DIY Network

Web Extra: Making a Tenoning Jig/Rabbet Cuts From "Freeform Furniture" episode DFFF-213

Host Amy Devers demonstrates how to make a tenoning jig.

Make Your Own Tenoning Jig

• A table saw tenon jig is easy to build and easy to use on any saw with a lain, unencumbered rip fence. The jig is designed to ride along the fence, offering sliding movement accurately parallel to blade as well as easy positioning for cutting centered or offset tenons, lap joints and bridle joints.

• The first thing to do when making your own tenoning jig is to get all your tools together. You will need a table saw, tape measure or steel ruler, drill with bits, clamps, pre-cut tenon, dust mask, and goggles for safety. After you have your materials together, you need to set up the saw. The accuracy of the jig will be determined by the saws setup as well as the fit of the tenon. For the saw's set up, you will first set the blade height equal to the length of your tenon. Then, center the tenon's cheek against the right side of the blade and make sure the fence is against the right side of the tenon stock. Make sure the fence is locked and set the miter gauge to 0.

• Once the saw and tenon have been set up, it is time to cut. Use a pre-arranged cut list to determine which cuts to make and to ensure accuracy. Glue and then clamp both the horizontal and vertical rail pieces together, then make sure that each laminated face on each rail is flat.
• Stand the miter gauge extension on its edge and scoot one edge against the fence, then make sure the face is touching the back side of the extension by moving the miter gauge forward. Now you can drive a screw through the slots in the miter gauge into the extension.

• Take your tenon and stand it on one end and move a laminated face of the vertical rail up to the face of the tenon stock. Drill screws into the back of the extension of the vertical rail then on the right side of the vertical rail, then clamp down your tenon. A handle or knob mounted on the bridge makes the jig easy to handle. Now your jig is complete.

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Host Amy Devers demonstrates the proper way to do a rabbet cut.

Rabbet Cuts

• Although simple in appearance, there's more to the rabbet cut than first meets the eye. To make the best use of rabbets, you need to know the various ways to cut them, when to use each method, and how to make the cuts effectively. The size of the rabbet is determined by the piece that will be joined to it. For example, if you were recessing a 1/4" panel into the back of a bookcase frame made of 3/4" stock, the rabbet would have to be 1/4" deep (to accommodate the panel) by about 3/8" wide (to provide fastening area without loss of strength to the side).

• A rabbet is simply a rectangular recess along the edge or end of a work piece. Although most often found as a joint in casework, a rabbet also can pop up as a design feature in a molding, as a recess for holding artwork in a picture frame, along the edges of a cabinet door to help recess it partway into its face frame, or as a half-lap or shiplap joint.

• You can cut rabbets with a variety of tools. You determine which one by the amount of pieces you have to work with. Another factor to consider is the quality of rabbet cut you are looking for. A table saw with a dado set, table saw with standard blade, handheld router with rabbeting bit, router table with a straight bit will each give you a rabbet cut with their own look.

RESOURCES :

Festool
Website: www.festoolusa.com

Stanley Tools Product Group
Website: www.stanleytools.com

Lie-Nielsen Toolworks, Inc.
Website: www.lie-nielsen.com

WMH Tool Group
Website: www.wmhtoolgroup.com

Adhesives, Abrasives and Safety Equipment
3M
The 3M Company
Website: www.3m.com

Power Tools
Porter Cable Power Tools
Website: www.deltaportercable.com

Gladiator GarageWorks
Website: gladiatorgarageworks.com

Hand Tools
Garrett Wade Co., Inc.
Website: www.garrettwade.com

The Peck Tool Company
Website: www.pecktool.com

Biesemeyer
Website: www.biesemeyer.com

Saw Blades
Forrest Manufacturing Company
Website: www.vacupress.com

Jogensen Adjustable Clamp Company
Website: www.adjustableclamp.com

Klein Tools
Website: www.kleintools.com

Power Tool Accessories
Woodcraft
Website: www.woodcraft.com

Ulmia GmbH
Website: www.ulmia.de

Shop Equipment
Eagle Manufacturing Company
Website: www.eagle-mfg.com

Delta Power Tools
Website: www.deltaportercable.com

MacBeath Hardwood
Website: www.macbeath.com

IMS Metal
Industrial Metal Supply Company
Website: www.imsmetals.com