VERITAS 05J42.01 User manual

Mini Tenon Cutters
05J42.01 –
1/4"
05J42.05 –
5/16"
05J42.02 –
3/8"
05J42.06 –
7/16"
05J42.03 –
1/2"
05J42.04 –
9/16"
Patented.
General Safety Rules
1. Read the manual. Learn the tool’s
applications and limitations as well as
the specific hazards related to the tool.
2. Use common sense. If an action
appears to be unsafe, it likely is.
3. Wear proper eye/ear protection.
Everyday eyeglasses have only
impact-resistant lenses; they are not
safety glasses. Also use a face or
dust mask if the cutting operation is
dusty. Visitors should wear the same
protection.
4. Wear proper apparel. Avoid wearing
clothing with loose sleeves. Do not
wear gloves, ties, rings or bracelets
as these can get caught in moving
machinery.
5. Long hair should be tied back and
secured.
6. Do not work under the influence of
drugs, alcohol, or medication. Drugs,
alcohol, medication and lack of
sleep cause impaired judgment and
coordination and should not be
combined with power tool operation.
7. Use in an appropriate environment.
Power tools should be used only in
dry, clean and well-lit environments.
Exposure to rain or use in the presence
of flammable liquids or gases could
result in damage or injury.
8. Do not operate electric tools in
gaseous or explosive environments.
The spark of the motor may cause
the fumes to ignite.
9. Keep workplace clean. Cluttered
areas and benches invite
accidents.
10. Use correct power supply. Never
use a power source for which this
tool was not designed. It could
cause serious injury. If the tool is
equipped with a three-prong plug,
it should be plugged into a three-
hole electric receptacle. An adapter
should be properly grounded.
11. Keep cord away from heat, oil and
sharp edges.
12. Do not carry a plugged-in portable
tool with finger on the switch.
Safety Rules
These safety instructions are meant to complement those that came with your
power tool. We suggest that you reread those, in addition to those listed here
before you begin to use this product. To use this product safely, always follow
both sets of safety and general instructions.
2

Mini Tenon Cutters
05J42.01 –
1/4"
05J42.05 –
5/16"
05J42.02 –
3/8"
05J42.06 –
7/16"
05J42.03 –
1/2"
05J42.04 –
9/16"
Patented.
Replacement Blade and Accessories
Product # Description
05J42.10 Replacement Blade
Mini Tenon Cutter
54K93.02 81/2"× 11"Micro-Abrasive
Sheet (15µ SiC, PSA)
54K94.02 81/2"× 11"Micro-Abrasive
Sheet (5µ SiC, PSA)
Other Sizes of Tenon Cutters Available
Product # Description
05J41.01 Power Tenon Cutter –
5/8"
05J41.02 Power Tenon Cutter –
3/4"
05J41.09 Power Tenon Cutter –
7/8"
05J41.03 Power Tenon Cutter – 1"
05J41.07 Power Tenon Cutter –11/4"
05J41.05 Power Tenon Cutter –11/2"
05J41.08 Power Tenon Cutter –13/4"
05J41.06 Power Tenon Cutter – 2"
General Safety Rules
1. Read the manual. Learn the tool’s
applications and limitations as well as
the specific hazards related to the tool.
2. Use common sense. If an action
appears to be unsafe, it likely is.
3. Wear proper eye/ear protection.
Everyday eyeglasses have only
impact-resistant lenses; they are not
safety glasses. Also use a face or
dust mask if the cutting operation is
dusty. Visitors should wear the same
protection.
4. Wear proper apparel. Avoid wearing
clothing with loose sleeves. Do not
wear gloves, ties, rings or bracelets
as these can get caught in moving
machinery.
5. Long hair should be tied back and
secured.
6. Do not work under the influence of
drugs, alcohol, or medication. Drugs,
alcohol, medication and lack of
sleep cause impaired judgment and
coordination and should not be
combined with power tool operation.
7. Use in an appropriate environment.
Power tools should be used only in
dry, clean and well-lit environments.
Exposure to rain or use in the presence
of flammable liquids or gases could
result in damage or injury.
8. Do not operate electric tools in
gaseous or explosive environments.
The spark of the motor may cause
the fumes to ignite.
9. Keep workplace clean. Cluttered
areas and benches invite
accidents.
10. Use correct power supply. Never
use a power source for which this
tool was not designed. It could
cause serious injury. If the tool is
equipped with a three-prong plug,
it should be plugged into a three-
hole electric receptacle. An adapter
should be properly grounded.
11. Keep cord away from heat, oil and
sharp edges.
12. Do not carry a plugged-in portable
tool with finger on the switch.
Safety Rules
These safety instructions are meant to complement those that came with your
power tool. We suggest that you reread those, in addition to those listed here
before you begin to use this product. To use this product safely, always follow both
sets of safety and general instructions.
2
341
© Veritas Tools Inc. 2005
814 Proctor Avenue
Ogdensburg, New York
13669-2205 USA
1090 Morrison Drive
Ottawa, Ontario
K2H 1C2 Canada
INS-123 Rev. D
Printed in Canada.

13. Never carry portable tools by the cord.
14. Use the right tool. Do not force a
small tool or attachment to do the job
of a heavy-duty tool.
15. Do not force tool. It will do the job
better and safer at the rate for which
it was designed.
16. Do not use damaged tools. A damaged
tool that does not operate correctly is
a safety hazard and should be fixed
before any further use.
17. Repairs and service should be
performed by a certified technician.
Use only identical replacement parts.
18. Do not alter or misuse the tool. Stop
any operation immediately if you
notice anything abnormal.
19. Practice proper maintenance. Keep all
tools sharp, clean and well lubricated
for the best and safest results. Sharp
blades minimize stalling, kickback,
and burning. They perform faster,
better and safer than dull blades.
20. Keep hands away from moving
parts until they have come to a
complete stop and the power has been
disconnected.
21. Always disconnect the tool from the
power source when changing cutters
or blades, or when performing any
general maintenance activities (such
as adjusting or cleaning).
22. Handle blades with care.
23. Unless otherwise specified, always
insert the shank as far as possible into
the chuck in order to provide proper
support. Tighten the chuck securely.
24. Remove all nails from a workpiece
before performing any operation on it.
25. Hold workpiece firmly in a vise or
clamp.
26. Ensure that depth and any other
adjustments are tight.
27. Remove adjusting keys and wrenches
before use.
28. Maintain good balance.
29. Do not remove workpiece or cut-off
pieces from tool during a cut while
the cutter is moving.
30. Do not leave tool until it comes to a
complete stop.
31. When not in use, power tools should
be stored in a dry area, elevated and
locked so that they are out of the
reach of children.
3
The Veritas®Mini Tenon Cutters cut 60°
shouldered tenons on small stock. These
small-diameter tenon cutters are ideal for
chair rungs, decorative work on rustic
furniture and wherever small tenons are
required, e.g., trellis and lattice work,
fan frames, etc. They require little torque
while being driven by an electric drill. The
included plug gauge allows the blade to
be adjusted to cut the exact size of tenon
required. It is easy to sharpen the blade on
a belt sander or sharpening stone.
Veritas®Tenon Cutters are for use in a hand
electric drill. They are not to be used in a
drill press for several reasons.
1) Because the workpiece must be rigidly
clamped in line with the equally rigid
axis of the drill-press chuck, any
misalignment or movement can create
high side loads on the tenon cutter,
leading to the shank failing. Any quill
run-out in the drill press contributes
further to the problem.
2) Because there is much less feel as to
how the cutter is performing when using
a drill press, it is possible to overload
the tenon cutter without realizing it.
This too can lead to the shank failing.
3) Overloading the tenon cutter or
operating it at high speeds can also
lead to overheating the high-carbon
steel blade, resulting in edge failure,
loss of hardness, and a useless blade.
Taking a Test Cut
Firmly tighten the tenon cutter in the chuck
of an electric drill.
Clamp a piece of wood horizontally in
a vise at about waist height. Ensure the
end is cut square. Maximum diameter of
workpiece for each tenon cutter size is
shown below.
Table 1: Maximum Wood Diameter for Tenon
Cutter Diameter.
Hint: If you do not have a vise, you can
improvise with a piece of 2×4 with various
sizes of V-shaped notches cut in it and two
C-clamps. Place the piece of wood in a
notch slightly smaller than its diameter,
and clamp the 2×4 to a bench or a large
stable surface.
Place the tenon cutter on the end of the
piece of wood and adjust the drill by eye
so that it is in line with the piece of wood.
The tenon cutter will cut tenons in line with
the axis of the drill. If you wish to have a
tenon come out of the end of the piece of
wood at an angle, clamp the piece in a vise
at the desired angle (using an inclinometer
if necessary). Cut the tenon while holding
the tenon cutter straight and level.
4
Tenon Dia. Max. Stock Dia.
1/4"3/4"
5/16"3/4"
3/8"7/8"
7/16"7/8"
1/2"1"
9/16"1"

13. Never carry portable tools by the cord.
14. Use the right tool. Do not force a
small tool or attachment to do the job
of a heavy-duty tool.
15. Do not force tool. It will do the job
better and safer at the rate for which
it was designed.
16. Do not use damaged tools. A damaged
tool that does not operate correctly is
a safety hazard and should be fixed
before any further use.
17. Repairs and service should be
performed by a certified technician.
Use only identical replacement parts.
18. Do not alter or misuse the tool. Stop
any operation immediately if you
notice anything abnormal.
19. Practice proper maintenance. Keep all
tools sharp, clean and well lubricated
for the best and safest results. Sharp
blades minimize stalling, kickback,
and burning. They perform faster,
better and safer than dull blades.
20. Keep hands away from moving
parts until they have come to a
complete stop and the power has been
disconnected.
21. Always disconnect the tool from the
power source when changing cutters
or blades, or when performing any
general maintenance activities (such
as adjusting or cleaning).
22. Handle blades with care.
23. Unless otherwise specified, always
insert the shank as far as possible into
the chuck in order to provide proper
support. Tighten the chuck securely.
24. Remove all nails from a workpiece
before performing any operation on it.
25. Hold workpiece firmly in a vise or
clamp.
26. Ensure that depth and any other
adjustments are tight.
27. Remove adjusting keys and wrenches
before use.
28. Maintain good balance.
29. Do not remove workpiece or cut-off
pieces from tool during a cut while
the cutter is moving.
30. Do not leave tool until it comes to a
complete stop.
31. When not in use, power tools should
be stored in a dry area, elevated and
locked so that they are out of the
reach of children.
3
The Veritas®Mini Tenon Cutters cut 60°
shouldered tenons on small stock. These
small-diameter tenon cutters are ideal for
chair rungs, decorative work on rustic
furniture and wherever small tenons are
required, e.g., trellis and lattice work,
fan frames, etc. They require little torque
while being driven by an electric drill. The
included plug gauge allows the blade to
be adjusted to cut the exact size of tenon
required. It is easy to sharpen the blade on
a belt sander or sharpening stone.
Veritas®Tenon Cutters are for use in a hand
electric drill. They are not to be used in a
drill press for several reasons.
1) Because the workpiece must be rigidly
clamped in line with the equally rigid
axis of the drill-press chuck, any
misalignment or movement can create
high side loads on the tenon cutter,
leading to the shank failing. Any quill
run-out in the drill press contributes
further to the problem.
2) Because there is much less feel as to
how the cutter is performing when using
a drill press, it is possible to overload
the tenon cutter without realizing it.
This too can lead to the shank failing.
3) Overloading the tenon cutter or
operating it at high speeds can also
lead to overheating the high-carbon
steel blade, resulting in edge failure,
loss of hardness, and a useless blade.
Taking a Test Cut
Firmly tighten the tenon cutter in the chuck
of an electric drill.
Clamp a piece of wood horizontally in
a vise at about waist height. Ensure the
end is cut square. Maximum diameter of
workpiece for each tenon cutter size is
shown below.
Table 1: Maximum Wood Diameter for Tenon
Cutter Diameter.
Hint: If you do not have a vise, you can
improvise with a piece of 2×4 with various
sizes of V-shaped notches cut in it and two
C-clamps. Place the piece of wood in a
notch slightly smaller than its diameter,
and clamp the 2×4 to a bench or a large
stable surface.
Place the tenon cutter on the end of the
piece of wood and adjust the drill by eye
so that it is in line with the piece of wood.
The tenon cutter will cut tenons in line with
the axis of the drill. If you wish to have a
tenon come out of the end of the piece of
wood at an angle, clamp the piece in a vise
at the desired angle (using an inclinometer
if necessary). Cut the tenon while holding
the tenon cutter straight and level.
4
Tenon Dia. Max. Stock Dia.
1/4"3/4"
5/16"3/4"
3/8"7/8"
7/16"7/8"
1/2"1"
9/16"1"

Note: The plug gauge will develop small
scratches as it is repeatedly rotated against
the blade prior to removal. It has been
made of soft brass so that it does not nick
the corner of the blade. It has also been
made long enough so that you may place it
in the tenon cutter at varying depths to find
an unblemished area.
While adjusting the blade, never allow the
blade to override the plug. Doing so will
cause deep scratches in the gauge as it is
rotated prior to removal, and likely result
in undersized tenons.
Tenon Length
A tenon cut to full depth will be 1"long with
the 1/4", 5/16"and 3/8"dia. tenon cutters, and
13/8"long with the 7/16", 1/2"and 9/16"dia.
tenon cutters. To cut shorter tenons, just stop
cutting before bottoming out.
Sharpening
You can hold the small blade for sharpening
by making a blade holder from 1/2" square
stock, 4"to 6"long. Using a bandsaw or
other thin blade, cut a center groove at least
3/4"deep in one end. Drill a 3/16"dia. hole
perpendicular to the groove, 3/16"from
the end, and just deep enough to reach the
groove. Countersink to accommodate a
#10 × 1/2"flat-head wood screw. Chamfer
the front portion of the non-drilled section
below the slit at approximately 30°.
Insert the blade in the slot (bevel facing
the chamfered section). Secure it in place
with the #10 × 1/2"flat-head wood screw.
Coat the entire length of the bevel with an
indelible marker. Clamp the blade holder
in a honing guide at a 30° angle, and
progressively hone the blade to 4000x.
Observe where the marker coating has
worn off. Continue sharpening until the
full width of the blade is clear of marker
coating (and at least 1/32"wide). Check to
ensure that the bevel remains square to the
side edge of the blade.
Alternatively, you can sharpen the blade
held at a 30° angle against a belt sander
(fitted with a 180x belt for rough sharpening,
progressing to 15µ or finer for finishing).
Do not hold the blade in contact with the
belt for extended periods of time (more
than few seconds) or you may overheat the
blade. Use indelible marker as described
above to ensure that the entire bevel has
been sharpened and remains square to the
side edge of the blade.
Remove the blade from the holder. To
remove the wire burr from the edge of
the blade, draw the face across a fine grit
(1000x or higher) sharpening stone or a
piece of silicon carbide abrasive paper on
a flat surface.
6
3/4"
1
/
2
"×
1
/
2
"stock,
4"to 6"long.
3/16"
30°
Figure 3: Shop-made blade holder.
Note: Whether you are cutting in-line
or angled tenons, the secret to cutting
a uniform tenon is to keep the drill very
steady while cutting.
While leaning into the wood, switch on the
drill at a moderate speed (800 to 1000 rpm).
Turning too fast may cause you to wander
from a straight cut. If the blade is properly
set, the shaving of wood will curl out of the
tenon cutter as it rotates. If the tenon cutter
stops cutting or does not cut at all, you will
need to adjust the blade.
Note: The tenon cutter’s shank has a hole
drilled down the center. This is to allow you
to insert a 3/16" dia. pin into the back end to
drive out a broken tenon.
Adjusting the Blade
A brass plug gauge has been provided to
help you obtain the desired tenon diameter.
To Adjust the Tenon Diameter:
Loosen the blade clamping screw slightly
to just allow the blade to slide with minimal
vertical play. Insert the plug gauge into the
tenon cutter, rotating it so that either of the
two round surfaces faces the blade. Lightly
push the blade in until the front corner
(the part that determines the final tenon
diameter) touches the plug gauge, while
the right-hand edge remains in contact with
the body shoulder. Firmly tighten the blade
clamping screw.
Rotate the plug in either direction until
the round surfaces are no longer touching
the blade. While the flat on the gauge
provides clearance under the blade,
withdraw the gauge. Make a test cut
and measure the tenon. If the tenon is
not cutting the desired size, repeat this
procedure, or see Troubleshooting.
Figure 1: Adjusting the blade.
To Adjust the Shaving Thickness:
The blade can be adjusted to cut more
aggressively to produce larger shavings.
Repeat the above procedure, but swivel
the blade away from the body shoulder,
rotating it about the right-hand front
corner, which is to remain in contact with
the plug gauge.
Figure 2: Adjusting shaving thickness.
5
Body
Shoulder
Swivel about front
corner of blade
Body
Shoulder
Blade
Clamping
Screw
Plug Gauge
Front Corner
of Blade

Note: The plug gauge will develop small
scratches as it is repeatedly rotated against
the blade prior to removal. It has been
made of soft brass so that it does not nick
the corner of the blade. It has also been
made long enough so that you may place it
in the tenon cutter at varying depths to find
an unblemished area.
While adjusting the blade, never allow the
blade to override the plug. Doing so will
cause deep scratches in the gauge as it is
rotated prior to removal, and likely result
in undersized tenons.
Tenon Length
A tenon cut to full depth will be 1"long with
the 1/4", 5/16"and 3/8"dia. tenon cutters, and
13/8"long with the 7/16", 1/2"and 9/16"dia.
tenon cutters. To cut shorter tenons, just stop
cutting before bottoming out.
Sharpening
You can hold the small blade for sharpening
by making a blade holder from 1/2" square
stock, 4"to 6"long. Using a bandsaw or
other thin blade, cut a center groove at least
3/4"deep in one end. Drill a 3/16"dia. hole
perpendicular to the groove, 3/16"from
the end, and just deep enough to reach the
groove. Countersink to accommodate a
#10 × 1/2"flat-head wood screw. Chamfer
the front portion of the non-drilled section
below the slit at approximately 30°.
Insert the blade in the slot (bevel facing
the chamfered section). Secure it in place
with the #10 × 1/2"flat-head wood screw.
Coat the entire length of the bevel with an
indelible marker. Clamp the blade holder
in a honing guide at a 30° angle, and
progressively hone the blade to 4000x.
Observe where the marker coating has
worn off. Continue sharpening until the
full width of the blade is clear of marker
coating (and at least 1/32"wide). Check to
ensure that the bevel remains square to the
side edge of the blade.
Alternatively, you can sharpen the blade
held at a 30° angle against a belt sander
(fitted with a 180x belt for rough sharpening,
progressing to 15µ or finer for finishing).
Do not hold the blade in contact with the
belt for extended periods of time (more
than few seconds) or you may overheat the
blade. Use indelible marker as described
above to ensure that the entire bevel has
been sharpened and remains square to the
side edge of the blade.
Remove the blade from the holder. To
remove the wire burr from the edge of
the blade, draw the face across a fine grit
(1000x or higher) sharpening stone or a
piece of silicon carbide abrasive paper on
a flat surface.
6
3/4"
1
/
2
"×
1
/
2
"stock,
4"to 6"long.
3/16"
30°
Figure 3: Shop-made blade holder.
Note: Whether you are cutting in-line
or angled tenons, the secret to cutting
a uniform tenon is to keep the drill very
steady while cutting.
While leaning into the wood, switch on the
drill at a moderate speed (800 to 1000 rpm).
Turning too fast may cause you to wander
from a straight cut. If the blade is properly
set, the shaving of wood will curl out of the
tenon cutter as it rotates. If the tenon cutter
stops cutting or does not cut at all, you will
need to adjust the blade.
Note: The tenon cutter’s shank has a hole
drilled down the center. This is to allow you
to insert a 3/16" dia. pin into the back end to
drive out a broken tenon.
Adjusting the Blade
A brass plug gauge has been provided to
help you obtain the desired tenon diameter.
To Adjust the Tenon Diameter:
Loosen the blade clamping screw slightly
to just allow the blade to slide with minimal
vertical play. Insert the plug gauge into the
tenon cutter, rotating it so that either of the
two round surfaces faces the blade. Lightly
push the blade in until the front corner
(the part that determines the final tenon
diameter) touches the plug gauge, while
the right-hand edge remains in contact with
the body shoulder. Firmly tighten the blade
clamping screw.
Rotate the plug in either direction until
the round surfaces are no longer touching
the blade. While the flat on the gauge
provides clearance under the blade,
withdraw the gauge. Make a test cut
and measure the tenon. If the tenon is
not cutting the desired size, repeat this
procedure, or see Troubleshooting.
Figure 1: Adjusting the blade.
To Adjust the Shaving Thickness:
The blade can be adjusted to cut more
aggressively to produce larger shavings.
Repeat the above procedure, but swivel
the blade away from the body shoulder,
rotating it about the right-hand front
corner, which is to remain in contact with
the plug gauge.
Figure 2: Adjusting shaving thickness.
5
Body
Shoulder
Swivel about front
corner of blade
Body
Shoulder
Blade
Clamping
Screw
Plug Gauge
Front Corner
of Blade

8
Theright-hand corner ofthe blade determines
the final tenon diameter. To increase its
longevity between sharpenings, you may
wish to "break" this corner very slightly.
Just draw it against a 4000x stone or 5µ
abrasive paper with one or two passes.
Troubleshooting
UNEVEN TENONS: This is usually
caused by one of two things:
1) An unsteady drill position while
cutting. Reduce your drill speed and
concentrate on holding the drill steady
while cutting.
2) Growth ring structure. If the corner of
the blade is cutting tangential to a very
consistent diameter growth ring, the
blade may peel that layer, much the
same way veneer is cut from a log.
This will result in uneven or undersized
tenons. An extremely sharp blade is just
about the only preventive measure.
UNDERSIZED TENONS: They
usually indicate a blade that has been
advanced too far. This is most often caused
by loosening the blade clamping screw too
much, which allows the blade to ride up
on the plug gauge and bend slightly once
tightened against the gauge. When the
gauge is removed the blade will drop to its
unstressed position and produce undersized
tenons. Readjust the blade.
OVERSIZED TENONS: These usually
arise when cutting green wood, where some
compression takes place. When the tenon
cutter is removed, the tenon will spring back
to an oversize condition. Adjust the blade
using the gauge as you normally would, but
then back off the blade clamping screw just
enough to tap the blade in a bit further, then
retighten. Note that you can use this sprung
oversize tenon to your advantage, as it will
shrink as it dries.
SCALLOPED TENONS: Applying
excessive force while cutting the tenon
can result in the cutter advancing at a rate
fast enough to make the tenon look like
a coarse thread. Reduce the inward force
applied to the drill.
Continuing to rotate the tenon cutter
clockwise while withdrawing it from the
tenon can also cause the blade to cut on its
return pass, leaving similar scallops. This is
especially so on green wood, where some
compression may have taken place as the
tenon was being cut. Instead, pull the tenon
cutter off the tenon with the drill switched
off, either without rotating it, or by slowly
rotating it counterclockwise.
OFF-CENTER TENONS: Nothing can be
done about the most common cause of off-
center tenons – natural variations in wood
density and growth patterns.
PARTIAL TENONS: If the tenon cutter
starts cutting, then fades and eventually
stops cutting, this indicates that a minor
blade adjustment is required. Swivel the
blade to produce a thicker shaving.
UNEVEN GRIND WHEN RESHARPENING:
This usually happens when the blade bevel
is not held parallel to the belt or stone.
Adjust the jig until the bevel is parallel to
the belt or stone.
7

Replacement Blade and Accessories
Product # Description
05J42.10 Replacement Blade
Mini Tenon Cutter
54K93.02 81/2"× 11"Micro-Abrasive
Sheet (15μ SiC, PSA)
54K94.02 81/2"× 11"Micro-Abrasive
Sheet (5μ SiC, PSA)
Other Sizes of Tenon Cutters Available
Product # Description
05J41.01 Power Tenon Cutter– 5/8"
05J41.02 Power Tenon Cutter– 3/4"
05J41.09 Power Tenon Cutter– 7/8"
05J41.03 Power Tenon Cutter– 1"
05J41.07 Power Tenon Cutter–11/4"
05J41.05 Power Tenon Cutter–11/2"
05J41.08 Power Tenon Cutter–13/4"
05J41.06 Power Tenon Cutter– 2"
341
© Veritas Tools Inc. 2005
814 Proctor Avenue
Ogdensburg, New York
13669-2205 USA
1090 Morrison Drive
Ottawa, Ontario
K2H 1C2 Canada
INS-123 Rev. D
Printed in Canada.