Loose Tenon Router Mortising Jig

I've looked at loose tenon joinery tools longingly but cannot afford one.  Searched maker sites too, but none had all the features I wanted, so I created this version designed to hold a 69mm cordless router with ¼ inch shank.  I have only tested with a Dewalt DCW600B cordless router.   Have now added 2 variants for 65 and 72.2mm compact routers per requests.  Fixed the two issues identified by users for the 65mm variant (still printed as 69, bolt pockets).

The features I like about my version are:

• No glue or epoxy needed – completely dry fit
• Fits cordless router (69mm barrel).  Optional variants for 65 and 72.2mm added 4/2026.
• Height adjustable, self-aligning slide
• Depth and width control set by printed hardware stops, not loose screws.
• Depth and width motion on perpendicular pairs of parallel linear bearing slides and rods
• Set up for common 1/4-20 hardware (USA)

Like some other jigs found, this uses 8mm linear bearings and two pairs of perpendicular rods for motion control (150 and 200mm).

I printed the key parts with ASA for additional rigidity and strength.

I have posted a new profile with multiple router cradle sizes (65, 69 and 72.2mm) for common cordless trim routers (only need to print the necessary one, of course).   Also added a spring spacer washer, as some reported having trouble finding washers with 8+ mm ID.

See the updated detailed assembly and use instructions for printing tips and setup/usage instructions, including improved tenon width control clip sizing information.