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All-Star 8Router Jigs Make your a multi-tasker with this problem-solving arsenal. By Joe Hurst-Wajszczuk

W Cutting circles, arcs, and ovals hen I bought my first you can employ selected jigs router twenty years ago, visions to rout panels too unwieldy to of roundovers, , and safely machine on a router table. After hanging the final sheet filled my head. Believing Over the next few pages, we’ll of drywall in my last shop, my the router should be saved for help you build an arsenal of drywall found a higher edge treatments, it sat idle on hardworking router jigs, some the shelf as I struggled to build of which are fresh spins on projects with a collection of rough old, reliable classics. I tweaked and a rebuilt the designs and used quality radial-arm . Now several years materials to make a sweet and four routers later, I view the collection of precision achievers tool as a multi-tasking Swiss-army that suit several needs while knife, ready to partner with any providing years of service. With numbers of jigs and accessories. just a small investment in time Additionally, -mounted and materials the resulting jigs routers provide great small-shop Note:won’t Somejust look of the good, jig dimensionsthey’ll ramp Mark lines on the acrylic to solutions. You can capitalize mayup your require craftsmanship adjustments too. to indicate the bit’s location. Nip on their versatility in limited- fit your machine. See “Making the corners off the bottom space shops, performing tasks the Jigs to Fit,” page 31. block for smaller circles. otherwise reserved for large 26heavy woodcraftmagazine.com machinery. Beyond that,Aug/Sept 2009 Figure 1: Trammel Jigs Circle-Cutting Jig Oval-Cutting Jig

calling. Attached to a router cutting jig. Unlike related jigs base, the 48" aluminum bar that require fussy router-cut now serves as the trammel dovetailed grooves, this simpler arm for my circle-and oval- stacked version can be easily Guide cutting jigs. I made the pivots in made with your . Cut strips similar fashion, allowing them the base to size. Then set the to share the same router base. angle to 7˚ and rip The two-block pivot (shown the top quadrant pieces and the opposite page) routs circles UHMW guide strips. Use the without pivot holes guide strips as spacers during in the workpiece. Instead, I assembly of the quadrant pieces adhered the bottom piece to to ensure a snug sliding fit and the workpiece with double- screw the parts in place. Trim off Position the router so that the faced tape. I’ve also found the corners, or trim the entire bit touches the minor axis. Then that a large 1-inch diameter jig to make smaller ovals. mark a hole for your pivot bolt. allows the blocks to spin Like the two-block pivot, tape The minor axis guide strip is moreFigure smoothly 1 than smaller- the oval-cutting pivot to the perpendicular to the arm. diameter pivot pins. As shown workpiece. Secure the trammel in , above, the acrylic arm with two bolts through piece on the top block clamps same-size holes in the arm. the trammel arm to the pivot block and shows the radius of the arc you’re routing. To set the Scrap radius , etch the acrylic Threaded to match your bit and attach hole it to the pivot as shown at left. Attach the arm to the base, make a test cut at a known length, Establish a centerpoint at the Rotate the router trammel and then trim the bar so that major and minor , and to the major axis and a the numbers match the cut. the jig will do the rest. hole for the second pivot. The oval-cutting jig is a largerPhotos: Doug variation Rowan of the circle- Aug/Sept 2009 woodcraftmagazine.com 27 Figure 2: T-Square and Straightedge

Squeeze the shelf material between the sacrificial guides (Inset) to set the width. Factor in the guide thickness when setting bit depth. Making , dadoes, and grooves Working in tandem, these guides with a ’s square to can help you make measure- set the before driving the Straightedge and T-Square guides free dadoes (see photo, above). remaining fasteners.) Add the rank as two of the simplest jigs Make the straightedge portion width of your straightedge to the going; offering great versatility of your jig from a straight board bit-to-base/ edge distance of your when paired with a router. Both about 6 inches longer than the router and1 8 rip a slightly oversized work well for rabbets, dadoes and material you expect to rout. strip of " thick Marlite or grooves. You can also use them (If you’re making the T-square . Attach the /strip to the for neatly trimming the ends of guide, rip a second shorter strip straightedge with double-faced1 8 panels or wide glued- and attach it to one end. Drive tape. Finally, trim the " bottom ups too large to cut on a tablesaw. one screw then check the angle with your router and straight bit. Routing breadboard ends

both faces of a large panel would also work), joint and The breadboard jig isn’t that for making the wide tenons the faces and edges,Figure and 3 then different from the above found in breadboard ends. Make drill a line of alignment holes straightedge, but the row of 1" the jig as shown about a foot where shown in . Rip diameter holes along the bar longer than you might typically the blank in half then attach the enables you to align the top and need; three dowel pins provide/2 guides with double-faced tape. Figurebottom fence 3: Breadboard so that you can Jig better alignment than two.1 To set the jig, position the Starting with a strip of 1 " panel between the (photo thick by 4" wide (6/4 at left), align the sacrificial guide or a kiln-dried two-by stock with the shoulder line, and it together. Rout the top face of the workpiece, and then flip the assembly and workpiece to finish the opposite face. Test the fit of the tongue before 28 woodcraftmagazine.com Aug/Sept 2009 removing the jig. Ripping and

If you think using a flush-trim bit with a straightedge in lieu of a isn’t new, then check out this jig’s flip side. Outfitted with two 48"-long miter channels enables it to work with track-saw-style clamps so that you can setup your workpiece as needed, and then do your ripping and jointing on a pair of or at your bench./2 You can build this back-saving1 jig from a few strips of - thick MDF or plywood. Rabbet Figure 4: Two-Faced Straightedge the jointer-edge so that the aluminum angle rests flush with the surface. Make the ripping guide strip wider than the blade-to-base dimension of your so that the first cut sets the cut line. Screw the guide strip to the assembly so that you can replace it if you change saw . To put the jig in jointer mode, simply flip it over and position the stock so that the edge hangs over the aluminum angle. Routing edges with a flush-trim helical bit produces an edge as clean as you’d expect from a well-tuned jointer. Carbide should be used on materials that would quickly dull high-speed knives, such as melamine, MDF, and plywood. Router-Table Jointer This table-mounted router jig, Figure 5, offers a router table. Use a straightedge to position the fence safe way to joint boards that might be too short so the outfeed fence is tangent to the circumference to safely machine on a standard jointer. And since of the bit, then clamp the remaining free end. spiral or helical bits cause less tear-out than straight jointer knives, you’re likely to save stock when Figure 5: Jointer Fence working figured . Two-cut settings make this jig different. It can rout a heavier1 /16"-deep cut for regular jointing, Optional dust and a super-light collection cut equal to the thickness of plastic laminate (about 1/32") for difficult materials. To use the jig, place the board To set up the against the infeed side and jig, clamp one move from right to left. end to your

Aug/Sept 2009 woodcraftmagazine.com 29 Subbase

These offset base plates add stability to edge-routing Subbase Figure 6: Full-size Baseplate

Use the two-level base to quickly and cleanly cut solid banding level with the a plywood face panel.

Figure 7: Trimmer-sized Baseplate

Removing the subbase transforms the jig into an offset base. Apply a little weight on the handled end to keep the router from tipping.

30 woodcraftmagazine.com Aug/Sept 2009 Flush-trimming and edging and you have a comfortable your router (See the sidebar, two-handed edger that’s “Making Jigs to Fit,” below.) I The offset/flush trimming virtually tip proof, even when used phenolic faced plywood to baseplate is another dual- most of the router is hanging make the baseplates that attach purpose jig. With the subbase off the edge of your work. to both router and UHMW for attached, the router works like Unlike some of the other the subbase smaller trim, but a steroid-powered shaver. I use jigs,Figure this one 6 is router specific. wound up sawing up a plastic it for trimming plugs, inlays, We provide rough dimensions cutting board I bought n at the bandings, even solid-wood in , but you’ll need mall to make the subbase for edging. Remove the subbase to adjust the designConvenienc to fit e - PLUSthe BUYING full-sized GUIDE router. Item WOODCRAFT # price Phenolic Faced MultiPly 1. 131171 $48.99 ½ x 24 x 48" UHMW Sheet ½-inch Thick, 2. 124227 $25.99 4 x 48" 3. Double Sided Tape 1" x 36 yards 15D28 $15.99 4. Incra T-Track, 48" 142806 $17.99 5. DeWalt TrackSaw Track Clamps 842588 $49.99 Phenolic Faced MultiPly 6. 131170 $59.99 ¾ x 24 x 48" Fence Adaptor 7. 147788 $4.99 Dust Collection Fitting 8. UHMW Sheet ¼" Thick, 4 x 48" 124226 $17.99 9. Ball Knob 27R17 $2.49 10. Jig Handle 146176 $7.50 Single-Flute for 11. 145634 $11.99 Set the bit a hair above the surface, rout, and #8 Screws then finish up with a or card Above items are available at Woodcraft stores, woodcraft.com or by calling scraper. Remove the subbase for edge work. (800) 225-1153. Prices subject to change without notice.

Making the Jigs to Fit Self-centering bit If all routers were made exactly alike, it would be a cinch to provide patterns and or specific hole locations, but since they aren’t, you’ll need to use a little common sense. To make a custom baseplate for your router, start with the base it came with as your master pattern. Trace its outline and Simple hole-sizing gauge use the shank end of to determine the diameter of the screw holes. (The screw holes should be slightly larger than the screws to allow for a little side-to-side adjustment.) Use a self-centering drill bit to start the holes. Don’t be surprised if the factory-supplied screws are too short for custom bases. A single flute countersink can be used to counterbore a Counterbore deeper hole, but if you overdo it, the screw may pull through your baseplate. To be safe, take the short screw to a hardware store, match the threads, and buy a handful of longer machine screws. Master templates

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