Table Saw Sled – Tenoning Jig Accessory

A Tenoning Jig you can build yourself!

Cutting tenons on a table saw requires a special jig to firmly hold the workpiece in the exact position for the cut.

A common use for tenoning jigs is making tenons for furniture joints. But a tenoning jig is handy any time you need to secure the workpiece in a vertical position for a special cut.

You can purchase a professional grade tenoning jig for prices starting around $100.00. These jigs enable you to position the workpieces in pretty much any way you want it. Plus, the jigs usually tilt for angle cuts.

If you don't have a need for something that elaborate, you can build your own tenoning jig that provides both the accuracy and versatility you need.

This jig mounts on your table saw sled and can be set to the exact distance from the blade you need.

It uses T-Track and hold down clamps to place your workpiece in any position you need. Use a triangle square to ensure the jig is square to the sled. Use a triangle square or protractor to set the workpiece to the angle you need.. To make angled cuts, just tilt your saw blade to the angle you need.

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Special Hardware You'll Need

Two small 1/4" threaded knobs. (Assuming your T-Track uses 1/4" bolts.)

Two 2 1/2" long by 1/4" hex head bolts and washers.

Step 1. Cut the Parts

Detailed drawings for parts dimensions, hole layout, cutout drawings, and a full size handle pattern are on the Shop Drawings page at the end of this file.

Step 2. Assemble the Braces

Attach the End Stiffeners, Middle Stiffener, and Vertical Braces with 1 1/2" #8 flathead screws through the bottom as shown above.

Be sure the edges of the stiffeners and braces are flush with the edges of the base.

Step 3. Attach Knob Risers

Insert two 1" #8 flathead screws, (1 1/2" will be too long) up through the bottom to attach each Knob Risers.

Be sure the 1/4" bolt holes, (indicated by red arrows), line up with the holes in the base. The Knob Risers keep the bolts straight so the Tenoning Jig slides smoothly.

Step 4. Assemble the Front

Apply glue to the back surface of each of the front panel pieces.

Verify position of screw holes! Position the Front Panels, and T-Track on the Front Backer Board as shown to the left. Make sure all pieces are flush on the edges and clamp in place.

When the glue is dry, drill all the screw holes through the Front using the same drill bits you used when drilling the Front Panel

Step 5. Attach the Front

Place the assembled parts on a flat surface as shown to the left.

Attach the Front to the Braces and Stiffeners using 1 1/2" #8flathead screws for the panels and 1 1/2" #6 flathead screws for the T-Track.

Make sure no screw heads are above the surface of the MDF. The surfaces must be flat for your Tenoning Jig to provide accurate cuts.

Step 6. Attach the Top Stiffener

Position the Top Stiffener as shown to the left. Hold it down firmly against the Vertical Braces and and secure it to the front with three 1 1/2" #8 flathead screws.

Next, secure the Top Stiffener to the top of the Vertical Braces with the same size screws. This will ensure a flat work surface for your tenoning jig.

Step 7. Assemble the Handle

Apply glue to mating surfaces of the Handle and Handle Brace.

Postion the Handle and Handle Brace on a flat surface with the Handle Brace centered in the back of the Handle. Secure them with two 1 1/2" #8 screws as shown in the drawing. (Flathead screws are not necessary here.)

Step 8. Attach the Handle

Position the Handle as shown to the left so it is centered sideto side.

Hold it firmly against the Knob Risers and secure it to the Knob Risers with two 1 1/2" #8 screws.

Step 8. Insert the Bottom Screws

Insert five 1 1/2" #8 flathead screws through the bottom to secure the Handle and Handle Brace.

Check all the bottom screws and be sure none of the screw heads sit above the bottom surface. This is necessary so yourTenoning sits flat when in use.

Step 9. Insert the T-Track Bolts and Knobs

(This step assumes you're using T-Track that uses 1/4" bolts.If not, use bolts and knobs that fit your T-Track.)

Insert a 1/4" by 2 1/2" bolt from the bottom up through each of the Knob Risers. Next, screw a 1/4" threaded knob with a 1/4" flat washer under it.

Step 10. Attach the Sandpaper

Using contact cement, glue 100 or 120 grit sandpaper to the Front Panels as shown above.

The sandpaper is not absolutely necessary but it helps hold the workpiece securely in place.

Congratulations! Your Tenoning Jig is complete.

Step 11. Mount the Tenoning Jig

Mount the Tenoning Jig to the Sled with the T-Track bolts..

The T-Track enables you to position the jig from side to sidefor the desired distance from the saw blade.

Making a Cut with the Tenoning Jig

This image shows the jig being used to make a precise cut through the end of a workpiece.

Tenoning Jig

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Parts Dimensions Drawings

Tenoning Jig

Screw Holes - Bottom

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Knob Riser

1 3/4 "

1 1/4 "

Drill a 1/4" diameter hole through each knob riser as shown above.

Drill the nineteen holes indicated by black circles with a 5/32" dia. bit. Then countersink them for a #8 flathead screw.

Drill two 1/4" diameter holes for the T-Track bolts as indicated by the red circles.

Bottom

9/16 "

1 1/2 "

3 5/8 "4 3/4 "

3 5/8 "4 3/4 "

3/8 "

2 1/2 "

6 "

4 3/8 "

1 1/2 "1 1/2 "

2 "

2 1/2 "

9/16 "

3 1/4 "

Tenoning Jig

Screw Holes - Front

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Front

1 "3 5/8 "

6 "

1 "3 5/8 "

7/8 "

2 3/8 "

4 "

1 "

1 5/8 "

Drill and countersink ten 5/32" dia. holes for No. 6 flathead screws for each location shown above with a double circle.

The eight holes shown in green with a single circle are used to mount the T-Track. These holes are 5/32" diameter and are not countersinked.

Top Stiffener

3 5/8 " 3 5/8 "1/2 "

Tenoning Jig

Cutout Drawings

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The MDF parts can be cut out of a 12" by 24" piece of 1/2" MDF Board

Top Stiffener (1 Required)

End Stiffener(2 Required)

Middle Stiffener(1 Required)

Knob Rizer

(2 Required)

HandleBrace

(1 Required)

Vertical Brace(2 Required)

Handle(1 Required)

Knob Rizer

(2 Required)

End Stiffener(2 Required)

5 1/2 "

28 "

The 3/4" wood parts can be cut out of a 24" by 28" piece of 5 1/2" wood board.

Bottom

(1 Required)

Front

(1 Required)

Bottom Track Spacer(1 Required)

Middle Track Spacer

(1 Required)

Top Track Spacer

(1 Required)

Tenoning Jig

Handle Pattern

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Please note: You may need to adjust your printer's scaling settingto get this pattern to print at the correct size.

Drill two 3/16" diameter holes through the

Handle as shown above.

3/8 "

5/8 "

5/8 "

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