Tenon jig to make log legs for slab tables

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Project by HalDougherty posted 07-12-2011 02:30 AM 13186 views 23 times favorited 12 comments Add to Favorites Watch

A few days ago, I saw a great blog post about making a tenon jig by (Don W) that used a router to cut tenons on round stock. It looked like a bigger version of a jig I made a long time ago to make dowels from square stock. Today I made a jig just like it, except I clamped it to my router table instead of attaching a router plate to the top. I just turned it upside down and attached two extensions to clamp it to the table. The last photo shows the tenon in a scrap block with a 1 1/2” round mortise. This face plate has a 1 1/2” hole and I also made a 2” diameter hole in another face plate. Only the 2” forster bits at the hardware store were over $30. 1 1/2” tenons will be fine. It should speed up making rustic tables and I’ll have a use for small tree limbs so there will be less waste. Look for more table and bench projects soon.

-- Hal, Tennessee

12 comments so far

View Don W's profile

Don W

17880 posts in 1990 days

#1 posted 07-12-2011 02:36 AM

cool. When I built mine I had’t built the router table yet. I’ve been going to convert mine so it works like yours does. Another project just waiting for the right moment.

-- Master hand plane hoarder. -

View devann's profile


2200 posts in 2115 days

#2 posted 07-12-2011 05:22 AM

Cool jig. where did you get that bit?

-- Darrell, making more sawdust than I know what to do with

View BTKS's profile


1984 posts in 2887 days

#3 posted 07-12-2011 07:41 AM

Thanks for posting!!!!
This one went straight to favorites. I plan on splitting some honey locust logs soon. The big plan is some patio benches and maybe a shave horse. Who knows, the trees gotta go, so they may as well be something besides firewood. This will be a huge help, I was going to turn them on the lathe but this will be a lot easier.

-- "Man's ingenuity has outrun his intelligence" (Joseph Wood Krutch)

View EMVarona's profile


437 posts in 2258 days

#4 posted 07-12-2011 01:15 PM

Very interesting. With some additions, this can be used of dowel making as well.

-- Ed "Real happiness is one that you share."

View HalDougherty's profile


1820 posts in 2660 days

#5 posted 07-12-2011 02:01 PM

I bought the bit on e-bay. It came in a set of round bits from 1/4” to 1 1/2”. Any round nose bit will work, but the larger the bit the bigger the limb that can be cut.

To make a dowel jig, it needs a hole in front of the cutter to center the square blank. for a 1” dowel, measure a 1 1/8” inch square from corner to corner and cut a hole so it fits, but will still turn. Cut down one end so you can chuck it in a drill and spin it as your router cuts it. You get a much smoother result than I got on these big tenons. They tend to wobble and the limbs aren’t straight enough to use a pilot hole with them.

-- Hal, Tennessee

View Bertha's profile


12989 posts in 2116 days

#6 posted 07-12-2011 02:09 PM

This is fantastic! Nice job.

-- My dad and I built a 65 chev pick up.I killed trannys in that thing for some reason-Hog

View STL's profile


68 posts in 2255 days

#7 posted 07-12-2011 11:31 PM

Great job! Thanks for sharing!

-- Dan Siggers, Alabama,

View Jiri Parkman's profile

Jiri Parkman

953 posts in 3235 days

#8 posted 07-13-2011 09:34 AM

Perfect. Thanks for sharing. It’s on list.

-- Jiri

View HalDougherty's profile


1820 posts in 2660 days

#9 posted 07-14-2011 05:12 AM

Here’s how I cut the legs for the bench. The sawblade on my sawmill is parallel with the deck and all four legs are going to be exactly the same length in just a few seconds. After I flatten the top and finish sanding the top, I’ll make a project page to show the bench tomorrow. The top is a slab from a Bartlett Pear tree. Pear is at least twice as hard as hard maple. Then I have to make some butterfly inserts to reinforce a crack.

-- Hal, Tennessee

View dubsaloon's profile


621 posts in 2216 days

#10 posted 07-21-2011 01:36 PM

Makes my brain hurt just thinking of the possibilities. That is one big bit. Great Idea!

-- The works of evil people are not the problem. It is the "Good" people standing by and watching not speaking up. Dubsaloon

View NormG's profile


5434 posts in 2426 days

#11 posted 08-03-2011 05:52 AM

Wow, great idea, thanks foe the pics

-- Norman

View Joe Lyddon's profile

Joe Lyddon

9330 posts in 3475 days

#12 posted 11-22-2011 07:41 PM

Now, THAT’s one Super GOOD IDEA!!

Thank you very much!

That forest… keeps on getting in my way sometimes!

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: ... My Small Gallery:"

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