ROUTER

MORTISING JIG

© 2015 August Home Publishing Co.

 best-built
jigs & fixtures

router
Mortising Jig
You’ll be making mortises in
minutes with your hand-held
router and this easy-to-build jig.
Creating a mortise with a hand-held plunge router is
my favorite method for completing the task. The key
to great results is guiding the router accurately so the
sides of the mortise end up perfectly smooth, straight,
and parallel to the faces of the workpiece.
The solution I use in my shop is the mortising jig you
see above. Clamping the workpiece in place only takes
a second. Then, it’s a simple task to adjust the table
and stops to locate the mortise on the workpiece. Once
everything is locked in place, you can knock out identi- {  Viewing Port. A wide opening in the table makes
cal mortises quickly, easily, and accurately. As you can the setup a snap. Plus, you can easily see your
see in the photo at right, the result speaks for itself. progress as you rout the mortise.

1 WoodsmithPlans.com SN11240 ©2015 August Home Publishing Co. All Rights Reserved.
Exploded View Details
OVERALL DIMENSIONS: 23"W x 14"H x 12"D

ADJUSTABLE TABLE
RIDES ALONG RUNNERS
TO ACCURATELY POSITION
ROUTER (AND BIT) OVER
THE WORKPIECE

ADJUSTABLE STOPS
LIMIT TRAVEL OF
ROUTER TO ESTABLISH
LENGTH OF MORTISE
WIDE PORT
PROVIDES CLEAR
VISIBILITY WIDE GROOVE
NOTE: IN TABLE GUIDES
WIDTH OF MORTISE ROUTER DURING USE
IS DETERMINED
BY DIAMETER OF
ROUTER BIT USED
HARDBOARD RUNNERS
GUIDE ADJUSTABLE
TABLE DURING SETUP
TOGGLE CLAMP POST
IS REPLACED WITH A
CUSTOM PAD FOR MORE
SECURE CLAMPING
AND ADJUSTABILITY
BASE EXTENSIONS
MAKES IT EASY TO
SECURELY CLAMP JIG
TO BENCHTOP

ADJUSTABLE FENCE
SUPPORTS WORKPIECE
HORIZONTALLY
OR VERTICALLY
(INSET PHOTO AT RIGHT)

NOTE: USE SPIRAL

UPCUT BIT TO PROVIDE
TOGGLE CLAMP SMOOTH RESULTS AND
MOUNTS TO FENCE FOR CLEAR WASTE QUICKLY
SECURE CLAMPING OF WHEN ROUTING MORTISES
WORKPIECE

Materials & Hardware

A Bottom (1) 61/2 x 23 - 3/4 Ply.
B Ends (2) 41/2 x 53/4 - 3/4 Ply.
C Back (1) 41/2 x 16 - 3/4 Ply.
D Top (1) 61/2 x 16 - 3/4 Ply.
E Runners (2) 1/ x 61/ - 1/ Hdbd.
2 2 4
F Front (1) 12 x 16 - 3/4 Ply.
G Adjustable Table (1) 12 x 16 - 3/4 Ply.
H Stops (2) 5 x 51/2 - 1/4 Hdbd.
I Fence (1) 5 x 111/2 - 3/4 Ply.
J Clamp Block (1) 23/4 x 5 - 3/4 Ply.
K Clamp Foot (1) 3/ x 1 - 2
4 the end of a workpiece.
• (1) 5⁄16"-18 Thru-Hole Knob
• (4) 1/4"-20 x 11/4" Studded Knobs
• (3) 5⁄16"-18 x 11/2" Studded Knobs
• (1) Toggle Clamp (De-Sta-Co TC-227-U)
• (6) 1/4"-20 T-Nuts
• (9) 5⁄16"-18 T-Nuts
• (4) 1/4" Washers
• (4) 5⁄16" Washers
• (1) 5⁄16" x 3" Carriage Bolt {  Optional Orientation. You can
• (4) #8 x 3/4" Ph Sheet Metal Screws easily turn the fence 90° to mortise
• (19) #8 x 11/2" Fh Woodscrews

2 WoodsmithPlans.com SN11240 ©2015 August Home Publishing Co. All Rights Reserved.
 start with the FIGURE
1
Base RUNNER RUNNER
(!/2" x 6!/2") E
E
2!/4

To make consistent, accurate mor- D

tises, the jig needs to hold a work- NOTE: CUT GROOVES
TOP
(6!/2" x 16")
piece securely. And there are three IN EXTRA-LONG
BLANK, THEN CUT
key parts to the jig to accomplish TOP TO SIZE. EXCESS CL B
IS USED LATER FOR
this. The first is an easy-to-build ADJUSTABLE TABLE ENDA B C D E F G H I
C (4!/2" x 5#/4")
base. Attached to the base is a large
%/16"-18
T-NUT
N O P Q R S T U V W
BACK
front panel which accepts a fence (4!/2" x 16") AA BB C C D D E E F F
that’s used to support and clamp J J K K L L MM N N O O
A SS T T UU V V WW X X
the workpiece securely in the jig. B BOTTOM
A B C D E F G H I J K L M END (6!/2" x 23") B BB C C C D DD E E
A AA NOTE:
And finally, there’s an adjustable
N O P Q R S T U V W X Y Z GGGALL PARTS
HHH I I I J J J K K
table that provides an accurate EXCEPT RUNNERS
AA BB C C D Dand E E F F GG H H I I ARE #/M4"MM NNN OOO P P P Q Q
PLYWOOD.
way to position the workpiece RUNNERS ARE !/4" HARDBOARD
J J K K L L MM N O O P P QQ R R
N S SS T T T U UU V V V WW
router for routing a mortise.
SS T T UU V V WW X X Y Y Z Z YYY Z Z Z C
Start with the Base. The mortis-
A AA B BB C C C D DD E E E F F F 3 RUNNER a. L
ing jig starts out as a simple base
GGG HHH I I I J J J K K K L L L
(Figure 1). The base N consists of a
MMM NN O OO P P P Q QQ R R R TOP EXPLODED VIEW
top and bottom,SaSS front
!/4 OVERALL DIMENSIONS:
T T and back,
T U UU V V V WWW XXX
!/2"-RAD. (24!/2" x 24!/2" x 24!/2")
and a pair of ends.
YYY Z Z Z CL DRILL
The bottom is sized to extend past #8 x 1!/2" Fh FRONT PART
#/8"-DIA. NAME
HOLE w/LETTER
the ends, as you can see in Figure
WOODSCREWS
END VIEW (first time used)
W/ &/8"-DIA.
COUNTERBORE
1. This makes itEXPLODED
easy to clamp VIEW the PART NAME
OVERALL DIMENSIONS:
jig securely to the top of
(24!/2" any work-
x 24!/2" x 24!/2") CALLOUT
surface. After cutting the ends and the top before you can attach it to Since the adjustable table has
back to final size,PART
they’re ready
NAME to be the base. First, you’ll need to cut matching grooves, I found
w/LETTER TOPit VIEWeasi-
(first time used)
glued and screwed to the bottom. grooves for a pair of hardboard est to start with an extra-long blank
Adding the PART Top.NAME There are a runners. The runners guide the (20") cut to final width and END VIEW
cut both
to take care of on adjustable table that’s added later. pieces from the same blank
couple of tasks CALLOUT (Figure
SIDE VIEW
1). This ensures that the grooves
TOP VIEW
2
FIGURE
TOP VIEW in both parts will line up(CROSS perfectly.
SECTION)
Then, after cutting the grooves to
END VIEW match the thickness of STEP the hard- 1: XXXX
SIDE VIEW board runners, all that XXXXXXXXXXXXXXX
needs to be
done is to cut the top and FIRST:adjust-
XXXXXXX
TOP VIEW able table to their final XXXXXXXXXXX
lengths.
(CROSS SECTION)
2 Before installing the NOTE: runners,XXXXXXX

a. SIDE VIEW STEP 1: XXXX

XXXXXXXXXXXXXXX
you’ll need to drill a XXXXXXXXXXX
counterbored
hole on the underside of the top
2!/2 “QUOTE MARKS”
FRONT FIRST: XXXXXXX and install a T-nut. The T-nut is
XXXXXXXXXXX #8 x 1!/2" Fh used to secure the adjustable table
TOP NOTE: XXXXXXX
WOODSCREW
in place. After gluing the runners PATTERN
XXXXXXXXXXX
3 into the grooves in the top, simply
“QUOTE MARKS” glue and screw the top flush with
the edges of the back and ends.

NOTE: DRILL PATTERN 2!/2

the
Completing the Base. Adding
front shown in Figure 2 will
#/8"-DIA. HOLES
W/ &/8"-DIA.
COUNTERBORES
%/16"-18
T-NUT
complete the base. As you can see,
FOR ALL T-NUTS 2 4 other than cutting the front to size
and sanding a radius on the lower
8 corners, the only other thing to do
!/2"-RAD. is drill a few holes. #8 x 1" Fh
F Like those on the top, theseWOODSCREW
holes
FRONT #8 x 1!/2" Fh
4 (12" x 16" - #/4" Ply.) are counterbored for a set of T-nuts.
WOODSCREW
#8 x 2" Fh 1!/4" 1!/2"
WOODSCREW
3 WoodsmithPlans.com SN11240 ©2015 August Home Publishing Co. All Rights Reserved.
#8 x 1" Fh
 %/16"-18 x 1!/2" NOTE:
KNOB w/WASHER WIDTH OF GROOVE MATCHES
DIAMETER OF ROUTER BASE,

3
FIGURE DEPTH MATCHES THICKNESS
Here, the T-nuts are used to hold OF HARDBOARD USED
FOR STOPS (FIGURE 4)
the fence in a variety of positions.
Careful layout and drilling of the G
holes ensures that you can install ADJUSTABLE TABLE
(12" x 16")
the fence horizontally or vertically, 1%/8
to suit the size of the workpiece and 1#/16 1
the mortising task at hand.
The front is glued and screwed
to the base. Just be sure the top
edge of the front is flush with and 1!/4
!/2"-RAD.
square to the top of the base.
CL CL
ADDING THE TABLE
With the base complete, the next A B C D E F G H I J K L M
step is to create a way to position N O P Q R S T U V W X Y Z
the router easily and accurately so AA BB C C D D E E F F GG H H I I
you can route the mortise. That’s 4"-20
K K L L MM N N O O P P QQ R R
J J!/T-NUT
the job of the adjustable table you NOTE:
DRILL %/16"-DIA.
SS T T UU V V WW X X Y Y Z Za. TOP VIEW
see detailed in Figure 3. HOLE w/ !!/16"-DIA. A AA B BB C C C D DD E E E F F F
COUNTERBORE
The adjustable table (with its FOR T-NUTS GGG HHH I I I J J!/2"-DIA. J KKK L L L 5
matching grooves) can now be MMM NNN OOO P P P Q QQ R R R
C
trimmed to final size from the S SS T T T U UU V VLV WWW X X X
WASTE
blank you cut earlier. So the next YYY Z Z Z CL B C D E F G H I J K L M
A #/4

step is to customize it for your N O P Q R S T U V W X Y Z

#/4 3!/2
router. What I mean by this is cut- from side to side. The depth of the AA BB C C D D E E F F GG H H I I
EXPLODED VIEW
J J K K L L MM N N O O P P QQ R R
ting a wide groove along the front groove should match theOVERALL
thicknessDIMENSIONS:
edge, as in Figure 3. The groove (24!/2"
of the 1⁄4" hardboard that’s used to x 24!/2" x 24!/2")
SS T T UU V V WW X X Y Y Z Z
acts as a guide for the router (and make the stops a little bit later. lockAthe B BB Cin
AA stops D DD The
C Cplace. E E EnextFFF
PART NAME w/LETTER Gis
GGtoHcutHH a I centered KKK L L L
I I J J J slot
stops) as you rout the mortise. Once the groove is complete, task
(first time used) near
MMM NNN OOO P P P Q QQ R R R
I used a dado blade in my table there are a few more thingsPARTto do. the back edge of the adjustable
NAME S SS T T T U UU V V V WWW X X X
saw to cut the shallow groove, The first is to drill a counterbored table. After positioning the table
YYY Z Z Z
CALLOUT C L
widening it until the base of my hole at each end of the groove for for routing the mortise, you can
router fit and traveled smoothly a pair of T-nuts. These are used to lock it securely in place by pass-
TOP VIEW ing a studded knob through the
EXPLODED VIEW
4 NOTE: STUDSEND ON VIEW slotOVERALL
and into
(24!/2"
DIMENSIONS:
the T-nut
x 24!/2" installed in
x 24!/2")
STOP FRONT VIEW a. KNOBS ARE TRIMMED
the top of the base.
1" IN LENGTHSIDE VIEW
TO SLIGHTLY LESS THAN
TO CLEAR Viewing Mortise. The last
the w/LETTER
WORKPIECE UNDER TABLE PART NAME
(first timeisused)
ADJUSTABLE TABLE TOP VIEW task on the list to create a view-
!/4"-20 (CROSS SECTION)
KNOB w/STUD ing port.
PART You
NAME can see what I mean
DRILL %/16"-DIA. in Figures 3 and 3a. The viewing
HOLE w/ !!/16"-DIA. STEP 1: XXXX CALLOUT
COUNTERBORE port
XXXXXXXXXXXXXXX gives you good visibility of
FOR T-NUTS
the TOP
workpiece
VIEW and router bit. By
%/16"-WIDE x FIRST: XXXXXXX
2&/8"-LONG XXXXXXXXXXX adding a centerline to the port, you
SLOT CENTERED !/4" WASHER can END
easilyVIEW locate the workpiece and
ON STOP NOTE: XXXXXXX
XXXXXXXXXXX stops SIDEto match
VIEWthe size of the mor-
ADD
tise you laid out. Plus, it’s a handy
CENTERLINE “QUOTE MARKS” TOP
way(CROSS
to check VIEWon the progress of
MARKS SECTION)
your mortise as you’re routing.
STOP PATTERN Limiting
STEP 1:theXXXX travel of the router
H XXXXXXXXXXXXXXX
establishes the length of the mor-
H tise. FIRST:
To accomplish
XXXXXXX this, you’ll
need XXXXXXXXXXX
to add a pair of stops, as in
STOP
(5" x 5!/2" - !/4" Hdbd.)
Figure 4. The
NOTE: XXXXXXX stops are just pieces
of 1⁄4"XXXXXXXXXXX
hardboard sized to match the
width of the groove. A centered
“QUOTE MARKS”
slot makes it easy to lock them in
place using studded knobs.
PATTERN
4 WoodsmithPlans.com SN11240 ©2015 August Home Publishing Co. All Rights Reserved.
#8 x 1" Fh
WOODSCREW
 adding a hold-down 5 FENCE

System
(5" x 11!/2" - #/4" Ply.)
I

#/8"-WIDE SLOT, !/4"-20

3!/2" LONG T-NUT
1
The main part of the mortising
jig is complete. But you still need 1#/4
NOTE:
a way to support and secure the A B C DRILLD E%/16"-DIA.
F G H I J4K L M
workpiece when you start rout-N O P HOLE w/ !!/16"-DIA.
Q R S T UFOR
COUNTERBORE V W X Y Z
ing. That’s the job of the fence T-NUTS IN FENCE
AA BB C C D D E E F F GG H H I I
and hold-down system you see J J K K L L MM N N O O P P QQ R R
in Figures 5 and 6. It consists of SS
a T T UU%/16"-18 W X X YY ZZ
V V xW1!/2" A B C D E F G H
KNOB w/WASHER 1#/4
fence that supports the workpiece A AA B BB C C C D DD E E E F F F N O P Q R S T U
and a clamping mechanism that’s GGG HHH I I I J J J K K K L L L AA BB C C D D E E F
attached to the fence. a.
MMM NNN OOO P P P Q QQ R R R
TOP VIEW J J K K L L MM N N O
A Simple Fence. The fence S SS T T T U UU V V V WWW X X X SS T T UU V V WW X
couldn’t be much simpler. It’s just YYY Z Z Z CL FRONT A AA B BB A CBC CC DDDD E
a rectangular piece of 3⁄4" plywood GGG HHH I I I Q JJJ
FENCE N O P R
with a pair of slots. The slots are MMM NNN OOO P P P
EXPLODED VIEW AA BB VC C V
S SS T T T U UU V
located to match the position of OVERALL DIMENSIONS:
the T-nuts installed in the front (24!/2" x 24!/2" x 24!/2") Y Y Y Z Z JZ J K KC L L M
SS T T LUU
earlier. Then, to provide a way to A AA B BB C
PART NAME w/LETTER
mount the clamping mechanism, (first time used)
EXPLODED GGG HVIEW
HH I
there’s a set of four counterbored the
PART NAME
fence in two different locations To install it, I used a carriage bolt
OVERALL MDIMENSIONS
MM N NN O
holes for another set of T-nuts. to suit the size of the workpiece. (Top View below at left).(24!/2" I alsox 24!/2"
S SS xT24!/2")
TT U
Securing the Workpiece. OnceCALLOUT The second is a basic toggle clamp added a small piece of sandpaper Y Y Y Z Z Z
PART NAME w/LETTER
the fence is completed, it won’t take for securing the workpiece. to the face of the foot to prevent (first time used)
long to add the clamping mecha- TOP VIEW
The third part is a modifica- the workpiece from slipping.
Once you have the clamp foot EXPLODE
PART NAME
nism. As you can see in Figure 6, ENDtionVIEW to the clamp. Since I didn’t OVERALL DIM
the clamping mechanism consists think the toggle clamp’s standard installed, you’re ready to CALLOUT rout a (24!/2" x 24!/2"
SIDE VIEW
of three parts. The first is a clamp rubber tip was up to the task of mortise. For more on that process,
TOP VIEW NAME w
block with a pair of holes drilled in TOP VIEW a workpiece, I replaced check out the instructions detailed PART(first
securing time
(CROSSit SECTION)
it. This allows you to mount it to with a larger, hardwood foot. on the next page. END VIEW
PART NAME
TOP VIEW STEP 1: XXXX SIDE VIEW
6
FIGURE
XXXXXXXXXXXXXXX a. SIDE VIEW CALLOUT

FIRST: XXXXXXX
TOP VIEW
XXXXXXXXXXX TOP VIEW
(CROSS SECTION)
ADD SANDPAPER
TO BOTTOM OF FOOT
FOR MORE SECURE GRIP
NOTE: XXXXXXX STEP 1:END XXXX VIEW
XXXXXXXXXXX XXXXXXXXXXXXXXX
CLAMP SIDE VIEW
FOOT FIRST: XXXXXXX
“QUOTE MARKS”
CLAMP FOOT XXXXXXXXXXXTOP VIEW
(#/4" x 1" - 2") (CROSS SECTION
K
PATTERN NOTE: XXXXXXX
XXXXXXXXXXX
!/4
STEP 1: XXXX
XXXXXXXXXXXXXX
“QUOTE MARKS”
NOTE: REPLACE POST
ON TOGGLE CLAMP FIRST: XXXXXX
WITH CARRIAGE BOLT
%/16" x 3"
CARRIAGE
PATTERN XXXXXXXXXXX

BOLT NOTE: XXXXXX

#/4 XXXXXXXXXXX
%/16"-18
THRU-HOLE
KNOB “QUOTE MARKS
1 TOP VIEW
TOGGLE CLAMP
(DE-STA-CO TC-227-U) FRONT PATTER
!/4" #8 x 1" Fh FENCE
WASHER WOODSCREW
#8 x 1!/2" Fh
J WOODSCREW TOGGLE CLAMP
SECURES WORKPIECE
!/4"-20 x 1!/4" CLAMP BLOCK #8 x 2" Fh 1!/4" 1!/2" 1#/4" IN JIG
KNOB (2#/4" x 5" - #/4" Ply.) WOODSCREW
CLAMP #8 x #/4" Ph #8 x 1" Fh
b. BLOCK SHEET METAL SCREW WOODSCREW
#8 x 1!/2" Fh
WOODSCREW
5 WoodsmithPlans.com SN11240 ©2015 August Home Publishing Co. All Rights Reserved.
#8 x 2" Fh 1!/4" 1
WOODSCREW
Routing a Mortise 1
If you thought building the mortising jig was simple, you’ll
find the overall process of routing a mortise even easier. The
basic steps are detailed in the photos you see here.
The Layout Drives the Process. As you can see in photo 1 at
right, the key to helping you position the workpiece is laying
out the location of the ends of the mortise and the centerline.
As a matter of fact, routing identical mortises is easy. After
using the first piece to set the stops, all you really need on the
rest of the pieces is a centerline.
Choosing a Bit. I find that a spiral upcut bit is the best choice
for routing mortises. This type of bit pulls the chips up and out
of the mortise as you rout. And for the best results, make multi-
ple, shallow (1⁄4"-deep) passes until you reach the final depth of {  Start with a Layout. You’ll need to lay out the width and
the mortise. Finally, using the depth stop on your router makes length of the mortise along with a centerline. The centerline
it easy to cut each mortise to exactly the same depth. will make positioning the workpiece an easy process.

2 3

{  Support the Workpiece. Adjust the fence so the workpiece {  Clamp Securely. After aligning the centerline of the
butts against the table. (You can use spacers under the fence mortise with the reference line on the adjustable table (inset),
and clamp block to accommodate thicker workpieces.) clamp the workpiece securely with the toggle clamp.

4 5

{  Match the Mortise. At this point, you can position the adjustable {  Setting the Stops. Finally, adjust each stop to set the
top so the bit lines up with the location of the mortise (inset). Then, length of the mortise (upper inset). To rout the mortise, make
tighten the knob to lock the adjustable table in place. shallow cuts (lower inset) until you reach the desired depth.

6 WoodsmithPlans.com SN11240 ©2015 August Home Publishing Co. All Rights Reserved.
 MAIL Project Sources
ORDER
SOURCES • Essentra Components
5⁄ "-18 Knob. . . . . . . . . . DK-138
16
Woodsmith Store 1⁄ "-20 x 11⁄ " Knob. . . . . RST-101
800-444-7527 4 4
5⁄ "-18 x 11⁄ " Knob. . . . RST-103
16 2
Essentra Components Toggle Clamp . . . . . . . . TC-227-U
800-847-0486 1⁄ "-20 T-Nut. . . . . . . . . . WN-115
4
essentracomponents.com 5⁄ "-18 T-Nut. . . . . . . . . WN-130
16

Manufacturers and retail-

ers will periodically redesign
or discontinue some of their
items. So you’ll want to gather
all the hardware, supplies,
and tools you need before
you get started. It’s easy to
adjust dimensions or drill dif-
ferent-sized holes to suit your
hardware.

7 WoodsmithPlans.com SN11240 ©2015 August Home Publishing Co. All Rights Reserved.