Jig for large tenon cut - Page 2 - Woodworking Talk - Woodworkers Forum
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post #21 of 25 Old 07-12-2020, 01:42 PM Thread Starter
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Still needs a little tidying in the joints, but ...

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post #22 of 25 Old 07-12-2020, 04:54 PM
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Not having a table saw to do what you did - yuou have my admiration.

Tony B Retired woodworker, among other things.


"Strive for excellence and settle for completion" Tony B
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post #23 of 25 Old 07-12-2020, 05:42 PM Thread Starter
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Originally Posted by Tony B View Post
Not having a table saw to do what you did - yuou have my admiration.
Thanks! It was pretty labor intensive, and the joinery isnít going to win any awards. But the piece is going to be ďrusticĒ and hanging fairly high, so Iím pretty satisfied. And the joints are beefy and solid and strong, even though theyíre not perfectly fitted.

Next step is attaching the hub with iron pipe spokes and drilling for the wires and sockets.
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post #24 of 25 Old 07-13-2020, 10:05 AM
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Hey, Dylan. You’re approach is well thought out. That said, how many tenons do you need to cut & how many could you cut by hand in the time it takes to figure out the jigs/make test cuts, etc?

Hand work is just as accurate, and in many cases, more accurate than by machine.

Re: Getting the tenon cheeks to match.

Don’t try to dial it in totally with saw cuts. Layout the mortise and tenons with knife lines using a square, get close with saw cuts, pare the cheeks to then knife line with a chisel. Leave tenon thick.

Brings up the point that tasks like this are as much about accurate layout as jig making.

Do the mortises first, tune up the tenon to fit using sharp chisel, rasp, block plane or combination of all 3. A rabbet block plane is the perfect tool for large tenons.

Think about cutting the tenons with a handsaw!
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post #25 of 25 Old 07-14-2020, 02:28 PM Thread Starter
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Originally Posted by DrRobert View Post
Hey, Dylan. Youíre approach is well thought out. That said, how many tenons do you need to cut & how many could you cut by hand in the time it takes to figure out the jigs/make test cuts, etc?

Hand work is just as accurate, and in many cases, more accurate than by machine.

Re: Getting the tenon cheeks to match.

Donít try to dial it in totally with saw cuts. Layout the mortise and tenons with knife lines using a square, get close with saw cuts, pare the cheeks to then knife line with a chisel. Leave tenon thick.

Brings up the point that tasks like this are as much about accurate layout as jig making.

Do the mortises first, tune up the tenon to fit using sharp chisel, rasp, block plane or combination of all 3. A rabbet block plane is the perfect tool for large tenons.

Think about cutting the tenons with a handsaw!
So, I did rough cut the first two, and then used a chisel and mallet to fit them, and those two are the tightest fit. But each one took me massive amounts of time.
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