Making The Doors

1 Cutting the tenons in the rails

Use your table saw to cut the open mortlse-and-tenons that join the rails and stiles of the doors. Saw the pieces to size, then install a commercial tenoning jig on the saw table; the model shown slides in the miter slot. Clamp one of the rails end-up to the jig, using a wood pad to protect the stock. Make the cutting height equal to the stock width and position the jig so the outside faces of the blade and the workpiece are aligned. Push the jig forward to feed the rail into the blade (right), then turn the stock around and repeat the cut on the other edge. Move the jig toward the blade slightly so the thickness of the tenon will be equal to about one-third the stock thickness and make two more passes. Repeat the process to cut tenon cheeks on the other end of the rail and at both ends of the remaining rails.

2 Sawing the mortises

Clamp one of the door stiles end-up to the jig, position the jig to center the edge of the workpiece with the blade, and feed the stock into the cut (left). Then move the jig very slightly away from the blade to enlarge the mortise. Make another pass, turn the stile around in the jig, and feed it into the blade again. Next, test-fit one of the rail tenons in the mortise. If the fit is too tight, move the jig away from the blade slightly and make two more passes, continuing until the tenon fits snugly in the mortise. Use the same procedure to cut the mortises at the other end of the stile and at both ends of the remaining stiles. You can also use a shop-made jig to cut this joint, as shown on page 106.

Making Tenons Both End

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