I've recently cut mortices using a template and busing guide with a plunge router to get easily reproducible results. I then cut mortices by routing away 5mm all round my timber. I then discovered that my timber is not very accurately machined - some tenons were over tight and others too loose.
To fix this in the future I would probably try to fit in a planer/thicknesser, but for my current project this is not practical. I want to have well fitting routed joints but not take away from the woods current finish - which is fine for the garden tubs I want.
How would I go about cutting exact 25x60mm tenons on the end of approx 35x70mm timber? I can't see how a trim router and template would be workable on the end of a small profile like this.