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Project by kiefer posted 05-07-2014 08:17 PM 4922 views 20 times favorited 18 comments Add to Favorites Watch

This tennon jig is really not different that others of this type but by using two blades to cut both sides of the tennon in one operation makes it easier and saves time and eliminates the process of having to flip the work piece or resetting the jig for the second cut .
This is not a new idea as my uncle did this on a shaper some fifty years ago and I have read about this method in books .
The jig is constructed to slide on the fence with as little play as possible and a handle that keeps my hand well away from the blades . The work piece is held in place by a toggle clamp and aligned by the tall fence and a back stop which both have to be perfectly set a right angle to the saw table .
I use a 1/4 ” box joint blade to cut the dado first and then set up the two 7 1/4” blades with a spacer and shims in between to match the tennon to the dado .
I use the 7 /14” blades because of the low price and can set it up once to the perfect fit and put it away for the next time I need it .

After I cut all the dados I set up the blades for the tennon cutting and align the jig with the work piece clamped in place to the dado for the length of the tennon by using the dadoed work piece as a hight gage
and visualy align the tennon position
This is done without the saw running and unplugged from power (Safety First )
A couple of test cuts and the alignment is perfect .
The waste that remains is cut on my sled with a stop block .

Here is the result of the first test and it turned out very well nice and flush and square and now I can make the doors for my daughters bathroom cabinets .

-- Kiefer

18 comments so far

View Jim Jakosh's profile

Jim Jakosh

25176 posts in 3951 days

#1 posted 05-07-2014 08:51 PM

Very nice sturdy jig, Kiefer. I love it. I had been thing about making one but I don’t cut too may tenons on the table saw. Thanks for sharing. I may have to make one of them some time too!!..............................Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View tyvekboy's profile


2045 posts in 3859 days

#2 posted 05-07-2014 09:07 PM

Great idea Kiefer.

Did you use a circle cutter for the wooden spacer or did you turn it on a lathe?
Was the wooden spacer solid wood or plywood?

Where did the brass looking spacers come from?

-- Tyvekboy -- Marietta, GA ………….. one can never be too organized

View kiefer's profile


5760 posts in 3513 days

#3 posted 05-07-2014 09:17 PM

Hi Alex
The wood looking spacer is made from laminate flooring (nice and hard ) and cut out on the band saw and the shims are from an old dado set ,the silver washers are saw blade stabilizers from Dimar which I like using with all my blades when possible especially thin kerf blades .

-- Kiefer

View hoss12992's profile


4176 posts in 2739 days

#4 posted 05-07-2014 09:35 PM

Cool jig, great job buddy

-- The Old Rednek Workshop

View HillbillyShooter's profile


5811 posts in 3138 days

#5 posted 05-07-2014 11:49 PM

Great idea—I particularly like your use of low cost 7-1/4” blades so you can set them up once and leave them set up for the next time. Innovative as always!

-- John C. -- "Firearms are second only to the Constitution in importance; they are the peoples' liberty's teeth." George Washington

View Mark's profile


1048 posts in 2821 days

#6 posted 05-08-2014 12:12 AM

Very cool idea Kiefer. Well done.

-- Mark

View DocSavage45's profile


9017 posts in 3688 days

#7 posted 05-08-2014 12:52 AM


Keep on creating!

-- Cau Haus Designs, Thomas J. Tieffenbacher

View steve_in_ohio's profile


1195 posts in 2457 days

#8 posted 05-08-2014 12:55 AM

great idea

-- steve, simple and effective

View Mauricio's profile


7165 posts in 3998 days

#9 posted 05-08-2014 02:51 AM

pretty cool.

-- Mauricio - Woodstock, GA - "Confusion is the Womb of Learning, with utter conviction being it's Tomb" Prof. T.O. Nitsch

View Woodknack's profile


13470 posts in 3226 days

#10 posted 05-08-2014 04:11 AM

Considered this many times but I don’t really cut enough tenons as a hobbyist to bother. Nice to know it works.

-- Rick M,

View stefang's profile


17040 posts in 4180 days

#11 posted 05-08-2014 07:51 AM

Your jig certainly works well Klaus and it’s a pretty simple set-up too.

-- Mike, an American living in Norway.

View doitforfun's profile


199 posts in 2454 days

#12 posted 05-08-2014 10:32 AM

I just finished building a tenon jig last night based on LJ thetinman’s design. The toggle clamp is a great idea. I’m going to add that to mine.

-- Brian in Wantagh, NY

View jbschutz's profile


603 posts in 3537 days

#13 posted 05-08-2014 02:16 PM

So much to like about this jig and setup. Best of all… is consistent, once you have it tuned.
Great build Kiefer!

-- jbschutz

View TechTeacher04's profile


447 posts in 2378 days

#14 posted 05-08-2014 05:29 PM

I have always thought of trying that but was concerned that the spacer might not survive. I guess I am overly cautious.

View Jerry's profile


3484 posts in 2494 days

#15 posted 05-08-2014 07:00 PM

Very clever, I like this!

-- There are good ships and there are wood ships, the ships that sail the sea, but the best ships are friendships and may they always be.

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