A recent project that required multiple tenons in 1" oak dowels prompted me to build a jig to machine them on my router table. The jig allows you to feed the dowels through a pair of 1" holes and cut the tenon in much the same way as you’d sharpen a pencil. The two holes provide for a straight alignment while providing support against kickback. The ¼" dowel pin provides a positive stop so that all tenons are the same length. (I didn’t glue the ¼" dowel in place, so it can be replaced if I adjusted it too close to the router bit and it became damaged.) The “wings” in the back can easily be clamped to the router table to hold the jig securely.
For a finer cut, twist the dowel as you slowly feed it into the bit. Some wax in the holes will reduce friction.
When machining the 1¼" x 3" parts, work with longer stock and drill them simultaneously by clamping or taping them together. The parts can then be crosscut to length at the same time if a short scrap of 1" dowel is placed through the holes to keep them aligned. It’s also important to mark the top corners of both pieces so that the parts are assembled in the same orientation as they were cut. That way, even if the holes are slightly off-center, you’ll still maintain alignment.
You can adjust the size of the holes and all parts to match your needs.
