A castle joint (also known as a Shiro Joint or a 3-way joint) is one of the strongest wood joints used when building furniture, beds, or tables. The way the wood pieces are assembled not only provides a strong bond but also makes the joint stand out aesthetically.
In a traditional way, you make a castle joint by using a saw (preferably a Japanese saw) and a chisel. However, you can also cut a castle joint on a table saw using a tenoning jig and a crosscut sled (or a miter gauge).
If you are planning to make a table or a bed frame and several castle joints are needed, the easiest and most accurate way to do it is by using a table saw tenoning jig with a table saw sled. Once the tenoning jig and the sled are set, you can precisely and repeatedly cut the individual parts of the castle joint.
Setting up the jigs to find the right position and cut the tenons might take some time in the beginning. But once you have it, cutting them is quite simple. I used this method the build an outdoor coffee table and it took me no more than 1 hour to cut all the tenons and make the joints.
In this article, I will walk you through step-by-step how to cut a castle joint with a table saw using a tenon jig and a crosscut sled. Here you will find all the information about what type of table saw blade is best for the job, how to make a tenoning jig to cut the castle and the tenons, or how to use a table saw sled/miter gauge to cut the shoulders of the tenons and to cut the cross-lap joints.
If you don’t have a table saw sled in the shop you can easily use a miter gaugue with a stopper to make all the cuts.
How to Make a Castle Joint With a Table Saw Video
I made an outdoor coffee table using this method. Take a look for a step-by-step guide on how to cut a castle joint on a table saw.
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Table of Contents
- General Questions
- Is it safe to cut a castle joint on a table saw?
- Is it possible to cut a perfect castle joint on a table saw?
- What are the drawbacks of cutting a castle joint on a table saw?
- How to Cut a Castle Joint on a Table Saw
- Step 1: Cut the Castle
- Step 2: Cut the Tenons in the Horizontal Parts
- Step 3: Cut the Cross-Lap Joints in the Tenons
- Step 4: Assemble the Castle Joint
- Key Takeaways When Making a Castle Joint on a Table Saw
- Woodworking Jigs used for the project
*Safety is your responsibility. Make sure you know what you’re doing and take all necessary safety precautions while working with power tools. Safety comes first! Always be cautious and careful when using any power tool.
Is it safe to cut a castle joint on a table saw?
Cutting a castle joint on a table saw is safe. However, it is necessary to observe all safety precautions and to use the right tools for the job, namely a tenoning jig and a miter gauge (or a crosscut sled).
Always follow the manufacturer’s guidelines for operating the saw. Keep your hands as far away from the blade as possible and use protective equipment such as glasses and hearing protectors.
Is it possible to cut a perfect castle joint on a table saw?
Yes, you can cut a perfect castle joint on a table saw by using a table saw tenoning jig and a miter gauge. After setting up the tenoning jig and the miter gauge, you can cleanly and repeatedly cut the individual parts of the castle joint.
The tenoning jig is used to cut the castle and the tenons. The miter gauge is used to cut the shoulders of the tenons and to cut the cross-lap joints.
What are the drawbacks of cutting a castle joint on a table saw?
While cutting a castle joint on a table saw can be quick and provide great results, there are certain limitations to this method. Here are some situations where using the traditional saw and chisel method is better for making a castle joint.
- Size considerations – for larger castle joints, a saw and chisel may be more practical. Handling big pieces of wood on a table saw can be challenging or even unfeasible.
- Precision concerns – to achieve a highly precise, accurate, and clean joint, the handcrafted touch of a saw and chisel often proves superior.
- Safety aspects – using a table saw for intricate cuts can increase the risk of injury if not handled with utmost care and attention.
Let's start building!
A castle joint is typically made out of 3 equal size pieces (same width, same thickness of the posts). However, it can also be made of wood pieces of different sizes – but the principle is the same.
If you have 3 equal size pieces you can set the table saw and the jigs once and then make all the cuts. If the size of the pieces differs for some of the dimensions you will need to set up the jigs again.
NOTE: When creating a castle joint on a table saw, it’s crucial to set up the jigs correctly. Take a little extra time to perfect the first cuts. Once that’s done, you can easily repeat all the following cuts on autopilot.
What table saw blade to cut a castle joint?
To achieve a clean final cut for a castle joint, you can use a flat-top grind saw blade. However, it’s not an absolute necessity. Even if you’re using a standard table saw blade, you can still get a neat finish by carefully cleaning up the cuts with a chisel.
It’s essential to have a sharp and high-quality blade to ensure precision. From my experience, blades from brands like CMT and Diablo have consistently given me excellent results and I highly recommend them for any table saw work.
TIP: This article will walk you through all the steps to make a castle joint. Some parts might not be as detailed though. For full information also take a look at the following article – Castle Joint Step by Step.
How to Cut a Castle Joint on a Table Saw
Step 1: Cut the Castle
Draw the castle on the wood piece. Make sure the piece is square and straight (both on the ends and the edges).
- Divide the vertical lines by 3
- The horizontal line equals the width of the other horizontal wood pieces
TIP: The best way to mark the lines is by using a marking gauge and a combination square. Keep the settings on the tools, you will need them in next steps.
1. Cut the Bridle Joint
Use a tenoning jig and a flat top grind saw blade to cut the bridle joint. Raise the blade to the horizontal line and move the tenoning jig so the blade touches the inner mark. Lock the fence, when the setting is good.
TIP: Use painter’s tape on the cuts to prevent wood tear-out. Start the cut a bit further from the line. You can always sneak up on the cut until you get it perfect.
Make the cut. Rotate the piece 3 times and repeat the cut on the other 3 sides.
Use the tenoning jig to cut the bulk of the material in the inner parts of the joint. Using a flat top grind blade will result in clean cuts.
NOTE: You might also consider getting rid of the material from the inner part in another way. Cleaning the material on a table saw is messy. Using a hand drill and a coping saw first to get rid of the main parts and then cleaning the rest on a table saw may seem like a more suitable way.
Step 2: Cut the Tenons in the Horizontal Parts
Reuse the same settings from the marking gauge to draw the cut lines on the tenons.
- Divide the vertical lines by 3
- The horizontal line equals the width of the castle post (Step1)
First, use a tenoning jig to make the main vertical cuts. Make a cut from one side, then rotate 180 degrees and make another cut. Switch to a miter gauge or a crosscut fence. Set the stopper on the table fence and cut off the shoulders of the tenons.
Try the fit and repeat the process until the joint is perfect.
TIP: Start your cuts further from the marks (both for the tenoning jig and the miter gauge). You can always sneak up on the cuts.
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Step 3: Cut the Cross-Lap Joints in the Tenons
Mark the cross laps on the tenons. Set the stoppers (either on the table fence or the crosscut sled), set the height of the saw blade, and make the cuts.
Try the fit. Repeat the process until the joint is perfect.
NOTE: If you are using the table saw fence as a stopper it is important to add an “additional” stopper to the fence and not cut directly against the table saw fence (see picture). The workpiece could get caught between the blade and the fence which could result in table saw binding.
Step 4: Assemble the Castle Joint
Assemble all the pieces of the castle joint. To get rid of the imperfections in the joint, you can make a paste from sawdust and apply it to the joint cracks. Then, sand the joint with a sander and you will end up with a beautiful joint with no imperfections.
The picture below shows a finished castle joint made on a table saw. Although the joint looks quite complex, it is a relatively simple joint to create.
Key Takeaways When Making a Castle Joint on a Table Saw
- Use a tenoning jig to cut the castle and the tenons in the horizontal parts.
- Use a miter gauge or a crosscut sled with stoppers to cut the tenons and the half-lap joints.
- Start the cuts a little further from the drawn marks and slowly sneak up on them until the cut/joint is perfect.
- Cut the inner parts of the Castle with a coping saw first, then use a tenoning jig to clean the rest.
- Use painter’s tape to prevent wood tear-out.
- Keep sawdust from the cuts.
- Use paste created from glue and sawdust to hide any imperfections in the joints.
Woodworking jigs you will need to cut a castle joint on a table saw
Find the necessary materials and the information on how to make these jigs in the videos below and provided blog posts.
1. Table Saw Tenon Jig
How to make a table saw tenoning jig for a table saw.
2. Table Saw Crosscut Sled
How to make a table saw crosscut sled.
