woodworking joinery – AllFlavor Workshop

How To Make a Tenon Jig for a Router Table

About the author, Lukas — Thu, 01 Dec 2022 07:37:15 +0000

AllFlavor Workshop

How To Make a Tenon Jig for a Router Table

The mortise and tenon joint is one of the strongest and most used joints in woodworking. The joint provides a robust and tight connection that may last for hundreds of years. Its uses are wide-ranging from making tables and chairs to doors, frames, and cabinets.

There are multiple ways how to make a tenon. You can cut it on a table saw using a crosscut sled or a dedicated tenoning jig, you can make it the traditional way using a chisel and a saw, or you can use a router together with a tenon jig. In this article, you will learn how to make a tenon jig for a router table.

The tenoning jig built in this article is designed for a benchtop router table. It is mainly intended for crosscutting and making tenons on narrow wood pieces. The narrower the wood piece, the harder it is to keep the stock perpendicular to the router table fence. The tenoning jig holds the stock firmly at a 90-degree angle to the fence and the router bit ensuring the cuts are clean, square, and precise.

The jig works as a tenon sled for a router table. It can slide in a miter slot or can be used against the side of the table as a reference. To achieve the best results, it is good to use a sacrificial block to prevent wood tearing and blowout.

The build is made of Baltic birch plywood and HDF. All the materials are easily available.

Read on to find out how to make a tenon sled for a router table, how to set it up, and how to use it.

RELATED:

DIY Router Table Tenon Jig Video

If you want to build a router tenon sled, watch the video below with a step-by-step guide and detailed steps.

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Router Tenon Jig Video
Router Table Tenon Jig Plans
The Material you will need
Frequently Asked Questions
1. What is the mortise and what is the tenon?
2. What are the different ways of creating a mortise and tenon?
3. How do you make a tenon with a router?
How to Make a Tenon Jig for a Router Table
1. Step 1: Make the Sled
2. Step 2: Make the Back Fence
3. Step 3: Make the Front Fence
4. Step 4: Make a Hold-Down Clamp
How to Use a Tenoning Jig for a Router Table
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!

Router Table Tenon Jig Plans

Download the Router Table Tenon Jig Plans here

Download plans here

What you'll need to make a Router Table Tenon Sled

Router Tenon Jig Base
HDF base board – 290 mm x 170 mm x 5 mm
Spruce wood Strip – 260 mm x 18 mm x 28 mm
Beechwood Strip – 260 mm x 7 mm x 6 mm

Tenon Jig Back Fence
Plywood – 45 mm x 170 mm x 12 mm – – https://amzn.to/3TPULp2
HDF Strips – 8 mm x 170 mm x 4 mm
DIY T-track bolts
DIY T-tracks
DIY Hold-down Clamp

Tenon Jig Front Fence
Aluminum flat bar- 70 mm x 30 mm x 2 mm
DIY T-track bolt

Tools:
Circular Saw – https://amzn.to/4aMD0xg
Trim Router – https://amzn.to/3HbQcOg
Hand Drill – https://amzn.to/3HqLEnH
Corded Hand Drill – https://amzn.to/3NSA3Bo
Proxxon Mini Table Saw
Angle Grinder – https://amzn.to/48K2klD
One Hand Clamps – https://amzn.to/48jGxkZ
Spring Clamps – https://amzn.to/41Nuh9D
F-Clamps – https://amzn.to/48ArzY1
Machinist Square / Speed Square

Other:
Wood Glue – https://amzn.to/48ltKhJ
Epoxy – https://amzn.to/3tJ5R4L
Straight router bit – https://amzn.to/3NQNDVX
Wood Screws, Washers, Bolts, T-nuts – https://amzn.to/41PodgQ
Threaded rod 6mm – https://amzn.to/48oo6vq

Check all the Tools I Use

We may earn an affiliate commission when you buy something through our retail links. As an Amazon Associate AllFlavor Workshop earns from qualifying purchases.

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What is the mortise and what is the tenon?

A mortise is an entrance, the hole of the joint. The tenon is the protrusion that fits into the mortise creating the joint.

What are the different ways of creating a mortise and tenon?

There are multiple ways how to create the mortise and tenon joint. Traditionally, the mortise and tenon joint is made by using hand tools such as a marking gauge, a wood chisel, a hand saw, and a mallet.

With the advent of modern electric tools, you can also make the joint using a table saw, a trim router, or a band saw. You can equip the tools with woodworking jigs that allow for repeatable cuts, thus allowing you to make the joints faster with the same quality.

How do you make a tenon with a router?

There are two main approaches to making a tenon with a router. You can either use the router as a stationary tool, such as a router table, and move the workpiece against the router, or use the router as a moving component and fix the workpiece.

Both approaches will use different types of woodworking jigs. In the first case, when the router is fixed, you can cut a tenon using a router tenon sled. In the second case, you can cut a tenon using a stationary mortise and tenoning jig.

Let's start building!

The router tenon sled consists of 3 main parts – the sled, the back fence with securing elements, and the front fence. The sled is made of HDF, the back fence of plywood, and the front fence of spruce wood.

Router Tenon Sled properties:

Material: HDF, Plywood, Spruce wood
Total dimensions: 29m x 17cm x 8,5cm
Back fence with T-tracks for additional accessories
Maximum adjustment distance of clamping width: 14cm
Can be used to cut short pieces as well as long pieces

NOTE: The base sled is made of a narrower HDF board (29m x 17cm x 0,5cm) with a custom t-track so that the maximum bit length can be used. Nevertheless, you can also make the base from a 9mm or 12mm plywood board with a standard t-track miter track.

This is a project for a beginner/advanced woodworker. Many areas require precision and increased attention to ensure an accurate and clean cut.

How to Make a Tenon Jig for a Router Table

Step 1: Make the Sled

Measure and cut the HDF base board to size (29m x 17,5cm x 0,5cm). To cut the board I used a circular saw straight edge guide. But if you have a table saw you can use a crosscut sled instead.

1. Cut the t-track

Cut a t-track in the base board. Use an adjustable router dado jig to cut an exact-width dado. Make sure the aluminum bar is flush with the base board.

NOTE: I am using a 5mm thick HDF board. That is because I want to use the maximum length of the router bit. Although this makes the build a bit more complicated. Using a thicker board would make it easier to create the t-track.

2. Attach the guiding fence

Cut 2 wooden strips and glue them to the bottom of the base. One (spruce), that runs along the edge of the router table, and the other (beech) that runs in the router table slot. Use flush head screws, if you are going to additionally secure the side guide.

Measure and attach the guides so that it extends slightly over the router bit. Once the glue dries cut off the wood excess.

NOTE: You can use any type of wood. I used the leftovers I found in the shop.

Step 2: Make the Back Fence

Glue 4 plywood strips together and make a t-track. You can easily route the slots on the router table. Make sure the front side is straight and perpendicular to the base.

Glue the back fence to the base board. Use a square to make sure it is perpendicular to the cut edge (perpendicular to the router bit).

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Step 3: Make the Front Fence

Cut the aluminum bar to size and round the edges for a better slide in the track. Make a t-track bolt and glue it to the aluminum bar with epoxy to ensure a firm connection (wood glue is not sufficient).

NOTE: Make sure the height of the bar and the bolt is lower than the height of the base board.

Cut the fence to size a drill a hole in for the t-track bolt. Mount it on the base and secure it with a wing nut.

Step 4: Make a Hold-Down Clamp

Cut a plywood piece to size, add a t-nut for attachment, a cut a slot for adjustability.

Mount the piece on the back fence using a t-track bolt and a wing nut. Run through the t-nut a threaded rod with a permanently attached wing nut at the (top) end and attach another piece of wood on the other side of the rod for pushing. You can add a non-slip mate to the bottom of the piece for better fix and security.

The push mechanism is the same as in the case of this wooden vise or this angle clamp.

Below is a picture of a finished router table tenon sled. A great jig for cutting tenons on large as well as small workpieces.

How to Use a Tenoning Jig for a Router Table

The steps provided below describe how to set up a tenon jig for a router table and how to use it. Make sure you are using all the necessary protective equipment. Especially safety glasses and a face mask. When using a router table, chips may fly away at high speeds, which can cause serious injury.

For a better understanding of how to set up and use the jig, refer to the video above.

How to use a tenon jig for a router table

Mount the tenon sled on the router table
Place the workpiece on the sled and push it against the back fence
Set the stopper to the desired position
Secure the workpiece with a hold-down clamp
Secure the workpiece with the front fence
Use the right router bit for the job
Slowly make the cut

TIP: To achieve the best result when cutting use a sacrificial piece of wood. Place it between the workpiece and the back fence. The sacrificial block will help to prevent a blowout at the back of the workpiece.

Router Table Tenon Sled Improvements

An oscillating tool such as a trim router can cause serious injury, so all safety precautions must be observed. In particular, it is necessary to protect the eyes, or possibly the entire face. Wood chips flying away from the router reach high speeds and can fly up to a distance of several meters.

You can add dust-proof plexiglass on the side of the jig right above the router bit to prevent wood chips from flying in your face. Also, you can add additional hold-down clamps to securely fix the cut piece in position.

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I hope the information shared in this blog post inspired you and now you are adding this router jig to your next builds. 😉

Homemade Tenon Jig for Router Table

Jigs used for this project:

This post How To Make a Tenon Jig for a Router Table first appeared on AllFlavor Workshop and is written by About the author, Lukas

How to Make a Castle Joint (Step by Step)

About the author, Lukas — Sun, 27 Feb 2022 09:53:51 +0000

AllFlavor Workshop

How to Make a Castle Joint (Step by Step)

A castle joint, also known as Shiro joint, is a combination of a half-lap cross joint and an intersecting bridle joint, resulting in a 3-way interlocking joint. The combination of these two joints makes the overall bond very strong, making the castle joint one of the strongest woodworking joints. The way how the wood pieces are assembled not only guarantees the strength of the joint but also makes the joint stand out aesthetically.

Its application can be found mainly in the production of furniture where a solid connection is needed but at the same time, a nice appearance is desired. Very often the castle joint is used in connecting corners of bed frames, making tables, and connecting table aprons.

Although the castle joint looks complicated it is actually one of the easiest woodworking joints.

There are multiple options and ways how to make a castle joint. It can be made by using an oscillating tool with a chisel a dado stack or a coping saw. All of these options will provide the desired outcome. But probably the easiest (quickest) and most accurate way to ensure the best result is by using a tenoning jig and a crosscut sled together with a table saw.

For the purposes of this article, I leaned toward the traditional way of cutting a castle joint, using a Japanese saw, a coping saw, and a chisel. Among the available choices, this approach is the most budget-friendly but also requires the most skill.

The final result not only looks fantastic but also showcases the joint’s strength. It is no wonder the castle joint is chosen for furniture that demands both durability and beauty. The extra effort spent on this joint is definitely worth it.

Keep reading to find out how to cut a castle joint and assemble all the parts together.

RELATED:

How to Make a Castle Joint Video

If you want to see how it is done, watch the video below for a step-by-step guide on how to cut a castle joint.

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Material you will need
General Questions
1. What is a half lap cross joint?
2. What is a bridle joint?
3. How strong is a castle joint?
4. Should you glue a castle joint?
Castle Joint Step by Step
Different Ways to Making a Castle Joint
Woodworking jigs used

*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.

Material you will need to make a Castle Joint

Castle Joint:
3 Pieces of Wood (The thickness of the pieces doesn’t matter)

For this project:
1 Spruce Wood (40 x 40 mm) – for the tower
2x Beech Wood (3 x 15 mm) – for the horizontal pieces

Other:
Japanese hand saw (Ryoba)
Coping Saw
Chisel (Narex)
Wood Glue
Wood Saw Dust
Sand Paper / Sanding Wheel

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What is a half lap cross joint?

A half-lap joint or a cross-lap joint is a 90-degree interlocking joint of two pieces of wood that are cut halfway through their depth and the width of the cut equals the thickness of the wood piece. The pieces slide together and overlap one another on an even plane.

Making a cross-lap joint is quite easy. Tools of choice for making this joint include routers or table saws with a miter gauge or a crosscut sled.

With a router, you will end up with a clean and precise cut. Nevertheless, using a router is mainly possible with thinner pieces of wood since they won’t have the reach for thicker lumber.

If you want to make deep cross laps then a circular saw is a better option. Circular saws typically have enough clearance to make deep cuts.

What is a bridle joint?

A bridle joint is very similar to the mortise and tenon joint. Actually, it is an easier alternative to the mortise and tenon joint. Both joints are much alike but there is a difference between these two, which is mainly reflected in the length of the tenon and the depth of the mortise.

In the case of a bridle joint, a recessed end from both sides of one wood piece fits into another wood piece recessed in the middle – one accepts the other provides. When locked together you can see the end grain of the tenon which makes the joint quite attractive. Since the bridle joint provides good strength and looks neat it is often used to make benches, tables, or narrow frames for furniture.

The joint is quite strong on its own, however, wood glue, pins, or mechanical fasteners can be additionally used to keep the joint together.

How strong is a castle joint?

The combination of the half-lap cross joint and the intersecting bridle joint makes the castle joint one of the strongest woodworking joints. The Castle joint is known for its impressive strength under vertical loads, it excels in bearing weight. However, when subjected to horizontal forces or lateral pressures, there’s a possibility that it might weaken over time, leading to potential cracks.

To fortify the joint further, consider using wood glue which binds the wooden pieces seamlessly. If you’re looking for even more stability, mechanical fasteners are a good choice, ensuring the joint remains intact and robust for a longer duration.

Should you glue a castle joint?

A significant benefit of the castle joint is its flexibility; you can put it together or take it apart as needed. For a heavy piece of furniture like a castle joint bed frame, this means you can transport the individual pieces and then assemble them right where you want it.

Once you’re happy with the placement and have no plans to disassemble it, I’d suggest firmly securing it with either glue or bolts to ensure it stays intact.

The castle joint naturally interlocks, eliminating the need for extra fasteners or adhesives. Its design inherently provides ample strength and support.

However, when deciding whether to add glue or screws for additional strength, several factors come into play:

The direction of stress (vertical vs. horizontal)
How visible the joint is
The presence of gaps in the joint

Take tables and beds, for instance. For tables, glue can be an excellent addition. It not only secures the joint under less lateral stress but also enhances its appearance by filling in minor gaps. For beds, which experience more side-to-side pressure, it’s wise to use fasteners in spots that remain hidden.

Let's Build It

Before starting with your project, you should consider what will be the joint used for and how much pressure should it take. For a small coffee table, you might not need as thick wood pieces as in the case of a bed.

A castle joint can be made using wood pieces of different sizes (thicknesses). Generally, you will find joints made out of 3 equal size pieces. In my case, the thickness of the castle is different from the thickness of the horizontal pieces.

In any case, regardless of the thickness of the wood, the principle is still the same.

Also, take into account that when building the castle joint there will be several cutouts both on the castle piece as well as on the horizontal pieces. Mind that the wood pieces will lose some of their strength after the cutouts. Select the wood thickness according to your project. The remaining wood thickness after the cutouts should still make up for a strong and tight fit.

How To Make a Castle Joint Step by Step

Step 1: Cut the Castle

The wood piece I am using for the castle is a square piece of spruce wood 40 x 40 mm.

First, mark the vertical lines to be cut off. Measure the width of the wood piece and divide it by three. It doesn’t have to be perfect, but it has to be the same on all four sides of the wood piece.

TIP: Mark the lines by using a marking gauge or a combination square

Then mark the horizontal lines. The distance (from the top) equals the width of the horizontal wood pieces to be used.

Start with the cuts. To cut the bridle joint I am using a Japanese saw for the vertical cuts and a Coping saw to make the cutoffs. For precise cleaning of both the vertical and horizontal cuts, I am using a chisel. Cutting can be also done easily on a table saw with a tenoning jig.

TIP: Don’t cut on the line but on the inner side of the line. Fine cleaning will be done with a chisel.

Once finished with all four sides you should be left with a 3×3 pattern.

After that, you can go ahead and clear out the bulk of the material using a coping saw from the middle of the joint. Clean the sides and surfaces with a sharp chisel.

Now you should have a piece looking like a tower of a castle.

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Step 2: Cut the Tenons in the Horizontal Parts

The horizontal parts are two identical pieces that will slide together and overlap one another on an even plane. The tenons’ width equals the width of the middle part of the tower piece.

To cut the tenons mark the places for the vertical cuts. Cut as deep on both sides of the piece to end up with the desired width. I am using a chisel to get rid of the shoulders. In my case, the cuts are quite shallow but if the wood pieces were thicker, I would use a coping saw to get rid of the material.

TIP: If you are cutting a tenon in the middle of the wood piece or anywhere near the end (but not precisely at the end) leave the distance from the edge a little bit longer. If the distance is too short the end can be brittle and break off. If you leave them longer you can always trim them afterward.

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Step 3: Cut Cross Lap Joints

The final cut that needs to be done is the cross-lap joint on the recently created tenons. Mark the edges for the cut by sliding the tenon into the tower. The depth of the cut is equal to half the width of the horizontal wood piece.

Again, start cutting on the inner side of the line and clean with a chisel afterward.

You should end up with a piece that looks like this.

TIP: Depending on the type of wood (soft x hard) you can add a diagonal offset to make sure the joint doesn’t break. This is especially the case with softwood. The good thing is the offset will not be seen as it will be hidden inside the tower joint itself.

Slowly add to the depth of the cut until both pieces are completely flush after assembly.

Step 4: Assemble all the Pieces of the Castle Joint

Once all the pieces are cut, you can start assembling the castle joint. Take one of the horizontal pieces and slide it into the tower piece. Make sure the socket faces upwards.

Take the second horizontal piece, make sure the socket faces downwards, and slide it into the castle. The two horizontal pieces will slide together, overlap one another, and interlock at 90 degrees. If done well you will get a really nice snug fit.

Below is a picture of a finished Castle Joint.

When to Glue a Castle Joint

If necessary, the castle joint can be additionally secured either with wood glue or screws. The decisive factor is the type of pressure to which the joint will be exposed and the visibility of the joint.

NOTE: If the joint is not perfectly snug after assembly and you want to get rid of the gaps you can put some paste created from glue and wood sawdust into the gaps between the joints. Sand it and the gaps will be gone. It is always good to keep some wood sawdust stored in the shop.

Different Ways to Making a Castle Joint

Using just a hand saw and chisel is one way to make a castle joint, but if you have some common power tools like a table saw or router, you can get the job done even quicker. Pairing them with the right woodworking jigs, can help a lot.

Choosing this way means you’ll likely get the job done quicker, with sharper and more accurate cuts. Plus, it often looks neater. The trick is picking the right jigs for your tool. If you’re using a table saw, tools like a crosscut sled or a tenoning jig can help. With a router, a mortising jig might be what you need.

KEEP READING: How to cut a Castle Joint on a Table Saw

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So, this is the castle joint (3 way wood joint). Despite how complicated it looks it is actually quite a simple joint and easy to learn. So, a good candidate from the field of woodworking joinery to start with.

I hope you liked it and now you are ready to try it out. I will be using this joint to make a coffee table as my next project. Let’s see how it turns out. Check out these other woodworking joints.

How do you make a Castle Joint

Jigs used for this project:

This post How to Make a Castle Joint (Step by Step) first appeared on AllFlavor Workshop and is written by About the author, Lukas

woodworking joinery – AllFlavor Workshop

How To Make a Tenon Jig for a Router Table

DIY Router Table Tenon Jig Video

Table of Contents

Router Table Tenon Jig Plans

What you'll need to make a Router Table Tenon Sled

What is the mortise and what is the tenon?

What are the different ways of creating a mortise and tenon?

How do you make a tenon with a router?

Let's start building!

How to Make a Tenon Jig for a Router Table

Step 1: Make the Sled

1. Cut the t-track

2. Attach the guiding fence

Step 2: Make the Back Fence

Find This Blog Post Useful?

Step 3: Make the Front Fence

Step 4: Make a Hold-Down Clamp

How to Use a Tenoning Jig for a Router Table

Router Table Tenon Sled Improvements

Homemade Tenon Jig for Router Table

Jigs used for this project:

How to Make a Castle Joint (Step by Step)

How to Make a Castle Joint Video

Table of Contents

Material you will need to make a Castle Joint

What is a half lap cross joint?

What is a bridle joint?

How strong is a castle joint?

Should you glue a castle joint?

Let's Build It

How To Make a Castle Joint Step by Step

Step 1: Cut the Castle

Step 2: Cut the Tenons in the Horizontal Parts

Find This Blog Post Useful?

Step 3: Cut Cross Lap Joints

Step 4: Assemble all the Pieces of the Castle Joint

When to Glue a Castle Joint

Different Ways to Making a Castle Joint

How do you make a Castle Joint

Jigs used for this project: