There are lots of bit sets that can make tight-fitting cope-and-stick joints, but Freud’s new rail and stile router-bit set (No. 99-760) allows full-length tenons, instead of the usual stub tenons created by these bits. The bits can be used with stock ranging from 5/8 in. to 1-1/4 in. thick, and Freud claims the cutters have a unique geometry to reduce tearout. I tried the bit set with several different wood species and found the claim to be true, even with red oak, which is especially prone to tearout.

Removing the upper portion of the two-piece cope cutter—which includes the guide bearing—extends the tenon length infinitely. But you can only increase the length 1/2 in. with each pass. If that takes too long, you could rough out the tenon with a dado set or bandsaw and finish the cut with the cope-cutter. Another minor inconvenience is that it takes two setups to create the long tenon: one for the profile side and one for the back. And since you remove the guide bearing for the cope-cutter for the profile cut and lower it beneath the table during the back cut, careful setup of the fence and miter gauge is crucial.

By adding or removing shims, you can adjust the groove from 7/32 in. to 3/8 in. The set comes in roundover, ogee, roundover bead, and bevel patterns. The basic set is $120 at woodcraft.com; double-profile ($96; No. 99-860) and glass-panel ($38; No. 54-760) cutters are also available.

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