Mortising Jig

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Project by Julian posted 03-13-2012 09:30 PM 8782 views 33 times favorited 16 comments Add to Favorites Watch

This is a mortising jig I made for loose tenon mortises. After looking at numerous jig on this website and others, i decided to make this one. I found it on a Festool website. I don’t own any Festool tools (would love to have one or two, but too much $). I used it to make a garden gate. Worked out very well. Cuts very clean mortises.

-- Julian

16 comments so far

View a1Jim's profile


117234 posts in 3720 days

#1 posted 03-13-2012 11:01 PM

Very cool Jig Julian,nice job.

-- wood crafting & woodworking classes

View cabmaker's profile


1740 posts in 2952 days

#2 posted 03-14-2012 12:56 AM

Good for you Julian, that looks like a very nice user friendly setup. I always enjoy seeing good utilitarian stuff that have not been over thought. Well done !

View lizardhead's profile


652 posts in 2985 days

#3 posted 03-14-2012 01:31 AM

We want to see your garden gate

-- Good, Better, Best--Never let it rest---Always make your Good be Better & your Better Best

View 559dustdesigns's profile


633 posts in 3311 days

#4 posted 03-14-2012 09:44 AM

Nice jig, thanks for sharing.

-- Aaron - central California "If you haven't got the time to do it right, when will you find the time to do it over?"

View eddie's profile


8565 posts in 2757 days

#5 posted 03-14-2012 12:21 PM

like the jig and you made a beautiful gate too.

-- Jesus Is Alright with me

View dragonnotes's profile


72 posts in 3175 days

#6 posted 03-14-2012 02:51 PM

Isn’t the 80/20 stuff awesome!

View Pete Pedisich's profile

Pete Pedisich

139 posts in 2790 days

#7 posted 03-14-2012 03:08 PM


It looks great to me!
I’m the guy who posted the jig on the Festool owners group forum, and I’m so glad someone made their own version. Since I posted it, I’ve sold my Festool router and gone back to using my DeWalt 618 (same as yours!), but I’ve found the edge guide was not as rigid and precise as the Festools. I’d love to hear if you have come up with new and improved methods for linear guidance, or ways to improve the DeWalt edge guide. There is just enough play to make some of the mortises looser than others.



View Julian's profile


1368 posts in 2834 days

#8 posted 03-14-2012 05:18 PM

I purchased two linear guides (just plastic that fits inside the slot) from 80/20 to work with the router edge guide. There is some play, but I just took my time routing the mortises and kept even pressure on the edge guide and it worked out well.

-- Julian

View mcgriffith's profile


87 posts in 2540 days

#9 posted 03-14-2012 06:45 PM


That is a great jig. Do you happen to have detailed plans (or maybe write up some plans) that you could share? I would love to make a jig like yours and be able to make mortise and tennon joints as smooth as the ones shown in the pictures of the gate.

Thanks …mike…

-- Michael TX, Not even my wife understands my sense of humor.

View pintodeluxe's profile


5757 posts in 2956 days

#10 posted 03-14-2012 06:51 PM

Aren’t those Dewalt routers terrific? I love mine.
Nice work on the jig, very clean construction.

-- Willie, Washington "If You Choose Not To Decide, You Still Have Made a Choice" - Rush

View mafe's profile


11741 posts in 3232 days

#11 posted 03-15-2012 08:24 AM

Super cool, nice build.
I have Festool router and aluprofiles in my shop, so I would love if you can put a link for the jig.
Best thoughts,

-- MAD F, the fanatical rhykenologist and vintage architect. Democraticwoodworking.

View Zippertail's profile


5 posts in 2398 days

#12 posted 03-24-2012 01:08 PM

Can you post the link to this jig? I’d love to make one.

View Pete Pedisich's profile

Pete Pedisich

139 posts in 2790 days

#13 posted 03-24-2012 02:02 PM

Here it is:*mortise-jig-for-of-1400-router*-other-versions/

Please note some key improvements Julian made to my design: 1) using 1010 extrusion (1”sq.) instead of 1020 (1×2”) especially on the ‘outrigger support’ gives more room for your hands and clamping on the face side. 2) side extensions for clamping to bench top. 3) use of toggle clamps, as they give greater clamping force, which is very important when mortising in a vertical workpiece – the new Bessey self-adjusting clamps would be ideal for this.

View Pete Pedisich's profile

Pete Pedisich

139 posts in 2790 days

#14 posted 03-24-2012 06:16 PM

Also, if you are buying the aluminum extrusion profiles on ebay or have them already, and many of you are already aware of this, but here are some facts to help you:
Well known manufacturers of quality extrusions: Bosch, item, 8020
8020 uses names such as 1010 (1”x1”) and 1515 (1.5”x1.5”) so the name tells you the size.
25×25mm extrusion will be very close to the US 1” x 1”, and 1/4-20 hardware usually works in both.
40×40mm extrusion will be close to US 1.5” x 1.5”, and 5/16-18 hardware usually works with both.

View StumpyNubs's profile


7656 posts in 2944 days

#15 posted 05-28-2012 12:54 PM

You should enter this into our jig contest! Email photos along with your LJ name to You might win!

-- Subscribe to "Stumpy Nubs Woodworking Journal"- One of the crafts' most unique publications:

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