Mods 14 Page 2
Tenon Cutter
WOW!
Unaware of all the latest jigs and mods, alloy rails and stop systems etc. Beau some time ago set about designing his own very accurate and repetitive tenon system for the 'Rat for industrial use. The purpose was to cut tenons to match mortises cut with his heavy duty mortising machine. This jig is stop controlled for cutting the cheeks but awaiting a vernier stop method for E/W cutting. The router is slid N/S by a clever wooden operating arm and the jig assembled from strong alloy angle. Notice that the 'Rat is an early model.
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The router is fixed at 90 degrees to standard and mounted on a square of six mm acrylic. He uses a 1/2inch solid carbide cutter which he says has never needed to be sharpened. The whole assembly is fixed to a solid 18mm plywood base. |
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The router movement is controlled by sliding nylon66 gib strips. Since the strips are cut at an angle on their engaging edges any sideways play or lift is simple to adjust out. This system is used on both sides but after consideration Beau has concluded that adjustment is only needed on one side. |
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This shot clearly shows the linkage and pivot of the control arm. The length of the arm of course makes for light and precise control. The router bar is used to set the N/S travel in conjunction with sliding alloy stops on each end of the frame. |
| Here is the front sliding alloy angle 'A' slid to the left to engage with the router bar 'B'. Note the fine adjustment screw on the end of the bar. |
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The angle stop slid to the right and so dis-engaged. |
| A similar principle applies to the rear sliding stop shown here set for dis-engagement. |
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A closer view and here in the engagement position. |
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A finished tenon which will exactly match the mortise chisel size. The work is normally held in the cam-lock for cutting at 90 degrees to the way that I have photographed it. |
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Beau doesn't own a plunge bar and sets the router to take a full depth cut. The up-cut solid carbide cutter had no difficulty with this. The whole operation was very quick and accurate. Even with a powerful dust extraction system it was still a bit messy with chips being thrown out from the front. Who said the 'Rat is not suitable for industrial use!? |
I never cease to be amazed at some of the mods done to a WoodRat and I believe that Beau's industrial strength jig is something to behold! He works to the most exacting of standards as you would expect from a David Savage student and his WoodRat additions ensure extremely accurate joints.
Thanks for sharing your ideas with us Beau.
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