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Blog entry by Dano posted 06-21-2007 03:05 AM 852 reads 0 times favorited 8 comments Add to Favorites Watch

Last time I discussed gluing up the legs, well the first lesson I learned is that gluing up pieces is more challenging than I thought. First I have 4 new Jet parallel clamps but I wanted to glue up 4 legs with 3 pieces of 4/4 stock each then cut them to size. So I thinks to myself – if I glue all of them up at once and put all four legs in the same clamps I could clamp all of them at the same time. I had glue everywhere! It is hard to keep all of the lumber aligned appropriately when applying the clamping pressure, 75% of the legs worked out but one had to be redone so I learned a few things and it was not too expensive in money or more importantly, time wasted. Oh, and I did mention that I had glue everywhere, right? Well what that translates into is that I not only had the glue where it was supposed to go but also between the layers that where not to be glued and would need to be separated. Not much mind you but enough to create extra work, 2 legs had to be chiseled apart. Lesson one – don’t get in a hurry!

Next I jointed 2 sides of the legs and trimmed the other sides to the final 2” dimension then cut them to length. Although I had made mistakes in the glue up what lies ahead scared me to death, cutting the 4 mortises in each leg. I have a Delta drill press and just bought the mortise attachment and had made a couple of test mortises and did a couple in a glass panel door for a bathroom cabinet, it worked OK but was not up to my expectations. Sunday afternoon was spent laying out the mortises and drilling the work pieces. Slow was the order of the day. That’s where we are now, ready to make tenons on the rails. For the bathroom cabinet I just nibbled away at the tenons but it really doesn’t make for a smooth glue surface so I have been studying tenon jigs the last few nights. Awh, to heck with it, I’ll just buy one, but wait, there seems to be a problem…what I have seen leads me to believe that most of the jigs are made for a 3/4 inch wide miter slot and guess what? I have a Craftsman saw that evidently has a miter slot only .740 wide so I guess I am back to making one. I have the plans to several but haven’t made a decision as to which one to build. Simple for speed or more complex to be more versatile and last longer, so what do you think?

-- Dan in Central Oklahoma, Able to turn good wood into saw dust in the blink of an eye!

8 comments so far

View gizmodyne's profile


1768 posts in 3510 days

#1 posted 06-21-2007 03:12 AM

Hi, Can you post some pics? You can make spacers or cauls for when you glue like this. Square up some scrap stock and wrap it in packing tape so the glue does not stick or use 1/8” melamine to separate the layers.

The quickest tenon jigs ride on the fence. Read Table Saw Magic. Get a dado stack?

-- -John "Do I have to keep typing a smiley? Just assume it's a joke."

View woodspar's profile


710 posts in 3519 days

#2 posted 06-21-2007 03:49 AM

Dan, if you have a router Lonnie Bird’s router book has an interesting router jig for cutting tenons.

-- John

View Dano's profile


222 posts in 3452 days

#3 posted 06-21-2007 05:26 AM


I thought about using the router table although I have some ideas I wasn’t sure about the success I would have. Thanks for the info, I;ll look into it.

-- Dan in Central Oklahoma, Able to turn good wood into saw dust in the blink of an eye!

View WayneC's profile


12642 posts in 3517 days

#4 posted 06-21-2007 06:21 AM

View woodspar's profile


710 posts in 3519 days

#5 posted 06-21-2007 04:39 PM

Actually, Lonnie Bird’s router jig is for a freehand router / router on top, not for a router table. If you can find the book at your library (or woodworking store,) it might be worth a look. Basically, he lays the workpiece flat in the jig and perpendicular to the router travel. The router rides on two pieces of wood that are perpendicular to the workpiece. You set the router depth of cut to the amount that you want to remove to get to the tenon thickness that you need.

-- John

View mot's profile


4911 posts in 3456 days

#6 posted 06-21-2007 04:48 PM

Ahhh the glueup. It always starts out calm, but can end up with some frantic moments. Some good advice has already been given in the other comments, so I’ll just leave it at understanding your glueup dilemma. Been there, done that.

-- You can discover more about a person in an hour of play than in a year of conversation. (Plato)

View Hawgnutz's profile


526 posts in 3496 days

#7 posted 06-21-2007 08:06 PM

I have found that BISCUITS help me keep my boards in line with each other during glue up. Another bonus to using biscuits is that they help reinforce the joint.
Another option, which I have not tried, yet, is using pocket screws. They keep the boards aligned and pull the boards toward each other.

As far as mortises, most everything I know has been covered in other posts.

Good Luck and God Bless,

-- Saving barnwood from the scrapyards

View oscorner's profile


4564 posts in 3731 days

#8 posted 06-22-2007 04:51 AM

Wax paper is also useful in keeping things from sticking together. I have used it to keep the glue off my clamps.

-- Jesus is Lord!

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