The gate frame is joined with mortise and loose tennons, although there’s nothing loose about them. Cutting matching mortises is a two-step process. First is cutting the mortises to length (4 1/2”, bottom, 2 1/2” top), width (3/4”), and initial depth (about 1 1/4”) using the Mortise Pal jig. The second step is adding more depth to the mortises (2 1/4”).
The largest mortise using this jig is 1/2” x 2 1/2” x about 1 1/4” deep. To produce a larger mortise I reposition the jig with a 1” offset in each (lengthwise) direction, and 1/8” offset on the width. By referencing the jig on both sides it produces a centered mortise. To deepen each mortise I removed the 5/8” OD collar, extended the bit, and used the bit’s shaft to reference off the wall of each mortise. I don’t know if this is the standard or accepted way of doing this, but it worked out just fine.
Next up… the initial dryfit and tweaking the joints.
-- tim hill www.newcalshop.com
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