Quick Answer
Making a mortise and tenon joint without machinery requires a combination of hand sawing, chiseling, and fitting. This traditional technique is still effective in timber frame cabin construction. Skilled craftsmen can achieve precise joints using basic hand tools.
Choosing the Right Wood
To create a strong mortise and tenon joint, choose two pieces of wood that are properly seasoned and have minimal warping or checking. A hardwood like oak or maple is ideal, as it holds its shape well and resists moisture damage. For a 2x6 timber frame, a 3/4" thick tenon and a 1" deep mortise are suitable sizes.
Cutting the Tenon
To cut the tenon, start by marking the width and length using a sharp pencil or marker. Use a tenon saw or a backsaw with a fine tooth to carefully cut along the marked line. Make sure the cut is square with the grain and slightly tapered at the end to facilitate fitting. A tenon saw with 14-16 teeth per inch is best suited for this task.
Creating the Mortise
To create the mortise, mark the mortise location using a square and a pencil. Use a chisel set to carefully remove the wood, starting with a 1/4" chisel and gradually working your way down to a 1/8" chisel. Use a mallet to tap the chisel and remove small amounts of wood, checking the depth frequently to avoid over-cutting. A mortise depth of 1" and a width of 1.5" to 2" is common for 2x6 timber frames.
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