I'm fixing to make some new windows for my house and have been thinking about working towards a better method than the router table which I have done in the past. I don't want to spend thousands on shaper tooling for the few windows I find my self making presently. So I see this old FHB article that looks just like what I was envisioning!
http://www.mustardseedbuild.com/inpr...ench_doors.pdf
Well, I have both a freud and amana router bit set for sash construction, both can cope extended tenons with a stub cutter, and I'm working on getting insert knives made for the shaper to match the coping cutter on the router. I find sticking on the router table to be marginal, lots of chatter and tear out, difficult to feed versus the shaper. So I want to cope on the router, mold on the shaper, glass rabbit on the shaper. I'd like to use this as an opportunity to really get some tenons made on the shaper. I'm trying to do this on the cheap, so the $500 Garniga groover/tenon cutter I want is a bit out of the budget at present. The FHB article shows two TK rip blades on a 1" arbor with a spacer being used, much like an actual single ended tenoner would. Anybody ever tried this, and anybody know a ready source for blades with a 1" or 1 1/4" arbor hole? I suppose I could get any blade punched out at my local tooling place, but a ready made option seems it would be cheaper, I just have't found one in my searching.
As a side note, anybody know of a chart to calculate spindle speed for different pulley configurations, or a formula? I have an 1 1/4" minimax that I could get a 1" arbor for, and it slows down to 3000RPM's, but the spindles cost a small fortune which will defeat my attempt to do this cheaply. My delta does 7000RPM minimum, I have a 1" arbor for that, but 7000rpm is too fast for the 7"-8" blades needed to make tenons this size. The guy in the article steps down the speed with a smaller motor pulley. Just not sure what size would be required?
Any thoughts or experiences on the subject are appreciated.