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How to cut mortise and tenon with table saw

Mark Stevens

April 25, 2018

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Mortise and tenon joints are some of the strongest and most reliable joinery techniques in woodworking. They are commonly used in furniture-making, cabinetry, and other woodworking projects. While there are several methods to create these joints, using a table saw can be a quick and efficient way to achieve accurate and precise results.

To cut mortise and tenons with a table saw, you will need a few essential tools and accessories. These include a table saw with a dado blade or a stacked dado set, a miter gauge or sled, a dado insert plate, and a drill press or chisel for cleaning up the mortise. It is important to ensure that you have a thorough understanding of the tools and safety procedures before attempting this technique.

Firstly, you will need to set up your table saw with the appropriate dado blade. A dado blade is specifically designed to cut wide grooves and can be adjusted to create different-sized mortises. It is important to choose the right blade size for your project and ensure that it is securely installed on your saw.

Next, you will need to set the blade height and fence position on your table saw. The blade should be set to the desired depth for the tenon, and the fence should be positioned to cut the width of the mortise. It is advisable to make test cuts on scrap wood to ensure the accuracy of your settings before cutting into your actual workpiece.

Preparing the Workpiece

Before you begin cutting the mortise and tenon joints using a table saw, it is important to properly prepare the workpiece. This will help ensure accurate and clean cuts.

First, select a suitable material for your workpiece. Hardwoods such as oak, maple, or cherry are commonly used for mortise and tenon joints due to their strength and durability. Softwoods like pine or cedar can also be used, but they may not provide the same level of sturdiness.

Next, measure and mark the dimensions of the mortise and tenon joints on your workpiece. Use a ruler or a square to ensure precise measurements. It is recommended to leave some extra material when marking the joints to allow for adjustments during the fitting process.

Once the dimensions are marked, use a marking gauge or a knife to score the lines where the cuts will be made. This will help guide the saw blade and ensure accuracy.

Before cutting, it is important to secure the workpiece to prevent any movement or slipping. You can use clamps or a vise to hold the workpiece securely in place. This will also help minimize the risk of accidents during the cutting process.

Lastly, ensure that the blade on your table saw is properly aligned and sharp. A misaligned or dull blade can result in inaccurate cuts and may cause the wood to bind or kick back. Take the time to adjust the blade and ensure it is sharp before proceeding.

By taking the time to properly prepare your workpiece, you will increase your chances of successfully cutting precise and clean mortise and tenon joints using a table saw.

Setting up the Table Saw

Before you can cut mortise and tenon joints with a table saw, it’s important to properly set up the saw to ensure accurate, clean cuts. Here are the steps to follow:

Step 1: Adjust the Blade Height

Start by adjusting the height of the table saw blade. The ideal height depends on the thickness of the material you’re working with. For most projects, a blade height of 1/8 to 1/4 inch above the material is recommended. Use the table saw’s height adjustment wheel or crank to raise or lower the blade to the desired height.

Step 2: Set the Fence

Next, position the fence on the table saw. The fence should be parallel to the blade and set at the desired distance from the blade to create the width of the tenon. Use a measuring tape or a specialized tool like a tenoning jig to accurately set the distance.

Step 3: Install a Dado Blade or Stacked Dado Set (Optional)

If you want to create a wider mortise, you can install a dado blade or stacked dado set on the table saw. A dado blade is specifically designed for cutting wider grooves, which can be useful for larger tenons. Make sure to follow the manufacturer’s instructions for installing and adjusting the dado blade.

Step 4: Adjust the Blade Angle (Optional)

If you want to cut angled tenons or mortises, you can adjust the blade angle on the table saw. Use the bevel adjustment knob to tilt the blade to the desired angle. Keep in mind that angled cuts require additional setup and may require more advanced techniques.

Once you’ve set up the table saw according to your project’s requirements, you’re ready to start cutting mortise and tenon joints. Always prioritize safety by wearing appropriate safety gear and following the manufacturer’s guidelines for your specific table saw model.

Making the Mortise Cuts

Once you have prepared your workpiece and set up your table saw, you can begin making the mortise cuts for your mortise and tenon joint. Follow these steps to ensure accurate and clean cuts:

1. Draw the outline of the mortise onto the workpiece using a pencil or marking knife. Use a square to make sure the lines are straight and parallel to the edges of the workpiece.
2. Adjust the depth of cut on your table saw according to the thickness of your mortise. You can do this by raising or lowering the blade, depending on the desired depth. It is recommended to start with a shallow depth and make multiple passes to gradually deepen the cut.
3. Set the width of the blade to match the width of the mortise. This can be done by using a dado blade or multiple passes with a standard blade.
4. Align the workpiece with the miter gauge or rip fence on your table saw. Make sure the workpiece is securely clamped in place to prevent any movement during the cut.
5. Start the table saw and slowly feed the workpiece into the blade, making sure to keep it steady and straight. Use a push stick or featherboard to maintain control and keep your hands away from the blade.
6. Make multiple passes to remove the waste material, adjusting the position of the fence or miter gauge as needed to cut the full length of the mortise.
7. Once the mortise is complete, clean up any rough edges or splinters with a chisel or sandpaper.

Remember to always prioritize safety when working with power tools. Wear safety goggles, hearing protection, and keep your fingers away from the blade at all times. Take your time and work carefully to achieve precise and clean mortise cuts.

Making the Tenon Cuts

Once you have prepared your mortise on one piece of wood, it’s time to cut the tenon on the other piece that will fit into the mortise. The tenon is a protruding piece of wood that will fit into the mortise, creating a strong joint.

Here is a step-by-step guide on how to make the tenon cuts using a table saw:

1. Measure the width and depth of the mortise you have prepared. These measurements will determine the size of the tenon you need to cut.
2. Using a miter gauge or a crosscut sled, set the table saw fence to the desired width of the tenon.
3. Adjust the height of the table saw blade to the desired depth of the tenon.
4. Position the piece of wood you are cutting the tenon on perpendicular to the table saw fence.
5. Hold the wood securely against the miter gauge or crosscut sled and slowly push it through the blade to make the first pass.
6. After the first pass, adjust the fence slightly to remove any remaining material until the tenon fits snugly into the mortise.
7. Repeat the process for all the other tenon cuts you need to make.

Remember to always wear proper safety equipment, such as safety glasses and hearing protection, when using a table saw. Take your time and work carefully to ensure accurate and clean cuts.

Tips:

• It’s recommended to practice on scrap pieces of wood before cutting the actual tenons to ensure you have the right settings on your table saw.
• If you need to make multiple tenons on a long piece of wood, consider using a tenoning jig to help you make consistent and accurate cuts.

Joining the Mortise and Tenon

Once you have successfully cut the mortise and tenon joints using your table saw, the next step is to join them together. This joining process is crucial in creating a strong and secure connection between two pieces of wood.

Gather your materials

Before you begin the joining process, make sure you have all the necessary materials at hand. This includes wood glue, clamps, a mallet, and sandpaper.

The glue-up process

To start the glue-up process, apply a thin layer of wood glue to the surfaces of the mortise and tenon joints. Make sure to brush the glue evenly and sparingly to prevent excessive squeeze-out when clamping.

Next, insert the tenon into the mortise and use a mallet to gently tap it in until it fits snugly. Ensure that the joint is aligned properly and check for any gaps or unevenness.

Once the joint is aligned and fits snugly, use clamps to apply pressure and hold the joint together. Position the clamps on opposite sides of the joint and tighten them evenly to distribute the pressure. Be careful not to over-tighten the clamps, as this can cause the joint to deform.

Finishing touches

After the glue has dried, remove the clamps and inspect the joint. Use sandpaper to smooth out any rough areas or excess glue. Pay attention to the overall appearance and feel of the joint, ensuring that it is flush, sturdy, and secure.

Remember to allow the glue to dry completely before applying any additional finishing or pressure to the joint. This will ensure a strong and durable connection.

Finishing Touches

Once you have successfully cut the mortise and tenon joints using a table saw, there are a few finishing touches that you can consider to enhance the overall look and strength of your joint.

Sanding

After cutting the mortise and tenon joints, it is important to sand them to achieve a smooth finish. You can use sandpaper of various grits, starting from a coarse grit and gradually moving to a finer grit. Sanding will not only remove any rough edges but also help in achieving a more polished and professional look.

Gluing

Applying glue to the mortise and tenon joint can further strengthen the bond between the two pieces. Use a high-quality wood glue and apply a thin, even layer to the surfaces that will come into contact with each other. Make sure to wipe off any excess glue before it dries.

By following these finishing touches, you can ensure that your mortise and tenon joints not only fit accurately but also look professional and sturdy. Remember to take your time and pay attention to detail for the best results.