Here’s another video on how to cut a perfect mortise using a plunge router – this one’s from Fine Woodworking. The video shows you how to make a mortising jig that guarantees perfect mortises and can be used over and over.
The jig is easy to build and works beautifully. To define the mortise’s start and stop points, a length of T-track has been set into the long beam that serves as the bearing surface for the router. This allows you to use repositionable stop blocks that don’t require you to clamp or screw stop blocks to the jig, and makes life a whole lot easier.
The router in the video is the DEWALT DW625 3-Horsepower Variable Speed Electronic Plunge Router. It’s a professional grade machine and the 3HP 15 Amp motor gives you all the power you could ever need with soft start for smoother operation and variable speeds from 8,000 to 22,000 RPM.