To learn how to make tenons with specialized table saw tools, follow the following steps: Set the tablesaw’s rip fence for the proper length, square the dado set with a miter gauge, and adjust the dado blade height accordingly. Using a dado guide will allow you to follow the process step-by-step. Once you’ve established the proper length, you can move on to compound angled tenons.
Compound angled tenons
The process for cutting angled tenons is similar to cutting straight tenons, but it requires a wedge of the correct angle. Most people cut tenons with a table saw, but they may ask, “Why not use an angle blade on my table saw?” This is a common mistake, because a table saw is not designed to cut the proper shoulder angle.
You should align the trunnion’s tangent with the face plate. After you’ve aligned your trunnion with the tenon’s tangent, adjust the saw blade’s height and position so the first cut is made in the right angle. Use a dado blade or a specialized saw blade for cutting angled tenons. Both methods require a similar process and result in a finished product that looks more complex than it is.
Using a dado blade
Using a dado blade on a table saw allows you to create a tenon with two matching rabbet cuts. The setup shown in Figure 3-44 determines the length of the tenon and the projection of the blade is one-half the thickness of the stock minus the thickness of the tenon. Make several passes to make all the cuts and clean the waste stock.
The first pass cuts across the stock thickness. You need a blade projection of about half the width of the stock. You can use clamps to hold the pieces together while you are making the cut. You can also mark the spacing between notches on the front piece of the joint. To ensure you cut the tenon with the right length, make sure the dado width and projection are equal.
Setting the height of the dado head
There are two methods of setting the height of the dado head with recipse dado blades. The first method involves making an insert that is dead even with the table. The difference should not be more than a few thousandths of an inch. If you are using the wrong material, this measurement may be significantly off. To get a more accurate reading, lay two blocks of wood on the table of the same height as the depth of the dado. Use a steel rule or square to align these blocks. Next, lay a peanut butter jar across both blocks and add a weight.
Setting the height of the dado head is easier when you are working with a smaller piece of wood, such as plywood. If you are working with large pieces of plywood, it can be tricky to hold them flat and align them. Alternatively, you can purchase a dado machine, such as a hand-held router, to cut your plywood. However, you should note that reciprocating large pieces of plywood with the dado head is not recommended – you’d be better off using a hand-held router. Also, you should know that the dado head on a table saw cannot make a stopped dado, which is necessary for certain projects.
Using a dado guide
Using a dado guide is one of the easiest ways to create a tenon. This piece of equipment will help you cut the tenon with a table saw. The setup in Figure 3-44 allows you to create tenons by making two overlapping cuts. The first cut will be the tenon cheek, while the second cut will be the tenon shoulder. The rabbet cuts can be controlled by setting the blade to one-half of the thickness of the stock, minus half. You can then make the next cut to finish the tenon.
The next step is to mark the piece of wood. If you don’t have cap molding, you can leave one side exposed. Place the guide on the table and set the blade to the proper height. Use a dado blade to make the first cut, and do the same for the other side. A dado blade allows you to make the cut once, while a regular saw blade requires multiple cuts.
Using a dado jig
Using a dado jigg is a simple way to make tenons with your table saw. You set up the jig so that the waste from the tenon falls to the outside. This way, you don’t have to change the height of the blade. Using a mitre gauge can be extremely useful.
When using a dado jig, you’ll want to set up your table saw so that the blade is set up for shoulder cuts and cheek cuts. Then, you’ll need to set up your miter gauge so that the rip fence and workpiece line up properly. You’ll also want to place a backup board underneath your workpiece for stability.
