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Mortising Jig

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Project by Julian posted 889 days ago 5644 views 31 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

a1Jim

112008 posts in 2201 days


#1 posted 889 days ago

Very cool Jig Julian,nice job.

-- http://artisticwoodstudio.com Custom furniture

View cabmaker's profile

cabmaker

1304 posts in 1433 days


#2 posted 889 days ago

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

lizardhead

517 posts in 1465 days


#3 posted 889 days ago

We want to see your garden gate

-- Lizardhead---Yeah but it's a dry heat--Tempe, Az

View 559dustdesigns's profile

559dustdesigns

632 posts in 1791 days


#4 posted 888 days ago

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

eddie

7197 posts in 1237 days


#5 posted 888 days ago

like the jig and you made a beautiful gate too.

-- Jesus Is Alright with me

View dragonnotes's profile

dragonnotes

69 posts in 1655 days


#6 posted 888 days ago

Isn’t the 80/20 stuff awesome!

View Pete Pedisich's profile

Pete Pedisich

126 posts in 1270 days


#7 posted 888 days ago

Julian,

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.

Thanks,

Pete

View Julian's profile

Julian

502 posts in 1314 days


#8 posted 888 days ago

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

mcgriffith

87 posts in 1021 days


#9 posted 888 days ago

Julian:

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

pintodeluxe

3315 posts in 1437 days


#10 posted 888 days ago

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

mafe

9475 posts in 1713 days


#11 posted 887 days ago

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,
Mads

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

View Zippertail's profile

Zippertail

5 posts in 879 days


#12 posted 878 days ago

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

View Pete Pedisich's profile

Pete Pedisich

126 posts in 1270 days


#13 posted 878 days ago

Here it is:
http://festoolownersgroup.com/festool-jigs-tool-enhancements/*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

126 posts in 1270 days


#14 posted 878 days ago

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
notes:
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.

www.8020.net
www.mcmastercarr.com

View StumpyNubs's profile

StumpyNubs

6156 posts in 1424 days


#15 posted 813 days ago

You should enter this into our jig contest! Email photos along with your LJ name to jigcontest@runbox.com. You might win!

-- It's the best woodworking show since the invention of wood... New episodes at: http://www.stumpynubs.com

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