Q:

In FWW #175, Jeff Miller made it look easy to install bed-rail brackets. I want to know how he gets such clean mortises in the end of 80-in.-long rails. Does he use a router or cut them by hand with a chisel?

Vincent Iannelli, Portage, MI

A:

There are a couple of tricks that help you use a router to cut mortises in the end of a long workpiece. First, use a jig to support the router. I built the T-shaped jig shown here. The top of the T supports the router, and the base clamps to the workpiece. Second, hold the workpiece at an angle in the workbench vise. I’ve found that angling the long rail this way is safe and comfortable, although it takes a little work to support the router. Scribe the exact outline of the bed-rail bracket you want to use. Once you’ve finished hollowing most of the mortise with the router, clean it up with a chisel. With most of the wood already removed, the chisel should track the scribed lines cleanly.

 

Simple Jig for Mortising. The long base on this jig (drawing) helps to steady it on a long rail (top photo). Size the base to match the width of the rails you’re using. Cut the mortise in the top larger than the bed-rail bracket (photo at right) to allow for use of a guide bushing on the router. Be sure the mortise is centered on the end of the rail (bottom left photo).

Fine Woodworking Recommended Products

Double Sided Tape

A thin woven core makes XFasten tape strong yet not too thick (0.008 in.), and helps it hold powerfully without being difficult to peel off.

Buy at Amazon

Hedgehog featherboards

The Hedgehog's unique spiral shape and single knob make it easy to set up and fast to adjust.

Buy at Amazon

Incra Miter 1000HD

One of many extremely accurate Incra miter gauges, this model offers 180-degree adjustment to 1/10 of a degree, and a long, straight fence with a telescoping stop system.

Buy at Amazon