I am helping make reproduction exterior shutters for an old school house as part of an Eagle Scout project.
It is a raised panel design with mortise and tenon joinery of the rails and stiles. The originals were made in the late 1800s with through mortises.
The stiles are 5 inches wide and 9 feet long. The rails are 5 inches and 7 inches in width. The material is white pine that will be painted.
My question is in regard to the depth of the tenons. I did not plan to do through mortises like the original design. What would be the appropriate length of the tenon or mortise depth? I do not want to cut corners on the project but I also want to be efficient. I have 54 of these to cut. I only have access to a plunge router, a table router and chisels. I also have a drill press. What would be a reasonable tenon length? What would be the consequences of making them too short?
Thanks for any help. Also FYI “helping with the Eagle project” is a great cover story for escaping to the woodshop. No questions asked from the wife. I might have to milk this one for awhile.