|Forum topic by Ben||posted 01-19-2011 09:59 PM||1804 views||0 times favorited||12 replies|
01-19-2011 09:59 PM
I am looking for some advice. I am making a buffet server with mortise and tenon joints joining each of the frame beams and center beams which will support the shelves, and I have reached a dilemma. I was able to pretty easily mortise the frame pieces using a mortising bit in the plunge router with an edge guide and a stop at each end of the mortise. I will be frame and paneling birch plywood in as the back and sides by mortising a ¼” groove and doing double half laps on the plywood.
I am having some trouble with the tenons. I know from previous posts that I could or should use a table saw and a dado set but my table saw is a cheapo, and I don’t have the cash or trust in myself to use or buy the dado set just yet (and a custom insert would have to be made as the Skil insert still leaves gaps). The saw just “aint right” as with a great carbide 80 tooth blade it wasn’t near flat when I tried it with the single blade. Anyway, many of the pieces are far too long for either the table saw or router table. I do not own a band saw.
So I have hand cut a few tenons but am having a heck of a time getting them rounded perfectly or getting flat faces. Moreover, it is very hard work even with a good back saw, and the accuracy is suffering. I read a post and tracked down an article by Bill Hylton here http://www.norwesttools.com.au/page/shop/info_page/a/infopage_id/e/57.
He used a jig, but if you band together the tenon pieces, I don’t see any reason why you couldn’t do this with a plunge router, a stop, and some scrap of the same width to support the router on the ends and sides. Simply rout all the way around the tenon pieces, one side at a time. I could then round the shoulders best that I can with a rasp and file. Or, use a chisel to square the mortise. Am I missing something? If I was able to do say four or five at a time, wouldn’t this work and save some time? Has anyone tried this? It might not be the most efficient, but is there something that prevents this from working?
-- Wood is good.