Loose Tenon Router Jig
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Router Jig for making joints using loose of floating 5mm tenons (similar to domino joints)
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I wanted a jig to use with my DeWalt DCW604 hand router, to be able to make floating or loose tenon joints (similar to the Festool Domino tool).
My router came with a 17mm collar, so I made the jig to fit that, and for inserting 5mm tenons (available from Amazon - https://amzn.eu/d/40mRWhv). I used a 5mm spiral upcut bit in the router to cut the slots. The uncut bit keeps the slot clear whilst cutting.
The model requires 4x M5 countersunk machine screws with suitable nuts, to hold the jig together. I wanted to make it so I could dis-assemble, and fit in the router case if needed.
I also use a single pan-head M5 machine screw as a locator pin. There are holes either side of the jig, to space the jig evenly from each end of the work piece. This could be modified for use with the same countersunk screws, which would allow these to stay in place whilst routing. Personally I found it easier to just line the jig up, clamp it and remove the pin (which I found easier to remove as a pan-head than with my fat fingers on a countersunk screw!), before routing the slot.
This is my first published model, so I have provided the Fusion 360 (.f3d) file, should you have a larger collar, and welcome any remixes. Enjoy!
This was printed as 0.2 layer, with 4 wall loops, and 60% infill on my Prusa Mk3.