I just moved in a new house and I would like to build all the doors from solid wood. I have about 20 doors, including wardrobes and everything. I own a Powermatic 5 HP shaper.
I saw multiple cutter heads for making 1 3/8 - 1 3/4 in doors:
- Busy Bee
However, what catched my attention is the Infinity cutters. They come with an extended tenon cutter to make extended tenons. This way, I would not have to use dowels or floating tenons to build the door.
Their first kit is a matched rail and stile pair of cutters, with interchangeable slot cutter : 1/4 slot for 1 3/8 in door, and 1/2 slot for 1 3/4 door:
They have an extended tenon cutter that permits a 1 7/8 tenon length, but you have to substract the spacer thickness above the cutter of about 1/4 in.
They also have a more professional version of these cutters with carbides insert. Instead of sharpening the cutter, you change the inserts. This is a reversible cutter head with shims instead of a pair of matched cutter heads. I heard that reversible cutters were very time consuming to adjust properly. However, the tenon cutter is much larger and would permit to make tenons a little bit less than two inches long. This cutter set is very expensive.
Any of you have ever used these cutters?
What would be the minimum tenon length for a solid wood door 30x80x 1 3/8 in?