Cutting out a tenon on a long board - Challenge!

[Dan Clark]

Hi.  On the WoodNet forum fellow wants make a King Size bed and cut tenons on the long boards. http://www.forums.woodnet.net/ubbth...&Number=3060906&page=0&view=collapsed&sb=5&o=

Now I know that you could probably do this faster and easier using say 4-8 Dominos per joint, BUT...  What is the best way to do this using Festool tools OTHER THAN a Domino?

This is a challenge to get the creative juices flowing! 

Oh, so you want to know how I would approach the problem?  Hmmm...  I think I'd slap the long board on my MFT and use my OF1400 router on a guide rail to route the long sides of the tenon.  For the short sides, that's more of an issue.  I think I'd just clamp a short straight edge parallel to the board, route out the tenon, and then use a chisel to clean up the rounded corner.  Or perhaps a PS/PSB300 on a clamped guide rail.  But then again, I've never cut a tenon with router or jigsaw, so there may be several MUCH easier ways to do it.    ;D

Regards,

Dan.

 

[clintholeman]

Dan-

I would do the first part the way you did with my OF 1400 then I would flip the piece 90 degrees and do the same.  I would likely use a piece of scrap to avoid tear out.  Somewhere on the old site I have some pix showing it.  I sometimes clean up with a hand plane, if necessary - but rarely though.  Fast and easy and accurate. - Though not so much as Domino. 

BD [before Domino], that's how I made a lot of my tenons - most actually. 

One of the huge advantages of Domino is there is little or no set-up involved.  Even less than with the router.  And it is very repeatable.

 

[ByronBlack]

Personally, I would use a router to take out the bulk of the waste on the two sides, and then cut the shoulders with a handsaw and clean up if required with a chisel.

 

[ROb McGilp]

Hi Dan,

I know you said "No Domino", but you could try this.
Place a 1" board along the top of the workpiece, then calculate how deep you want the shoulder. Add about 2mm to the width of the tenon to allow for clean up. Set the Domino to this cut height and by either moving the 1" board out from the workpiece, or using "Rick's ring" (for that shallower orifice), set the cut depth. Set the cut width on the Domino to 3 then rout. Make sure you overlap each cut to remove any of the "waviness you will get from the pendular movement of the Domino cutter. Clean up after with a sander or file. to get correct shoulder depth. For the cheeks a saw and chisel should do the job.

Regards

Ablert (AFL player)

 

[Tezzer]

Like this 

 

[ROb McGilp]

Yup

 

[Rocker]

Dan,

Without the Domino, it would be easiest to use shop-made floating tenons, and rout mortises in the ends of the long board by clamping it vertically in a bench vise and then clamping a simple mortising jig like this one to the top end of the board. Then stand on the workbench to rout the mortises in its end.

David Dundas

 

[ROb McGilp]

Rocker,
I think the idea was not to use floating tenons and the question was what's the best way to make tenons using Festool products. But I might be wrong

 

[Dan Clark]

Gentlemen,

I'm constantly amazed at the level of ingenuity in this board.   Day in and day out, I think I've read of all the ways of attacking a problem.   Then, Bang...  I see a half dozen more!

I love it!  Many thanks!  

Dan.

 

[Dan Clark]

Rocker,
I think the idea was not to use floating tenons and the question was what's the best way to make tenons using Festool products. But I might be wrong

Albert,

You're right; that was the question.  But it doesn't make any difference.  Thinking outside of the box is where it's at.  I love to see the creativeness in all of these posts. 

Regards,

Dan.

 

[clintholeman]

I love Teezers approach of using Domino to cut the tenon - minimal set up, just dial in and go!  And it works, WAY scarry!  ;D

 

[Tezzer]

Onyu Clint ;D But its more of a way to show Domi is multiplungefunctional. (think ive just invented a word ;D)

Anyway, id never do it in the real world (why bother when Domi will plunge a mortice)

But what a great conundrum. Domi will cut a super fast tenon so clean and crisp - the envy of other jigs --- But, will plunge 2 mortices twice as quick. Wow what a machine

 

[James Metcalf]

Tezzer

But its more of a way to show Domi is multiplungefunctional.

;DMay not be a German word, but it could pass for one.

 

[Tezzer]

Tezzer

But its more of a way to show Domi is multiplungefunctional.

;DMay not be a German word, but it could pass for one.

Well i like it, and in fact im going to submit it to the Oxford and macquarie dictionarys for approval 

 

[clintholeman]

Tezzer-

I think your language skills may be comensurate with your Domino skills and that is a scarry thing!! ;D  We should ask one of the Festo folks if they are going to start using it - maybe Jerry will in in manuals  ;D ;D ;D

Hard to know which way to turn with such an incredible machine.  I do like your tenon approach though - might be just the ticket for big items like beds - or long tables.  Have to noodle that around for a while.

 

[John Stevens]

My usual answer:

 

[Brice Burrell]

Hey John, do you bigger pictures?

 

[cdconey]

Dan,
I did one of these about five years ago.  I made a guide board with a cleat @ 90 degrees to register against the face.  Think of a bench hook to guide a pattern bit ( top mounted bearing  on  a straight bit ), then you just line it up with your mark, clamp it securely,  & go around the board.  Easy to register, only takes one layout mark.  Just be certain that the cleat is 90 degrees from the edge.

 

[John Stevens]

Hey John, do you bigger pictures?

Hi, Brice.  I inserted these images from some posts on an earlier thread--
http://festoolownersgroup.com/index.php?topic=221.0;all

Regards,

John