Re: Why not a router plane?
William Duffield, on the Cohansey
>You must be one of those engineer fellers :^) The problem is that you have to get the piece of scrap the same thickness as the rail you're putting the tenon on. Otherwise, the tenon ends up tapered anyhow. And, you're only removing about 1/4" wide swath at a time.
Even if I cut the cheeks with a table saw, I index both cuts off the face of the rail, the same way the mortise gauge works when cutting them by hand sawing. That way, any differences in thickness of the frame parts is immaterial.
What do you do if you have to cut a tenon that is not supposed to be parallel with the face of the board, for example, for the joint between the side seat rail and the back leg of a chair? In this case, the face of the board is actually twisted, so you don't even have a flat face to ride the router base plate on.
I do a test fit, feel for where some material needs to be removed, drop the rail onto a bench hook, and take a swipe or two with a plane, adjusting my pressure to preferentially remove material from wherever the fit is tightest, and retry the fit. Usually one or two passes, at most two refit attempts, are sufficient for a fit that I can just manage to force together and pull apart again without persuasion with a mallet, depending on how good my sawing technique happens to be that particular day.
Routers are designed for fitting things like hinge, lock and striker plate mortises and for flattening the bottoms of recesses for inlays.