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I am building a work bench. I am using resawn lumber for the main structure supports (legs and connecting boards in between them). I don't have a jointer, but after resawing them and sending them through the tablesaw they are very close to being square, but not perfect like a jointer would do.
With that in mind I have two questions: 1) Would you cute the tennons first and then make the mortise to fit? I will be doing a combo of bandsaw and plane/chisels for the tennons and drill out and chisels for the mortises.
2) How big and deep would you make the tennons? Is there a general rule of thumb for sizing? The boards are 1" 3/8 by 3" 3/8 and the legs are 3 3/8 x 2 3/8.
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