I am building a large wine cellar door (48 x 80) that will have an inset antique Indian “tiger door”. Stock is 2.25″ stave constructed with oak veneer. Design will have top (5.5″) and bottom (11″) rails only as it will essentially frame out the tiger door. I planed floating tenons with mortises of 3/4″ x 3″ x 3″. One mortise on the top rail and 2 on the bottom rail. Now for the problem.
I built a standard router mortise jig to use with a MLCS upcut spiral 3/4″ router bit in my plunge router. It works wonderfully, the problem is I can only get 2″ of depth on test cuts at full plunge. I then bought a router collet extension and it seems too sketchy and I worry it will spin out and destroy wood or worse. I have now been sitting on the project for weeks and hoping for suggestions.
Couple other points:
-I would say I am an intermediate woodworker, but a beginner with hand tools.
-Thinking I could have done standard mortise and tenon and cut tenons on table saw, but stock is too short and not possible now.
-Thought about buying a mortising machine but cutting end of rails would be seemingly impossible
-I have a festool domino but it is 500 series and not the XL