How to Cut Mortises with a Plunge Router
Refinements to a Fine Woodworking contributor’s jig yield faster mortises
May 27, 2015
Back in 2007, issue 172 of Fine Woodworking magazine featured an article by furniture maker Jeff Miller on how to execute Perfect Mortise-and-Tenon Joints. Miller outlined a variety of techniques, including how to cut perfect mortises using a specially-built jig that traps the edge guide of a plunge router, thus keeping the machine on a perfectly straight path during routing.
The jig is easy to build and works beautifully. To define a mortise’s start and stop point, Miller simply screws on a pair of stop blocks. That works just fine, but I thought I might refine the jig, just a bit, to make it easier to use. By adding a length of T-track to the long beam that serves as the bearing surface for the router, I’m able to use repositionable stop blocks that don’t require me to break out my drill-driver every time I want to make a mortise.
This short video demonstrates how I built the jig, and how it’s put to use in cutting accurate mortise-and-tenon joinery.
Comments
Where would I find bench hold-down clamps like the ones used on this jig?
This has definite improvements over Jeff's design. I will be adding them to the one I made. Thanks!
I made a version of this two years ago for my granddaughter's crib and it was fantastic. One of the best jigs I've ever built.
This is great, same question, where can I find the hold down clamps?
@levinw, look in the specialy clamps section at ponyjorgensen.com for Pony hold-down clamp.
Lowes carries the 3 in clamps for online purchase.
I also build Ed Pirnik's upgraded version of Jeff Miller. I love my jig!
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