Quote Originally Posted by Ben (TM) View Post
BTW - anyone got any thoughts on cutting the tenons with a router? My workshop is a bit basic - only a router, sliding compound miter saw. I imagine a good table saw would be the go....but alas, no room or cash for one of those babies.
You need a table. a very basic one will do. I've used an old desk, attached router the the bottom and plunged up the desk. A thick sheet of MDF or (maybe better) melamine would serve. Support on sawhorses.

I'd use loose tenons, mortice both workpieces and size tenon to suit. If you make a tenon too thin, no drama. Just make another.

You could then make 2m of tenon, cut to length(s) as required.

.