Making Tenons on large pieces

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Forum topic by longboarder posted 06-27-2009 07:46 PM 1274 views 0 times favorited 5 replies Add to Favorites Watch
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29 posts in 3260 days

06-27-2009 07:46 PM

Topic tags/keywords: question

I am building a headboard that has rails (horizontals) that are 3/4×5”x 60” long which is hard to do on my table saw. Thinking about doing loose tenons and just mortising these pieces and also mortising the Styles(verticals).The Styles I can do with my mortising machine as I can lay them horizontally and mortise but the rails are too long and stand up to do them on my mortising machine. Any advice would be appreciated. I don’t want to have to by a new machine right now but any jigs out there. Thanks so much in advance.

5 replies so far

View SCOTSMAN's profile


5849 posts in 3580 days

#1 posted 06-27-2009 08:11 PM

Best advice I can give it to do them with a router with an appropriate bit and then square off the round edges by hand or round the tenons.Alistair

-- excuse my typing as I have a form of parkinsons disease

View brianinpa's profile


1812 posts in 3718 days

#2 posted 06-29-2009 02:42 AM

I use my RAS with a dado stack set. Works great. If you don’t have a RAS, then the router would be my suggestion.

-- Brian, Lebanon PA, If you aren’t having fun doing it, find something else to do.

View PurpLev's profile


8535 posts in 3644 days

#3 posted 06-29-2009 04:13 AM

good time to make a sled for the table saw.

otherwise – the router would be my second choice. build some sort of a fixture that will house the end of the rails, and will allow the router to slide on (if you use the rail as the base for the router – once you start taking off material ,you’ll be left with very little base that might not be stable) – then set a straight edge that will define the edge of the tenon, and route down the edge of the rails till you hit that straight edge.

of course you could always also use a handsaw, and planes/chisels.

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View pickles's profile


68 posts in 3408 days

#4 posted 06-29-2009 04:09 PM

I think the suggestions above are for making integral tenons. I would clamp the rail in my tail vise at an angle so I could reach the end and then use a router and fence setup to make a slot mortise and clean up rounded corners with a chisel.

View Kent Shepherd's profile

Kent Shepherd

2718 posts in 3281 days

#5 posted 06-29-2009 04:48 PM

The tenon could be done on a table saw. Use a dado set and a cross cut sled. That way you don’t have to stand it on end like you would with a tenoning jig.


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