diameter straight bit. and the shop-built jig shown here, see Fig. 1. And once the jig is built, it can be used to cut longer tenons and half laps. too.

The jig holds the workpiece securely and guides the router for a perfect 90° cut. The stop block assures that the tenon's shoulders are properly aligned. advantages. One advantage to using this jig is your router will cut a much smoother tenon than your saw or dado blade. This will make fitting and assembling the joints easier. Another advantage is that the straight bit will cut square shoulders, so you're assured of a tight fit.

making the jig. I built the jig to cut tenons on V4 "-thick stock. (Note: This is one of the limitations of the jig. To cut tenons on thicker or thinner stock, you'd have to make a new jig. or replace the fence and slop block.)

The jig is made up of four pieces: a base of W plywood, a fence, a hold-down arm. and a stop block, all made from W-thick stock, see Fig. 1.

To build the jig, start by screwing the fence to the base, see Fig. 1. Then, cut the 3"-wide hold-down arm to length.

Next, clamp the arm 8" from the end of the jig so it's square to the fence. Then screw it down to the fence, see Fig. 1.

To hold the workpiece in place, drill a hole through the arm and the base for a carriage bolt, see Fig. la. The bolt extends up through the base and arm, and a wing nut on top tightens the arm down to pinch the workpiece in the jig.

stop block. For a stop block, use a piece of scrap that's the same thickness or a little thinner than the fence.

reference dado. To provide a point for aligning the work-piece in the jig. rout a ^"-dcep reference dado across the fence, see Fig. 2. Use the same router and bit that youll use to cut the tenons. (Note: The collet on a router can be out of center in relation to the base plate. To avoid problems with shoulder alignment, hold the router the same way each time you rout a tenon.)

using the jig. To cut a tenon, start by marking the location of the shoulder on a test piece.

Then slide the piece under the arm and align the mark with the left edge of the dado in the fence, see Fig. 3. Now tighten the wing nut to hold the test piece in place. And then move the stop up against the test piece and clamp it. see Fig. 3.

Next, set your router bit to slightly less than the depth of the shoulder, and make a test cut. To do this, hold the edge of the

Cutting Cabinet Corners With Dado

router base against the right side of the arm. Rout across the end of the workpiece and all the way through the fence, see Fig. 4. (Thisfirstcut may remove the corner of the stop block.)

Next, loosen the wing nut. flip the piece over, and cut the other side of the tenon. Then check the fit in the mortise. If it doesn't fit, increase the depth of cut. sneaking up on the final depth. (Note: To keep the tenon centered, always rout both faces of the workpiece after changing the depth of cut.)

long tenons and half laps. I >onger tenons and end half laps joints are routed much like the stub tenons. But these joints will take a number of passes.

Align the workpiece in the jig and set the stop. Then, back the workpiece away from the stop and make the first pass on the end of the piece. After each pass, move the piece closer to the stop. The last pass is made when the end of the workpiece touches the stop.

What Bolt Relief Cut

CUT CHAMFER IN FENCE FOR SAWDUST RELIEF

CARRIAGE BOLT

COUNTERBORE HEAD —-OF BOLT IN BASE

CUT CHAMFER IN FENCE FOR SAWDUST RELIEF

CARRIAGE BOLT

ALIGN TENON SHOULDER MARK WITH REFERENCE DADO

CLAMP STOP BLOCK AGAINST WORKPIECE

ROUT ACROSS END OF WORKPIECE TO CUT TENON

CUT BOTH FACES OF WORKPIECE TO FORM TENON

ALIGN TENON SHOULDER MARK WITH REFERENCE DADO

CLAMP STOP BLOCK AGAINST WORKPIECE

ROUT ACROSS END OF WORKPIECE TO CUT TENON

CUT BOTH FACES OF WORKPIECE TO FORM TENON

SHOP PROJECT

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Woodworking Tools and Installation Tips

Woodworking Tools and Installation Tips

There are a lot of things that either needs to be repaired, or put together when youre a homeowner. If youre a new homeowner, and have just gotten out of apartment style living, you might want to take this list with you to the hardware store. From remolding jobs to putting together furniture you can use these 5 power tools to get your stuff together. Dont forget too that youll need a few extra tools for other jobs around the house.

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