The Ultimate Router Mortising Jig - now with PLANS! 

Yay! Great to hear it!

Thank you, though I can't take credit for the DX!

Yes, I am very pleased with it. If this were my only way of cutting mortices, I would manage just fine.

Yes, but I have the right to be so, don't I? :)

@@SteveMaskery Amen!

@@MrPatdeeee where can I buy the plans

You make a good point, but in reality the keys are so small, as are changes in humidity and temperature, that expansion is not a problem. If I used this every day, and I lived in the kind of environment you describe, then yes, I can see the advantage, but I don't and I have never had such a problem.

I have indeed published plans for a couple of different router tenon jigs, many years ago on Workshop Essentials Volume 1. But unless you have only a router and no tablesaw or bandsaw, then I suggest that you would be better off building the Ultimate Tablesaw Tenon Jig or the Ultimate Bandsaw Tenon Jig. They are both easier to use and have greater capacity.

@@SteveMaskery Thanks for the quick response Steve. I tried to reply (twice), but seem to have failed. I have both alternatives, but was trying to produce tenons with rounded edges that fit the routed mortices perfectly without having to round them manually (need to make ~120 joints in my project), in a similar fashion t the General #870 mortice & tenon jig for instance. (ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-boYiNmE7IWU.html)

I have made several mortising jigs over the years, including ones based on bushes. Indeed, I still have, and use, a cross-mortising jig that has the entire base in a guide. But this is a development of a desigh I first published 16 years ago. The fence guide idea came from a FWW video which I can no longer find. But this is defiitely the best mortising jig I've ever used, I'm not going back.

I have just such a jig. It's not on RU-vid, but iit is published on Workshop Essentials Volume 2 : www.workshopessentials.com/shop/index.php?route=product/product&path=35&product_id=50 You can see it in use on my horizontal boring jig: ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-uHW5-6X2z0w.html

Because I don't have an uncut bit. I used to have an upcut bit, but someone stole it, so I use what I have. Anyway, I want to cut the wood, I don't want to uncut it - that would be counter-productive.

No, this is perfect! :) My original version of this, about 15 years ago now, did have two fences, but it made for a very bulky setup. Functionally fine, but ergonically clumsy. In this version the fence does not just run against the fence, which can lead to slippage, I grant you, but it runs in a groove, so it is trapped and the router cannot move off its required trajectory. Really, it's perfect :)

@@SteveMaskery aha! Sorry I missed the groove. Will watch again and pay more attention. Thank you Steve

Well if you have a 2" diameter cutter, I don't see why not. I assume that the workpiece is also massive, so you might need to beef up the front support. I have to say that I have never seen such a large router cutter.

@@SteveMaskery With apologies for my not making myself clear. I have 4" x 5" leg for a Roubo bench that I need to cut a mortise into for the crisscross glide. The dimensions of the hole are essentially 2" x 2" 19." I had planned to use a 3/4" pattern bit or a 1" straight bit.

"Beef up the front support?" Could you please expand on that suggestion?

@@CooledgeR Ah, OK, that makes a bit more sense... :) Yes, I think so. You would have to cut two mortices, essentially, side by side, just offset the position of the router, leaving the stops in place.

@@CooledgeR Well the front supporton mine is suitable for 1" or 2" stock, it's not designed for 4" stock. So you might want to make it more sustantial and rely on something stronger than a couple of toggle clamps to hold it in place.