Jesada's
Rail & Stile Instructions

Please Note: Wherever you see these pictures, the specified bits are for use in a router table only! Never attempt to use them in a hand-held router! Warning! Router Table Use Only!

Note: These instructions are based upon a door with 3/4" x 2-1/4" stiles and rails. Other sizes may be used, but please adjust the following set-up instructions accordingly. Be sure your stock is straight & flat with perfectly-square edges.

Set up cut #1 as shown, making test cuts on scrap stock (Keep lots of pieces of scrap handy). Make this cut on one edge of each stile and rail.

Now, set up cut #2. Be sure that your test cut fits into the cut you made in the previous step. Make cut #2 across both ends of each rail. When cutting rails to length, allow 7/16" for each tenon. If your stiles are 2-1/4" wide, your rails should be 3-5/8" shorter than the width of the door.

TIP: To prevent tear-out when routing rail ends (Cut #2), clamp a backing board to your miter gauge or right angle fixture.

Illustration

A note about our Rail & Stile Sets:

We make every effort to ship our Rail & Stile Sets so they are ready to make perfect, tight-fitting joints right out of the box. Many factors can effect the fit however, including the wood species, the condition of your router, even your routing technique. Resharpening of the edge also will result in a loose joint. From time to time you may wish to adjust the fit of the joint as explained below.

Fine Tuning your Rail and Stile Set:

Each of our bits includes several shims placed between the cutters, bearing and retaining nut. As shown to the right, adding or removing shims at various points can tighten or loosen the joint.


Safety Tips:

  • Use pusher blocks or push stick to keep hands well clear of bit when cutting stiles!
  • Use a right angle fixture for cutting rail ends.
  • Wear eye and ear protection at all times.
  • Use a router table fence for all cuts.
Illustration Illustration
Cut #1 Cut #2
  1. Adjusting the fit of the tongue & groove:
    1. Too Loose? Add shims to the Rail Bit.
    2. Too tight? Remove shims from the Rail Bit.
  1. Adjusting the fit of the profile area:
    1. Too Loose? Add shims to the Stile Bit.
    2. Too tight? Remove shims from the Stile Bit.

Copyright © 1997, Jesada Tools™.
Any reproduction in whole or in part strictly prohibited.