New - CMT Divided Light Bit Set - "Making a Special Mirror"

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     The new instructions call for cutting 1/4" mortises in the two rails.
   Of course, you also need to mortise the dividers  (mullions/muntins) as well, but I am going to do that after I have the outside frame together. I confuse easily, so I will do them once I master the basic four corners.
   Another reason for doing them separately is that I may cut and shape them so that they fit on top the mirror, rather than be a part of the frame — and require a lot of little pieces of mirrors.

  So I marked the mortise to be near the center — actually 1/4" down from the front surface. I also cut them so that the tenons would  have shoulders.

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       With the mortises cut, I carefully cut tenons to fit. Since my mortise was slightly off center, I try to cut the tenon to match exactly.

   This is the tenon that fits. Using the Incra Miter Gauge allowed me to cut the top and bottom shoulders exactly right. Do you notice that one is slightly out of alignment with the other? The instructions call for the bottom to be 1/16th wider that the top. The Incra Stop allowed me to do that exactly, but I don't know what that 1/16" will be for — yet.

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  The next step says to mount the coping bit in the router and set the height so that the top of the bit "brushes" the tenon. But, with this adjusted, the pilot bearing is under the table top. I frankly couldn't understand the instructions as they were written.

   Do you remember my showing this Delta Miter Gauge with hold-downs and saying "I would probably never need such a setup." Well, I needed it.
   I figured that it you have to raise the bit so that the bearing is exposed, you would have to use a jig that could guide against that bearing and hold the tenoned stock in place.
   One holddown screw is holding the base plate (1/2" MDF) so that it rubs against the bearing. I use the other hold-down to hold the stile. It is simple to set. You slide it until the shoulder is lined up with the edge of the MDF. You will see this setup in greater detail when Beth tries it.

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    And I have my coped tenon on the stile. Now to cut the profile on the mating pieces.

   Have I ever mentioned that the bent wrench makes bit changing so fast and easy! (I know — ad nauseum.) Anyway, I install the profiling bit from the set.

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  The RouterRaizer is also such a need addition to the router table. I am cranking in the router depth to match the thickness of the rule (1/16".) I will make a test cut and see how it mates with the cope.

  I use the ruler to adjust the fence to line up with the pattern bearing.

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   I make my test cut. I will set up featherboards for the actual run, but this block holddown works fine for this pass.

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