Joinery Made Simple

Loose-Tenon Options
Spend a little, spend a lot: three great ways to make loose-tenon joints.
By Jim Harrold

T
here’s little doubt that the
mortise-and-tenon joint is
one of the strongest joints
in woodworking. But it’s not always
the quickest or easiest to cut. There’s
an alternative that’s a lot easier to
make—the loose-tenon joint. This
joint can be made quickly with a
router, a cordless drill, or a high-speed
mortiser, and when it’s assembled
with modern adhesives, it’s plenty
strong for most projects.
With a traditional mortise-and-
tenon joint, you cut a mortise (a
slot) in one of the mating pieces
(for example, a table leg). Then you
cut away material from the end of
the other mating piece (the apron)
to create a tenon. The challenge lies
in getting the tenon to fit perfectly
in the mortise. Since you’re cutting
the mortise and the tenon with two
different tools and two different of the tenons (i.e., no math). And, While one saves time, another
setups, the possibility for a joint that finally, you can easily use loose tenons saves money. Hopefully, you’ll find
doesn’t quite fit together perfectly is with angled joints such as miters. one that best suits your needs and
always present. Here, we’ll cover three distinct budget. (See the Convenience-
On a loose-tenon joint, you cut approaches to cutting loose-tenon Plus Buying Guide on page 31 for
mortises in both pieces with the same joints. They all have their advantages. products mentioned.)
machine or jig and the same setup.Then
you cut a loose tenon (sort of a short Guidelines For Sizing Mortises
spline) to fit halfway into each piece. It’s
glued securely in place for a very strong WIDTH = Bit size =
face-grain-to-face-grain joint. 1
/3 the thickness of
One benefit of the loose tenon is the thinnest mating
the instant fit you get with little or no piece
additional handwork with a plane or LENGTH = 2/3
sanding block. Another benefit is that the width of the
by cutting the loose tenon narrower narrowest mating
than the mortises, you have a “fudge piece
factor” that helps you align pieces DEPTH = As deep
flush, even if you slightly miscut the as possible based
mortise length or location. A third on bit length, but
and very big benefit is that you cut all at least 1/16" deeper
of the workpieces to finished length than half the length
before cutting the joints. You don’t of the tenon
have to take into account the length

www.WoodcraftMagazine.com w o o d c r a f t m a g a z i n e    27
Joinery Made Simple

The jig and Figure 1

router combo Router mortising jig
Our low-tech, low-dough approach
features a plunge-router mortising jig
that you can make out of plywood,
acrylic plastic, scrapwood, and some
common hardware (Figure 1). Add
jig-building to your set-up time, and
you have an approach that takes the
longest of the three to get started. And
yet, the result will yield a long-lasting
joint that’s quicker to make than a
traditional mortise and tenon.

Building the jig

The heart of this mortising jig is a
platform that holds and “corrals” your
plunge router. The platform sits on
top of a vertical clamping face and
base that can be clamped securely to
the top of your bench. The vertical
support also features a toggle clamp
and a work rest to position and secure
the workpiece during machining. The
3/8"-thick clear acrylic plastic platform

lets you to see through the “window”

to set up exactly where you’re routing.
Two rows of T-nuts in the clamping
face help hold the workpiece vertically,
horizontally, or even at an angle
(Figure 2).
Build the jig to fit your plunge
router by screwing a couple of
hardwood fences along the edges of
the platform. The distance between
the fences should equal the diameter
of your router base.

Create crosshairs in the center

tip alert

(bottom) of the platform by

scratching lines with a sharp awl,
filling them in with a permanent ink
marker, and then wiping away the
excess ink.

Using the jig

To use the jig, hold the mating pieces
together and then lay out a centerline A
for the mortise across the front (“show”)
face and edges or ends of each piece as Mark the centerline of the mortise on the front
shown in Photo A. Then lay out lines faces of both pieces and transfer the line to
showing the mortise length and the the appropriate end or edge. Then lay out the
position of the mortise on the thickness length of the mortise.
of the piece as shown in the Inset.

28   w o o d c r a f t m a g a z i n e A p r i l / M ay 2 0 0 9
Figure 2
Part Views

Platform Toggle clamp

Workpiece

B
Position both the vertical and horizontal hairlines,
then toggle-clamp the workpiece in place and
tighten the knobs under the platform.

Vertical support Finally, cut a mortise by

plunging down 1/4" into one
end. Then slowly rout side
to side making increasingly
deeper cuts. After the
mortises are cut in the edges
of all the appropriate pieces
as shown in Photo D, reset
the jig and cut the matching
mortises in the mating ends
as shown in Photo E. It’s
always a good idea to make C
test cuts with scrap the same
thickness as your finish Watch the bit to set the
cuts. This allows for any stopblocks and align with
Now, use the toggle clamp and work fine-tuning of the jig before each end of the mortise,
rest to clamp the workpiece in position cutting your project pieces. then tighten the knobs.
under the short vertical hairline on the
jig. (Note: Always check that the marked
“show” face is against the clamping
face.) Then position the platform so the
long horizontal hairline aligns with your
layout line and tighten the two knobs
under the platform (Photo B).
Mount a spiral upcut bit in your
router. (Note: A spiral upcut bit
plunges, cuts sideways with a clean
shearing cut, and lifts the chips up
and out of the mortise.) Set the depth
of cut taking into consideration the
thickness of the acrylic platform and
length of the tenon. D E
Next, set the router on the
platform and position the stopblocks Plunge down then rout from side to Switch the position of the work rest
to determine the length of the side. Gradually rout the mortise in 1/4" until it’s vertical and cut mortises in the
mortise as shown in Photo C. deep increments. ends of the mating pieces.

www.WoodcraftMagazine.com w o o d c r a f t m a g a z i n e    29
Joinery Made Simple

See Charles Neil demo the

Mortising JessEm Pocket Zip Slot Mortise
Mill at WoodcraftMagazine.com/onlineextras.
drill bit

best to use a corded drill at high speed

unless you’ve got a powerful cordless
drill and a recently-charged battery.)
The JessEm Pocket Zip Slot
Mortise Mill sells for $99.99, but if
you step up to its big brother, the
standard JessEm Zip Slot Mortise
Mill ($249.99), you’ll get easier
adjustability, more clamping surface
for workpieces, longer mortises, and
the option of going with 1/4"-, 3/8"-, or
1/2"-wide mortises.

The ultimate loose-tenon

F joiner at a stiff price
If you have the bucks for the high-
You can cut clean and consistent mortises simply with a JessEm Pocket Zip Slot tech end of the spectrum, you’ll
Mortise Mill jig, an electric drill, and a special mortising drill bit. find the ultimate in speed and
precision in Festool’s Domino Joiner.
The commercial jig and and the only width mortise (i.e., Though from outward appearances
portable drill combo thickness of the loose tenon) this jig it looks like a biscuit jointer, it
Our second approach looks at using a will cut is 1/4". works differently, with noteworthy
store-bought jig and a portable drill. After marking the location of the advantages.
It costs a little more, but is a good mortise, secure the workpiece and jig in It features a router-like bit that
alternative if you don’t have a plunge a vise. Then, with the setup established, plunges into the work and then
router or don’t want to take the time work the jig’s lever back and forth with oscillates from side to side. Within
to build the shop-made jig. one hand while drilling down using a a few seconds, you’ve cut a perfectly
Using a drill to rough out mortises portable drill with your other hand as clean mortise that accepts a custom-
is a common operation but it usually shown in Photo F. (Note: I found it sized loose tenon. And here’s the real
involves drilling a series of overlapping
holes with a drill press and then
cleaning out the scalloped edges by
hand with a chisel. The JessEm Pocket
Zip Slot Mortise Mill takes this to a
new level. The Mortise Mill comes
with a special 1/4" “mortising drill bit”
(see the Inset in Photo F). It’s similar
to a spiral upcut router bit, but with
a longer shank. That means you drill
the end holes with it and also work the
bit sideways to clean out the mortise,
eliminating the need for chisel work.
Expect some time loss in trial and
error when setting up the Mortise
Mill jig. The length of the mortise
is slightly adjustable but you have
to keep removing the workpiece G
and checking the length to match
a specific width loose tenon. The Pushing the Festool Domino Joiner into the edge, end, face, or a miter creates a
maximum loose tenon width is 11/8" very accurate mortise that will accept a domino-shaped loose tenon.

30   w o o d c r a f t m a g a z i n e A p r i l / M ay 2 0 0 9
 Four Assembly Tips
• Sand slight chamfers on the ends of loose tenons so they
insert more easily into the mortise.
• Dry-assemble your project to check that everything fits.
• Use a small brush to apply glue down into each mortise
and on the first 1/4" or so of the tenon.
• Make your tenons 1/8" narrower than needed. This creates
slight adjustability for a precision fit. That said, always
check that mating pieces are flush on the ends and edges
during clamp-up. H
Round over all four edges of your tenon stock on the router
advantage—the loose tenon is much larger and thicker table to match the mortise.
than a biscuit, providing greater face-grain-to-face-grain
gluing surface.
Layout is as quick and easy as a biscuit jointer. You can
work anywhere on the board, even on a mitered end as
shown in Photo G. Just hold your two mating workpieces
against one another and draw a pencil line across both
pieces where you want the matching mortises. Then set the
Domino Joiner for the desired depth and width. Secure the
workpiece with clamps or in a vise, line up a cursor on the
tool with your pencil line, and plunge.
Okay, what’s the downside? Well, other than the price I
($775), you’re limited to five different depth settings and
three different width settings. Also, you’ll need to work in Clamp a stopblock to your rip fence to prevent kickback
metric sizes. All of the bits, depth and width settings, and when cutting short tenons.
domino thicknesses are in millimeters. If you’ve worked in
millimeters, then it’s simple. If not, I’d recommend picking
Convenience- PLUS BUYING GUIDE
up a ruler or tape measure with both metric and inch
Item WOODCRAFT # price
settings across from each other.
23/4 × 4" Vertical Handle Quick
1. Action Toggle Clamp 143934 $11.99
Making or buying Knob, Four Arm with 1/4"-20 × $2.50
loose tenons 2. 11/2" Stud (2 Needed) 27R15 each
After choosing a mortising approach, you’ll need to decide 3.
Knob, Four Arm with 1/4"-20
27R14 $2.50
Insert (4 Needed) each
on one of the options for obtaining loose tenons. These
include making your own to fit any size mortise, or buying 4. T-Nuts, 1/4"-20 (pack of 10) 130226 $2.50

pre-made tenons. Festool tenons are available in metric 5. Clear Acrylic Stock, 3/8 × 12 × 12" 16L71 $15.99
sizes for mortises cut with the Domino Joiner. JessEm sells 6.
CMT Upcut Spiral Bit, ¼" D, 1"
820268 $27.99
CL (1/4" SH)
tenons in two different lengths and three thicknesses (all in
JessEm Pocket Zip Slot Mortise
inch measurements) to match their bits. 7. Mill 149198 $99.99
To make your own loose tenons, start by planing some JessEm Zip Slot Mortise Mill
8. 149197 $249.99
scrap hardwood stock; aim for a slight friction fit in your test
9. Festool Domino Joiner DF 500Q 574258 $775.00
mortise. Rip off strips 1/8" narrower than the length of the
12" (300mm) Stainless Steel
mortise to allow some wiggle room during assembly. Next, 10. Cabinetmaker’s Rule 140656 $6.99
round over all four edges of the tenon stock to match the JessEm Zip Slot Tenons: /4 × 1 /4", #149206, 50/pack,
1 1

rounded ends of the mortises. Do this with a block plane, 11. $8.99; 3/8 × 11/4", #149207, 40/pack, $12.99; 1/2 × 13/8",
#149208, 30/pack, $14.99
sandpaper, or a router table and round-over bit as shown in
Festool Beech Dominos ($71.50 per pack): 5mm ×
Photo H. The final step is to cut the loose tenons to length 30mm, 1,800/pack, #493296; 6mm × 40mm, 1,140/pack,
with a miter gauge and auxiliary wood fence on the table saw 12. #493297; 8mm × 40mm, 780/pack, #493298; 8mm ×
50mm, 600/pack, #493299; 10mm × 50mm, 510/pack,
as shown in Photo I. To allow room for glue, cut them 1/8" #493300,
shorter than the combined depth of the two mortises. For Above items are available at Woodcraft stores, woodcraft.com or by calling
(800) 225-1153. Prices subject to change without notice.
more on assembly, see the tips above.

www.WoodcraftMagazine.com w o o d c r a f t m a g a z i n e    31
 SUBSCRIBE!
2 YEARS for $29.99!
go to woodcraftmagazine.com
and click SUBSCRIBE
-or-
Complete the form below and
mail in an envelope addressed to:
WOODCRAFT MAGAZINE
PO BOX 7020
PARKERSBURG WV 26102-9916

□ Payment Enclosed □ Bill Me

Name
Address
City
State Zip
Country
E-mail
Best-ever DECORATIVE FINISHES Build Better

Send in now to get

LUMBER RACK Done Right with a CUT LIST

2 Years for $29.99!

Projects, Techniques and Products

Build this
classic

SPICE BOX
And learn how to…
n Dovetail a case
n Divide a cabinet into

or go to woodcraftmagazine.com and click SUBSCRIBE

compartments
n Create a cornice

By providing my e-mail address, I am indicating I’d like to receive information

about my subscription and other offers from Woodcraft Magazine via e-mail.
Outside of the U.S and Canada add $30 for postage. Plus…
Foreign orders must be prepaid. Payment in U.S. Funds only. n

n
4 more projects
Famous furniture