Table Stub Tenon Stile Table Rail Stub Tenon
Contents
1. Stile lengths Should be equal to the finished height of the door Rail lengths are determined based on the width of the stiles and the length of the tenon you plan to use The rail length should be equal to the width of the door minus the width of two stiles plus the length of the two stub tenons The stub tenons are 10mm 13 32 long so the formula is Door Width Stile Width x 2 13 16 Rail length Note For doors with extended tenons add twice the length of the desired tenon Mill and Cut Your Door Parts a Read and follow all safety instructions that came with these router bits as well as your planer saw and all other tools b Mill all stock to final thickness If you do not have a thickness planer many lumber dealers and millwork shops will plane stock for a fee c Rip all stock to finished width See recommended widths in the previous section Be sure all edges are perfectly square and that all surfaces are straight and flat Freud s LM75R series ripping blades are excellent choices for this stock d Cut all parts to length using the formulas in the previous section Tip 1 Determine the best or face side of all components and use a pencil to label each component on the back Doors with Standard Stub Tenons Your Freud Premier Adjustable Rail and Stile bits come factory assembled to produce perfectly fit stub tenon joints right out of the box This is the most common type of cabinet door I2. on the face side e Unplug the router remove the threaded plug and carefully thread the spindle containing the bearing and upper cutter back into the rail bit Tighten with the spanner wrench E DO NOT change the position of the fence Fence With out moving the fence rout using multiple passes of 1 2 increments E Rail flipped over Lower the router and bit F Turn your rail face up and use the stub tenon you routed to adjust the bit height The top of the cutter should be lower than the underside of the stub tenon for the first pass Important Note because you will remove the back of the tenon in a width greater than 1 2 you will make this cut in multiple passes by starting with the top of the bit no more than 1 8 above the table Make multiple cuts by moving the bit up no more than 1 8 per cut On the final pass the top of the rail bit should precisely match the underside of the stub tenon This will create a long tenon and profile that will perfectly match the stile profile Finish the mortise and tenon joints a First carefully haunch the tenons as shown in the photo This step produces a stronger and more attractive joint and conceals the tenon within the end of the stile Cut the haunched tenon with a band saw jig saw or handsaw gt 4 Note length of haunch must match the stile profile Make test cuts to ensure proper fit b Lay out and cut mortises in the door stiles
3. Using Your Premier Adjustable Rail amp Stile System Stile Bit Rail Bit This new unique patented solution allows woodworkers to build any style of cabinet door in a range of door thicknesses and size Congratulations on your purchase of Freud s Premier Adjustable Stile and Rail Router Bit System These unique bits allow you to build a remarkable variety of different styles and sizes of cabinet doors including e Rail and Stile doors with stub tenons e Rail and Stile doors with extended tenons for added strength e Rail and Stile doors with panels of undersized plywood e Double Sided Rail and Stile doors with decorative profiles on both sides requires optional cutters e Glass Panel doors requires optional cutters e Doors with thicknesses from 5 8 to 1 1 4 Introduction to Cabinet Door Construction Cabinet doors may consist of a number of elements Here are some common terms that will be used throughout these instructions Stiles The vertical frame components of the door Rails The horizontal frame components of the door Tenon An extended piece of wood on the end of a rail that fits into a pocket or mortise in the stile Mortise A pocket cut in a stile that matches the tenon on the end of a rail Panel The center portion of a door which is contained within the frame of rails amp stiles Panels may be solid wood normally a raised panel plywood or glass Glass trim The wooden molding whi
4. ch holds glass in the door frame Materials Required In addition to your Freud router bits you will need the following tools and supplies to build your door unit e Variable speed router 2 1 4 HP minimum e Router table with fence and miter gauge For best results use featherboards and push blocks to control work pieces when possible We also strongly recommend that a shop vacuum or dust collector be used with the router table e Table saw for ripping stiles rails and other door parts e For long tenon door construction Mortising machine Drill Press with mortising attachment or Drill Press with brad point bits e Various common woodworking hand tools including hammer chisels rule straight edge square coping saw e Clamps with the capacity to secure all door joints e A sturdy level work table or saw horses for door assembly Safety Tips Creating your own doors is a fun and rewarding woodworking project As with any woodworking project however your first concern must always be safety To get the best performance and results from your Freud cutting tools observe these safety recommendations for EACH operation e Make sure that you are well rested before working with power equipment e Do not use power equipment if you have consumed any drugs or alcohol If you are taking prescription medication check with your physician to ensure it is safe for you to operate power equipment e Never use a router bit that is damage
5. d or dull e Always turn off and unplug the router before removing installing or adjusting bits adjusting the router or fence or assembling or disassembling bits WARNING Failure to obey these warnings could lead to serious bodily injury or death e Use router bits with a router only e Carbide is a very hard and brittle material Slight shocks can damage the carbide Before each use check that the bit is sharp and free from damage DO NOT use the bit if it is dull broken cracked or if any damage is noticed or suspected e Before each use make sure that at least 80 of the router bit shank is inserted into the collet The end of the bit shank should be at least 1 8 from the bottom of the collet e Before each use ensure that the collet has been tightened and that the work piece is secure e Read and obey all warnings and instructions contained in the routers user s manual and for any accessory that is used If you do not have the correct user s manual obtain one from the manufacturer before using the router bit e Always wear eye protection or a full face shield complying with current ANSI Standard 287 1 e Keep body clothing and hair clear of spinning bit Do not wear loose hanging clothing or jewelry e Use a router table and fence wherever possible Be sure all guards are in place e Bits over 1 1 2 in diameter must only be used with the router mounted in the table e Use multiple passes when removing lar
6. ge quantities of material e Never use bit on router that will exceed maximum recommended RPM of bit e Ifyou have any questions regarding your router bits please call Freud Customer Service at 800 472 7307 In Canada call 800 263 7016 e Keep these instructions in a safe place for future reference Getting Started Planning and Preparation Plan the project carefully before purchasing materials Refer to the reference below for formulas to calculate the widths and lengths of your stiles rails and glass inserts Be sure to obtain enough stock to build all doors plus extra stock for making test cuts This will make it easier to match the grain and color of the material for a more attractive finish and milling all stock to thickness at the same time avoids inconsistencies that can affect the quality of your joints Choose stock with care Lumber for door construction should be straight and free from defects such as knots splits and checks Calculating Sizes of Door Parts Stock thickness Your Premier Adjustable Stile and Rail bit set is suitable for stock from 5 8 to 1 1 4 thick To mill double sided or glass panel doors in thicker stock please contact your Freud Distributor to purchase the optional cutter set to match your profile Stile and Rails for common cabinet doors are normally 2 1 4 to 2 1 2 wide depending on your preference and application Your Freud bits can easily be used to mill stiles and rails of any width
7. ofile cutter and two slot cutters e Use a straight edge to align the router table infeed and outfeed fences with the bearing on the bit e Plug the router in and carefully make a test cut in scrap material to check your set up Use push blocks to control narrow stiles e Test the fit of your stile sample to the rail ends you routed in the previous step If you need to adjust the height of the bit unplug the router adjust the bit and make another test cut Once the height matches perfectly rout one edge of all stiles and rails Routing rail ends with extended tenons For stronger joints in your cabinet doors your Freud set offers a unique capability to mill tenons of unlimited length This capability is especially important for large or heavy doors and doors that will be subjected to excessive use and stress e First calculate the length of your tenons As a general rule plan on your long tenons being as long as half the width of your stiles For example if your stile width is 2 1 2 then a 1 1 4 long tenon will be a good choice Fence aligned with bearing Rail Bit Cope Cutter Rail good side down e Be sure that the fence is parallel to the miter gauge track then rout across each rail end using the same procedure described for routing the stub tenons B For this first cut leave the rail bit fully assembled with the bearing and upper cutter in place This will produce a stub tenon e Now unplug the r
8. outer Use the supplied spanner wrench to remove the upper portion of the cutter as shown C Use the router spindle lock or your router wrench to prevent the bit from turning DO NOT change the height of the bit amp Without adjusting the height use the included wrench to remove upper portion of cutter and insert the threaded plug Rail fd good side down Fence move in 1 2 increments Rout ends using multiple passes of 1 2 increments ae 4 Rail SE good side down B Table 40 e m QI e Insert the threaded plug supplied with your set into the threaded hole in the rail bit Tighten securely with a 3 16 or 5mm Allen wrench not supplied e Second pass Long tenons should be routed in multiple passes D Move the fence back 1 2 from the position used for the first pass Use a miter gauge and with the good or face side of the rails facing down make the rail end cut on one side of each end of all rail parts that are to have long tenons ROUT ONLY the face side of the rail ALLELE With out moving the fence remove the threaded plug Fence and with the included do not wrench re attach change the upper portion position J gt o of rail cutter Rail flipped over e Move the fence back in increments of not more than 1 2 and repeat the procedure described for the second pass Continue this process until the tenon reaches the desired length
9. t Use the supplied Allen wrench to loosen the screw and remove the top cutter To make the tongue thinner remove some of the shims you will find on top of the bearing To make the tongue thicker add shims in this area from the collection of extra shims you will find in the package containing the wrenches Reassemble the bit secure the screw and make test cuts to check your adjustment Stile Bit Plug Rail Bit KeU Premier Adjustable Rail amp Stile System www freudtools com 1 800 334 4107
10. t is fast and easy to produce and gives a beautiful finished appearance Routing rail ends a Install the rail bit into the router collet b Set the bit height and make a test cut as follows Set the bit height to produce the Inset Bead desired profile A common rule is pe to have the inset bead on the face of the stile the same thickness as the shoulder on the back of the stile but this can vary depending on stock P thickness and the appearance you desire In 3 4 thick material the inset Shoulder bead should be approximately 1 8 deep e Use a straight edge to align the router table infeed and outfeed fences with the bearing on the bit e Be sure that the fence is parallel to the miter gauge track e Make a test cut across the end of a test piece of stock by using a miter gauge to feed the stock perpendicularly across the cutter B Tip 1 Make the opening between the infeed and outfeed fence as narrow as possible without touching the cutter to provide maximum support Tip 2 Use a backer board on the sled or miter gauge to reduce the chance for blow out at the back end of the cope cut Fence aligned with bearing Stub Tenon Stile Bit Stick Cutter Table pnei Router Routing edges of stiles and rails e With the router unplugged install the stile bit in the router A The stile bit is the tallest of the two bits in your set with one pr
11. to accept the tenons The tenon should fit snugly into the mortise There are several ways to cut mortises e The easiest method is to use a mortiser or drill press mortising attachment e If you don t have a mortiser or mortising machine an alternative technique is to use a brad point bit or forstner bit in a drill press to remove most of the stock for the mortise and then use a chisel to remove the remaining stock and to square up the mortise Drill only about 1 16 deeper than required for the tenon as Plywood Panels Adjusting the bits for thinner grooves for plywood panels If you want to make doors with plywood panels your bits can be adjusted to produce grooves as thin as 5 5mm This is important because most 1 4 plywood is actually much thinner than a true 1 4 To adjust the groove width produced by the stile bit unplug the router and install the bit in the collet Use a 1 2 open end wrench or adjustable wrench not included to remove the nut on top of the spindle Carefully unstack the components of the bits until you remove the upper of the two slot cutters You will find thin shims between these cutters Removing some of these shims will produce a narrower groove Adding shims from the extras stored under the nut will make the groove thicker Reassemble the bit secure the nut and make tests cuts to check your adjustment To adjust the thickness of the tongue unplug the router and install the rail bi
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