Tenons on long boards
I need to cut 5" long tenons on both ends of 20, 1 1/2" square boards. The tenons will be 1 5/16" square. the wood is poplar and range in length from 48" to 101". I'm trying to find the most accurate and safe way to cut these. The 1st time I did thid I used my table saw, but it was hot a good, accurate, or safe way to cut them. What alternatives are out there to make this many and have them all the same? I have 5 router tables, but like the tablesaw it is really hard to handle 8' boards while moving them across a moving bit/blade. I have the same problem when trying to cut the shoulders off for a 5" long tenon on the band saw. Am hoping that some one here has a good way to use a router to cut these tenons. If it weren't for the fact that they have to fit into square metal sockets, I would just chuck them up in my Leblond metal lathe and turn the tenons round, and know they would be exact. I know a rtound peg will fit into a square hole, and they will be pinned, but the setup time would be slowed down a bunch in lining up the pin holes. Any help would be greatly appreciated!!!