Home » Tip of the Day

Tip of the Day

Daily woodworking tips to improve your accuracy, better organize your shop, make your tools work harder, and help you work safer. Stop back daily for more woodworking tips from the editors at WOOD magazine and our enthusiastic readers.

July 28, 2016

How to safely make mortise plugs using your tablesaw

How to safely make mortise plugs using your tablesaw

Here’s a simple and safe way to form small plugs for the square mortises. This method keeps your fingers out of harm’s way and prevents having to push a small workpiece between the blade and fence.

To make a 3⁄8″-square blank 8″ long for the mortise plugs (G), for example, cut a piece of 3⁄4″ stock to 2 1⁄2x 16″. Position the fence 3⁄8″ from the inside of the blade. Place a piece of masking tape about 5″ long on the saw table 4″ in front of the blade and perpendicular to the fence for a visual stop, as shown top left. Raise the blade to 7⁄16″. With the stock on edge and tightly against the fence, rip the piece, stopping when the back end reaches the tape. Raise the blade 1⁄16″ (1⁄2″ total height). Flip the stock onto its face, and rip it again to form a 3⁄8″-square blank. Now, crosscut the piece to free the blank.

To safely and accurately crosscut the 7⁄16″-long plugs from the blank, attach an L-shaped extension/sled made from 3⁄4″ scrap to your miter gauge, as shown bottom left. Raise the blade to about 1 1⁄2″, and make a cut through the extension/sled. Draw a line on the sled 7⁄16″ from the kerf. Align the end of the blank with the mark to crosscut the plugs.

© Copyright , Meredith Corporation. All Rights Reserved | Privacy Policy | By using this site, you agree to our Terms of Service.