Tiny Mortise and Tenon

[Bill Adamsen]

I have a proposed project using 5/16" thick hardwoods and relatively small pieces that I'd like to connect using mortise and tenon. But maybe I am just stuck in a rut and can't think about alternative joinery to M&T. The volume of connections is such that I have to use some type of machining, hand cutting the mortises is out of the question.

The tenons ... no problem ... but what do I do for the mortise? I assume I should just jig up my router table with a 1/8" or 5/32" plunge bit? Is there such a bit? This is where I wish I had one of JTE's router based mortisers.

Am I missing an obvious way to mill really small pieces together?

[Bryan Lisowski]

What are you actually making? It seems that would help determine if there is a better joinery method. To me it seems that the walls of the mortise might be to thin and could be an issue.

[Bill Adamsen]

They are lightweight frames. The tenon (and mortise) would provide significantly more strength than a simple butt joint. Half-laps could possibly work but would add undesirable aesthetics. The frames will be clear coated ... not sure yet but likely I'll spray with a waterborne conversion varnish. The specific species have not been chosen, but will be a typical close-grained eastern hardwood (maple, cherry, perhaps walnut). Total size is 14" by 10" or thereabouts.

[Warren Lake]

think Jack Forsberg posted a 1/8" mortise chisel, doesnt seem possible as im saying it however im not ready for the retirement home either so maybe the memory is correct.

[John Lanciani]

4mm domino?

[Bill Adamsen]

I see that article (thank you) on Canadian Woodworker ... Jack displays a 3mm which he said was very hard to get (not available NA) and very expensive. I have the Domino and actually have 4mm tenons ... technically that should work.

[Bill Adamsen]

4mm domino?

That could work! I was actually just measuring those in the shop (C O L D) ... but then does anyone use the Domino for mortises on the ends of pieces 8mm by say 30mm? It feels like an operation where I'd want a fixed tool rather than a portable one.

[Myk Rian]

There are 1/8" bits, but in 5/16" hardwood, you should buy several of them. They are easy to break.

[John Gornall]

You could do these on a Leigh FMT - Leigh sells bits for this.

https://www.leighjigs.com/fmt_overview.php

[Bill Adamsen]

This looks like a simple build that could possibly work ...

https://www.instagram.com/p/BKtx799hjkC/

[Matt Day]

When you say lightweight frames, do you mean pictures frames?

For something that small my first thought would be to keep it simple. Half lap joint miter, or possibly just a butt joint. Wonder if 2p-10 would work?

[Edwin Santos]

Usually for thinner stock, I look to splines as a joinery choice. Would that be an option?

You could cut the splines slots with a slot cutter at the router table, or on the table saw or with a biscuit joiner.

If you're up for dowel joinery, you could fashion dowels from dowel rods from a home center. I would think smaller diameter dowel pins are available also. If it's a production situation, I think splines would be faster than dowels in the absence of specialized machinery.

Edwin

[Vince Shriver]

How about a bridle joint - see John's post.

[Jim Becker]

That could work! I was actually just measuring those in the shop (C O L D) ... but then does anyone use the Domino for mortises on the ends of pieces 8mm by say 30mm? It feels like an operation where I'd want a fixed tool rather than a portable one.

Can you place the mortises on a wider piece of material spaced such that ripping them after mortises are cut with the Domino can happen? (kerf width taken into consideration) that would provide you with a more stable workpiece to cut those tiny slots with the machine...

[John TenEyck]

Well, if you want one of my HRM's you can have one. Not hard to build, or send me a PM. Amana does make a 3/16" plunge router bit as well as smaller diameter ones, all with a 1/8" shank. They also sell some 1/4" shank ones but I'm not sure they will plunge cut. Eagle American has some small 1/4" shank ones, too, and I'm sure there are others. Once you find the right router bit what you want to do would be a simple task on a HRM.

John