Joinery · 8 min read
Mortise and tenon by router: template guides and stop collars
A router with a template guide and a stop collar cuts consistent mortises without a dedicated mortiser. Here is the setup and sequence.
By SQUAREFORGE Shop Desk · Updated
Key takeaways
- A template guide bushing keeps the router referenced to a fixed jig, not freehand.
- Cut mortises in shallow passes to keep the bit from wandering.
- Fit the tenon to the mortise, not the other way around.
Setting up the jig
- A template with a slot sized for your guide bushing and bit combination.
- Stop blocks clamped to the jig to fix mortise length.
- A plunge base so the bit enters cleanly at full depth control.
Cutting sequence
- Rough the wastePlunge in shallow passes, working from one end of the mortise to the other.
- Clean the wallsRun the guide bushing along the template edges for a final clean pass.
- Square the endsChisel the rounded ends left by the round bit if you need a square-shouldered tenon.
| Mortise depth | Recommended pass depth |
|---|---|
| Up to 1 in. | 1/4 in. per pass |
| Over 1 in. | 1/4 in. per pass, with a longer bit and slower feed |
Joinery setup checklist
| Stage | Tasks |
|---|---|
| Before cutting | Confirm stock thickness, test-fit on scrap, check bit or cutter sharpness |
| During assembly | Dry-fit every joint, check squareness, have clamps and glue ready before mixing |
| After glue-up | Recheck diagonals, clean squeeze-out before it skins over |
/ Frequently asked
Do I need a dedicated mortiser?+
Not for most furniture-scale joints; a plunge router with a template guide produces clean, repeatable mortises.
How tight should a mortise and tenon fit?+
The tenon should slide in with hand pressure and a mallet tap, not require force that risks splitting the mortise walls.