Tenon cutter

[Larry]

I have been making chairs, stools, and benches for a long time. I've always used tapered mortise and tenons for the leg joints. To make the leg tenons I've always made them on the lathe. To get a good fit it always took a few tries to get a perfect fit. I've been wanting to try the Lee Valley tenon cutter to speed production but the size I need seems to be always out of stock......so I made one today.

Similar to what is called a rounding plane for making dowels but I need it to make tapered tenons.


Most commonly a old plane iron is used for the cutter but I did not have one so I grabbed a piece of 1095 tool steel and made the cutter. When I milled the slots I made them .030 wider than the bolts to allow for adjustments.

Just like a pencil sharpener. Stupid mistake, I put the cutter on the wrong side so I have to turn the leg left to cut. They can be made to cut with the leg held in a vise but since all my legs are tapered and hard to clamp I turn the leg into the cutter.

The end result.


First try into a test mortise and with luck the fit was close. I tweaked it just a hair and got it perfect. I have lots of chairs to make and this should speed production.

[Brad_bb]

That looks sweet!  I like the use of Osage for the body too.  Good choice.  I'm inspired, and I'll think I'll make a similar dowel maker  with Osage.  I think I have an extra plane iron.

[Ljohnsaw]

Cool! But what do you use to make the tapered hole?

[Larry]

For these chairs I drill a 5/8" hole than follow up with a 12 degree tapered reamer I bought from Lee Valley. The tenon cutter pictured cuts a 12 degree taper to match.

I also have 6 and 8 degree shop made reamers that I sometimes use.

[Tom K]

Great job on finding a home made solution to your problem!

Does anyone else wish they were Larry's neighbor? I'd stop over at least once a week to to see what cool stuff he was up to.

[Old Greenhorn]

I do, but I don't think he would tolerate me for long. I'd be over weekly asking if I could 'just run these dozen or so leg blanks through his tenon cutter?' and other such small things.

[doc henderson]

Tom, I am sure Larry knows the teach a man to fish parable, and he would quickly offer to help you make your own.  

[Larry]

I really enjoy shop visitors. I get questions like "why did ya do it thata way?" "why not this way?". We exchange ideas and thoughts. I think both parties are well rewarded with thoughtful conversation.