Hi,
I'm nearly done with TWW guild build for 2 Morris Chairs and accompanying foot stools, and it's time to cut the tenons on the back rest slats.
The slats are bent laminations, and Marc builds a form to hold them vertically while using a routing template to cut the tenons. Looks like this:
router jig.JPG
In my mind, it would be far easier to build a setup to consistently hold the laminations "level" in my table saw sled. A concave "cradle" could hold the piece to cut one side of the tenon, and a convex support block could support the laminations when cutting the other side.
Once setup, I could cut one side of each tenon quickly and repeatedly... Switch the setup and cut the other side of each. Both setups using the same stop block to define the tenon length consistently.
This seems like far less jig building, far more repeatable, much faster, and way less room for an errant router pass ruining a tenon.
Any flaws in my thinking here?
Thanks!
Bob R.