Routers – Mortise and Tenon Joints
First off, I am a novice / beginer at woodworking.
I have been reading and was originally looking to purchase a table saw for a project. However, I was at a Barnes and Noble today looking thrugh router books and came across a section on how to use the router to cut both mortise and tenon joints.
I am planning on reproducing storm windows for the house and decided that it might be to my advantage to gather tools for projects as I need them.
So I am going to ask some questions that hopefully I can get some answers to:
1) Has anyone used a router to cut both mortise and tenon joints without the purchase of an expensive 3rd party jig?
I was hoping that someone could share some information on homemade jigs that they used to cut both. Also, either a homemade router table or a resonably priced already made table.
2) What brands of plunge routers have people had good luck with?
I was looking at Festool 1400 b/c of the dust collection (adding sanders and jig saw to this as well possibly later).
3) Assuming that I can cut the mortise and tenons with a router, what other tools might I need to complete this project?
Thanks,
Chuck
Replies
Charles,
There are a ton of different ways to cut the M&T but I find the simplest is to use the workbench with a few cleats, template and clamps. First, I take a piece of plywood and make a template with the router that reflects the distance from the router edge to the cutter. You'll probably use a 1/4" or 3/8" upspiral bit for the mortice. Putting the stock in the front vise of the workbench, I can place the template on the cut line and nail a cleat on top of the workbench that'll serve as a back stop for your router. I can then make start and stop cleats the same way. Now I'm all set to cut mortices one 1/4" depth at a time using a plunge router.
Tenons are easier. Gang clamp the rails flush using the template on top of the workbench and route away.
My concern with making storm windows using M&T is getting the frames flat. Any slight tension cause by twisting stock or joinery gets modified 5' down the line....and I've got a cockeyed frame. I might plan on pinning the joints and using epoxy to fill the gaps.
I was thinking of using a lap joint and glue/dowel to pin them together. I think this would be pretty easy (I think). However, the originals have mortise and tenon (like a 'through joint'). I just wanted to reproduce the original.
That being said, I want to accumulate tools as I need them. I was thinking with a router I could do both.
I was thinking of a band saw and a router. But as people say, the table saw is the center of the workshop.
So, with the two projects I have planned - wooden storms and a fence for the yard (do a Google search on Popular Mechanics and picke fence for the plan) I wanted to get buy with the fewest number of tools that I could buy to complete the projects. I don't mind spending money on quality tools that I will use for a LONG time but am having a difficult time putting up a TON of money to start up.
I am open to suggestions for a tool list to complete the projects above. Name brands aren't needed just yet but a list of tools would be be great.
I am sorry that I seem to have somewhat similar posts (see table saw for me) but I want to get things right the first time around and spend my money wisely.
Chuck
Edited 5/10/2006 8:39 am ET by Charles Wilson
Charles,
The best, most economical and most productive systems have been offered to you.
Burt
Chuck,
I might be able to offer you some tips on making the storm windows. Can you give me some details about the originals you're planning to copy?
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