iWW07 Show Notes

Show Notes
iWW07

Meet the Mortise

Introduction: Mortise & Tenon Joint

Purpose of M&T
  • Join an endgrain member to a long grain member
    • example - joining a horizontal board to a vertical board - as in a door or the frame for a panel
  • Create a long lasting joint that survives dimensional stresses of many seasons
  • A joint that does not rely solely on glue, provides mechanical support

Definitions
  • Mortise - a “pocket” cut into the board to receive the tenon
  • Tenon - a “stub” or “tongue” cut to the precise dimensions of the mortise

Method
  • Using the plunge router with a shop made jig

Why this method? (There are at least 6 others that come to mind)
  • Good method for those inexperienced with hand tools
  • Allow for precise results
  • Quick learning curve

Introduction to the Shop made Base Plate Jig

Right Click on Link below to download a .pdf of the jig I discuss...
Router Plate Jig Layout

Introduction to the Plunge Router

Note: I made a mistake - Routers spin up to around 22,000 RPMs, not 2200 RPM’s....Duh!!!

Router Safety and Proper Set Up
  • Placing the bit properly in the collet is very important
    • Don’t overtighten or treat collet roughly

Layout the Mortise
  • Pencils are no good for accurate layout
  • Use a knife edge to draw the lines
    • respect the bevel angle of the knife when you cut to insure the bevel rides the square

Cut the Mortise
  • Line up with Left side of Mortise (leave 1/4” from the knife line)
  • Motion of cut must be either straight up and down or 90 degrees to the right
  • All motions must be smooth (not rushed)
  • Hog out waste with multiple smooth cuts
  • Think safety
    • eye protection
    • hearing protection
  • Final pass is the pass that defines the left and right ends of the mortise
    • Climb Cutting the left edge of the mortise
      • Climb cutting is moving the router in the direction the bit is spinning
      • Extended Climb Cutting will cause the router to try and “take off” so always use sparingly and be ready for vibration and a feeling the router wants to pull away



iWW06b Show Notes

Sorry for the delay, folks. I really thought I had already posted these...

Show Notes
iWW06b
Crosscutting with a Circular Saw

Introduction: Using the hand held circular saw to quickly process stock into more convenient sized (i.e. safer) blanks for a batch of panels...

Circular Saw Safety
  • Kickback can occur - when front tooth makes contact with the offcut side of the cut and the back tooth makes contact with the “infeed” side simultaneously (i.e. the saw gets shifted crooked in the saw kerf)
    • Kickback on a Circular Saw will often cause the saw to move rather than just the wood - it can come back at you...
  • Always support the offcut
    • I like the the Lee Valley Supports
    • Allows me to support or deflect long and short offcuts easily
  • Remember to protect your feet from offcuts that drop unexpectedly
  • Verify before you cut that NOTHING is obstructing the path of the saw blade
    • Like a support....
  • Clamp infeed side of stock securely
  • Hearing protection and Dust Filtration

The First Cut
  • Cut off end of board
    • Remove any stock with checks off the end
      • Checks = thin cracks that develop at the ends when lumber is dried
      • Good test of saw set up and depth of cut
  • Donʼt want to cut so shallow that the blade does not fully cut through the board
    • Attempting to cut a groove will increase your chance of kickback to almost 100%
  • Cut must be straight but does not have to be square to the edges of the board
    • You can do this free hand, without jigs or fences
  • Note to Self: Next time I plan to cut 2+” old growth walnut, I might need to upgrade to a larger hand held saw
    • You donʼt want the saw bogging down as much as you hear in the podcast...

Mark Kicks Back!
  • I get a kickback on the saw - all according to plan, I assure you....right... Winking
    • This is what happens when the blade doesnʼt clear the bottom of the stock
    • Oops....

More Cuts
  • More of the same
  • Technique Tip - With the power off, line up to the cut and press the blade forward until it contacts the wood, then back off - it is now safe to press the power trigger and start the cut with the blade spinning before it touches any wood
  • Note how well the Lee Valley supports the offcut for this operation
Upcoming

We will be following these panels through all the steps to process into panels for my exterior doors...

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Mark