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Router Mortising Jig

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Project by woodenwarrior posted 123 days ago 2070 views 21 times favorited 10 comments Add to Favorites Watch

I’ve become a lot more disappointed with my hollow chisel mortise machine the past few months. It’s finicky to set up, the walls of my mortises are rough and less than perfect and the support for the work piece is less than ideal…it’s just an all around PITA. I decided to build this jig based on a desire for a quicker, repeatable more accurate way to make mortises.

This jig is a hybrid of a mortise jig from Shop Notes #64 and an idea I found on here from TJU at http://lumberjocks.com/topics/27176 . This jig will produce mortises for loose tenon joinery in end grain as well as traditional mortises.

The jig works by trapping the router edge guide in a slot in the back of the jig enabling the router lateral movement only. This takes a lot of the error out of making mortises. The body of the jig is nothing more than a couple of 2×4 pieces dimensioned and cleaned up at the jointer/planer. This is a attached to a plywood base with room for clamps to attach it to the work surface Two sliding plates limit the travel of the router. The plates are lipped in the back to help register them against the jig.

The plate that registers the workpiece has a shallow cross grooved key way to accept a hardboard key on the back of the support plate. I can mortise pieces up to 1 1/2 inches thick with the clamp set up I currently have. By replacing the clamp set up with a thicker mounting block I can extend that thickness to 3 inches or so.

-- Do or do not...there is no try - Master Yoda





10 comments so far

View woodenwarrior's profile

woodenwarrior

131 posts in 693 days


#1 posted 123 days ago

Here is a photo of the jig in use. I apologize for the rotated photos…I messed with them forever and still couldn’t get them to post right side up…I hate craning my neck to see other people’s photos as well :/

-- Do or do not...there is no try - Master Yoda

View Dan Krager's profile

Dan Krager

1355 posts in 732 days


#2 posted 123 days ago

Nicely done Warrior! This is almost identical to one I made for myself perhaps a year ago. It sure beats a hollow chisel. Because of this setup, I’ve begun to use loose tenons and now very precise MT joints are a breeze. I use CL (center line) and “true surfaces” (same face to the table) to be sure things match up correctly. I built mine from birch plywood and made it to accommodate compound angles.

DanK

-- Dan Krager, Olney IL http://www.kragerwoodworking.weebly.com

View woodenwarrior's profile

woodenwarrior

131 posts in 693 days


#3 posted 123 days ago

Dan, you sure are right about it being easier and more accurate than a mortising machine!! I also use a center line for reference purposes. It makes making repeating cuts MUCH faster. The plans in Shop Notes call for 45 degree angles on one side of the clamping plate to accommodate loose tenon miters. I don’t use loose tenons too often in miter joints so I left it square for the time being, however, if the need arises, I can always do some quick cuts to the plate to make it suit that need.

-- Do or do not...there is no try - Master Yoda

View hoss12992's profile

hoss12992

2250 posts in 391 days


#4 posted 123 days ago

I really need to make one of these, Great job

-- The Old Rednek Workshop https://www.facebook.com/theoldrednekworkshoptn

View hoss12992's profile

hoss12992

2250 posts in 391 days


#5 posted 123 days ago

This might help a wee bit

-- The Old Rednek Workshop https://www.facebook.com/theoldrednekworkshoptn

View DMC1903's profile

DMC1903

174 posts in 826 days


#6 posted 123 days ago

Very nice jig, that is on the list

View woodenwarrior's profile

woodenwarrior

131 posts in 693 days


#7 posted 123 days ago

Thanks for the save Hoss!!

-- Do or do not...there is no try - Master Yoda

View RonGoldberg's profile

RonGoldberg

27 posts in 856 days


#8 posted 122 days ago

Yes, I agree with your comments about the hollow chisel mortiser. I thought it was just me. Can u send a video of your in action. Do you think you could do us a favor and make some plans for your and post step by step directions. Thanks
Ron
McLean, VA

View Dan Krager's profile

Dan Krager

1355 posts in 732 days


#9 posted 122 days ago

I have a downloadable Sketchup drawing of the jig I made. It’s a little crude by what I can do now, but it gets you parts and dimensions with an idea of how it goes together.
DanK

-- Dan Krager, Olney IL http://www.kragerwoodworking.weebly.com

View Don Johnson's profile

Don Johnson

580 posts in 1279 days


#10 posted 122 days ago

Interesting jig . . . . filed away for reference!

Woodenwarrior: . . . . . . A free and easy to use program for rotating pics (and doing lots of other things) is Irfanview – see http://www.irfanview.com/.

If you look at the 4th post on http://lumberjocks.com/projects/93618 you’ll see how I used Irfanview to add red spots to the first picture, but it can do tons of other stuff.

-- Don, Somerset UK, http://www.donjohnson24.co.uk

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