Best Ever Woodworking Jigs

124 Pages·2008·33.33 MB·English

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Tablesaw ligs
Thin-StripR ippingJ ig
Feels afers izingt inyp ieces.
Four-SidedT aperingJ ig
Shape table legs fast.
10 Dead-On9 0' CrosscutS led
Squareb oardse asilyo n your tablesaw.
12 Raised-PaneJli g
Createt hree styleso f doors.
16 Corner-RabbetingJ ig
Dress up miteredf rames with face keys.
18 Spline-CuttingJ ig
Givef rame corners a new look.
Router Iigs
20 Two-PartD ado Jig
Rout dadoes for perfect-fittings helves.
22 Multi-HoleD owelingJ ig
Positiond owels for even sPactng.
24 Two Pushsticks
With these projects,i t's all about safety.
26 RouterT rammel
Fora ccuratec ircles,y ou'lln eedt hisj ig,
\.--..-
29 Flush-TrimmingFence
Put a professronaledgoen plywoodp anels
32 MortisingJ ig
Rout dead-on lz"-wide mortises.
33 Keyhole-RoutinJgi g
Hangingp rcturef ramesj ust got easier.
33 Panel-RoutinJgi g
Cut super-simplep anelsf rom MDF.
34 Circle-CuttingT rammel
Thinkb ig, perfectc irclesw ith thisj ig. 35
#
35 Router-TableP ush Pad
Right-angles upportt o mtnimizete arout.
36 Dovetail-KeyJ ig
More Iigs
Cut dovetailk eys with ease.
38 Router-PlaningJ ig
47 BandsawM ulti-Jig
Thiss urfacingji g tames wild grain.
Make your 14" bandsaw do more.
Drill-Press Iigs 51 AlignableB andsawF ence
Uset his.a nd rio cuts will neverw ander.
40 Drill-PressT able 52 Circle-CuttingG uide
Transformy our drillp ress into a shop star. Make perfect disks at your bandsaw.
45 Sanding-DrumD ustC ollector 54 Biscuit-JointeJri g
Removef ined ust at the source. Cut slots in 3/+m" ateriale ffortlesslv.
Best-EverW oodworking Jigs, Homemade Tools,& Shop Organizers 2008
Homemade Tools
57 Hand Plane
This littles haverf its your hand likea glove.
61 HeightG auge
Set the precise saw blade height every time.
62 MarkingG auge
Relyo nt hisc lassitco olf orp rojeclta youts.
64 Dead-BlowM allet Workcenters & Supports
Coax parts togetherw ith this tool.
68 Marking Knife 108 RollingW orkshop Storage
Scribed linesh ave neverl ooked cleaner. Mobilizey our storagea nd organization.
72 SandingB lock 1O9 Tapes-to-goW all-HungD ispensers
Prepp rojectwsi tht hiss hopmadbee auty. Readyt o rollw hen you need them.
74 Centerfinder/Trammel 11O Rock-SolidW orkbench
Simplifyt he layouto f circleso r arcs. Buildt his basic workbench in a weekend.
111 WorkbenchU pgrades
Shop Organizers Sixa dd-onisn creasyeo ubr enchv'se rsatility.
115 Outfeed Table
78 Tool-CabinetS ystem Ina supportinrogl et,h ist ables hines
Find lots of drawers, shelves,a nd dividers,
118 3-in-1W ork Support
79 Mitersaw Work Station Tryt heses afewr aysto machinleo ngs tock.
Expandy our tool's horizons.
124 Right-AngleS upport
80 Sheet-GoodsR ack Clampinsgq uareesn surgeO og lue-ups.
Buildh orizontasl toragef or bulky plywood.
126 Portable FinishingC enter
81 Wall Gabinet Useth isp lastitce ntf ord ust-frefien ishing.
Tidyu py ours hopw itht hiss olution.
128 Portable Workstation Upgrades
82 Drill/DriverO rganizer Expancdl ampinwgo rkstatiotnhse e asyw ay.
Multitieredb ox bdngs order to your bits.
85 Storage Tray
Tuckto olsb eneatyho uwr all-huncga binets.
88 ClamshellC abinetD oors
Doublyeo urs pacefo rt oolsa ndh ardware.
89 Quick Clamp Rack
Corraylo urc lampast t hiss tation.
92 Lumber Storage
Organizyeo uwr oodfo rg ood.
96 Lathe-StandRetrofit
Creatset oragbee neatyho urla the.
98 Utility Cabinet System
Whipy ourg aragoer s hopin tos hape.
1O7 RevolvingS torage
Lazy-Susapnla tformex pandsst orage.
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Editor-in-ChBieILf LK RIER
ManaginEgd itorM ARLEKNE MMET
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Gift PerfectWine Box KeepsakeB ox Contributilnllgu stratorTsI MC AHILLL,0 RNAJ0 HNSON,
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Downloaadn y0 ft hesew oodworkinpgla nsfo rt hep ricesli stedo, r In Memoriam- E.TM. eredithlll (1933-2003)
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Best-EverW oodworking Jigs, Homemade Tools,& Shop Organizers
sk seasonedw oodworkersa bout For example,a ftery ou take an eveningo r maple. If you pref-er,y ou can substitute
the benefitso f stocking a shop two to build the sledo n page1 0,w e predict medium-densityf iberboard (MDF) for
with a variety of hardworking that you'll constantlyu se the crosscuts led plywood and anotherd enseh ardwoodf or
jigs. They'll likely tell you that for repetitivec uts.T hef our-sidedta peringji g maple.S eeS ources on pctgeI I for help
somej igs get useda gain and again, while ands pline-cuttinjgig providey ou with more in buyingt he inexpensivhea rdwareit ems
others gather dust. We guarantee that specializetde chniques. you'll needf or thej igs in this chapter.
these six jigs will be worth your invest- We constructemd osto f theses hoph elp- Seep age 6l for a simple height gauge
ment in time and materials. ers from Baltic birch plywood and hard that complementtsh eset ablesawji gs.
'fitirt*S
;riti
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t*ruyp d*r*:es,
onretinresy ou need to rip several each cut. bLrtt hat's tecliousa ncl itraccu- Cut two pieces of rnaple to size fbr
thin strips of wood to eclr-rathl ick- rate.T his thin-strip rippin-t. ji-lc loest he the nriter-slot- guideb ar (acliustth e di-
ness to serve as ed-uin-uv. eneer. job saf-elya. ccurately.a nclc luickly. rlensionss hclwni f necessaryt o fit your
or benclings tock.S licine off thin Ref'ert o Sources or.l/ )rr,ga1 1 lbr harcl- tablesaw'ss lots)a nd the sliclin-bs ar.C ctt-
stock on the f'ences ide of the blacle.I 'urw- ware firr this prolect. ter tl'rem iter-skrt- uuicleb ar in the bottont
ever. could prove Lrnsal'eT.h at's becartse clado.a nd gh-reit in place.D rill a pair of
it beconres awkwarcl to use your blacle F:!r':s9kl.a. xsE9d* ts$* rs* /r," holesi n tl'res liclin-gb ar. where shown.
guarci and pr-rshstickw hen yoll cLltc lose CLrt a piece of 7i" plywoocl to the scrollsawt he nraterialb etweent hetl. attcl
to the I'ence.T lie solLrtion:R un the wicle clinrensionss hown tirl the base on sn.roothth e insicleo f the slot with a file.
portion ol- yoLrr workpiece between the yrgc 7. Cut a clitcloo n the bottclrn sicleo f Set the jig in yor.rr tablesit\/ 's lel.t
f'encea rrclb lacle.c Lrttin_tsl' res trips on thc the base lbr the guicleb ar. where sl.town. niiter--eau-{sel ot. Placet he sliclingb ar
sicleo l'the blade oppositet he f'ence.Y oLr Now. cut the y'+"c lacloo n the top side ol' in tl-rec ladow ith its lelt enclf h"rshw ith the
coulcla cconiplisht his by nreasurin-fuo r' the basel ur the slidine bar. base.S lide the ji-s tbrward. and mark the
tr
To make a cursor, scribe a line across Sizey our thin-stripr ippingj ig to suit your Removet he jig beforem akingt he cut so
the acrylici ndicatorw ith a sharpk nife tablesaw,s o that a 1" screwi n the guide the workpieced oesn't bind betweent he
and a square.C olort he scribedl inew ith bar can contactt he blade.l nstalla zero- rip fence and the screw head.R eplacet he
a permanentm arker.W ipe off the excess clearancet hroat platet o preventt he jig in the slot without makinga ny adjust-
ink with a cloth,l eavinga fine line. sawn strip from fallingi nto the saw. ments to set up the next cut.
h Best-EverW oodworkingJ igs, HomemadeT ools,& Shop Organizers 2008
Four-armk nob with t/+"i nsert
I
EXPLODEDV IEW -J /
G./ #8 x 1" brassF .H.
--
w
r
i .'- t/q"l lal washer 5/0" slot
@r
--1--.
#8 x3/q"F .H. wood screw\
.!
Yses"h anhko te,
I
lNDrcAroR Z t ii .'"o'o!l"r:tottn
2'-^fi1
SLIDINGB AR
Cursorl ine s/+" dado
1t/sz"d eap
t/+x 11/zx 2" clear acrylic 1tl2"s ectiono f steel rule
1/zx 3/q x 9"
/+" hole,c ountersunk I
on bottoms ide i
'/2
MITER-SLOTG UIDEB AR
t/+-2x0 11/z'F.H.machinscer ew- -------€
point wherea left-leanings awbladet ooth an inexpensives teelr ule, align its left end Position your workpiece againstt he rip
- touchest he bar. Make a secondm ark t/2" with the mark, and attachi t with epoxy. fence,a nd move the fencet o bring the left
closer to the base.R emovet he bar, and JCut a piece of t/q" acrylic to the edge of the workpiecea gainstt he screw
crosscuti t at the secondm ark. f dimensions shown for the indicaror. head, as shown in Photo B. Lock the
',rl Drill a 7/e+"p ilot hole in the slid- Drill and countersink the two mount- fence,s et the jig out of the way, and you're
tfing
bar, centeredo n the end you just ing holes, and scribe and mark a cur- readyt o cut a strip, as showni n Photo G.
cut. Drive a brass screw halfway into sor line. as shown in Photo A. Attach After completingt he cut, clean up the
the wood. (We used brass to avoid any the indicatort o the base,a nd add the knob. workpieceo n the jointer. Replacet he jig
chance of damaging a tablesawb lade.) in the slot. Then unlock the rip fence,
You'll turn this screw in or out to fine- Now, cut some strips move it to bring the jointed edgea gainst
tune your jig's basic "zero" setting,o r to To cut a thin strip with the jig, place its the screwh ead,l ock the rip fence,r emove
adjusti t for a bladeo f different thickness guide bar in the left-handm iter gauges lot the jig, and saw anothers trip. Repeatt he
or with a different tooth set. on your tablesawL. oosent he knob, set the processa s many times as necessaryt o
fiFrom the bottom sideo f the assembly, cursor to zero (the bottom end of the rule), producea ll of the stripst hat you needf or
Udrill andc ountersinka Vq"h olethrough and retightent he knob. Slide the jig so that your project.. F
the miter-slotg uide bar and basef or the the brasss crewh eadi s besidet he sawb lade.
machines crewt hatholdst heplastick nob. Turn the screwi n or out with a screwdriver Writtenb y Jim Pollock with Jeff Mertz
and Kevin Boyle
Sanda ll of the wood partst o 180g rit, and until the head lightly contactsa leftlean- lllustrationsR: oxanne LeMoine; Lorna Johnson
apply three coatso f clear finish. ing tooth. Pull the jig toward you, loosen
ftMake a mark 1" from the left end of the knob, sett he cursorf or the desireds trip
uthe sliding bar. Cut the first lr/2"f rom thickness,a nd retightent he knob.
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Four-$ided
TaperinJgig
Here'sa slick way to taper
four sideso f a tablel eg-all
with one simplej ig.
ou can tapero ne sideo f a tablel eg the groove,w ith eachh ole centeredi n the bottom edgeo f the blank. Next, drrll a Vq"
without much head-scratching, groovea ndV z"fr om thee nd.C ut a 3" piece hole centeredi n the groove2 Vz"f tom the
but taperinga ll four sidese qually from each end to make two hold-down rabbetede nd. Glue in the 3t/2"g urdeb ar
presentsm oreo f a challengeW. ith bases.N ext, glue one guide bar piecei n piece, making it flush with the rabbeted
thisj ig, howevery, ouc anc uta ll fourt apers the grooveo n eachh old-downb ase.A fter end. After the glue dries, drill a t/q"h ole
withoutc hangingy our setup.Y ou simply the glued ries,d rill a t/q"h olethroughe ach through the blank, using the previously
rotatey our workpieceb etweenc uts. assembly,u sing the previously drilled drilled hole as a guide.T rim the blank to
Locatet heh old-downsto suitt hel ength holesa s guides. 3/i' rn length.S anda ndf inish the assembly.
of your workpiece.( The pivot block can ;fi Cut a maple blank to t/qx2xl2" to fiAssemble the hold-downsa s shown.
afmake
sit at eithere ndo f thej ig.) If your tablesaw the pivot block.( We beginw ith t#For the pivot block, file or grind one
hasa 10"b lade,y oucanhandleworkpieces an oversizedp iecet o assures afetyd uring edge of the washer flat, as shown on
up to 2" thick. the cuttingp rocess.C) ut a rabbeto n one Drawing 1a, and then assembleth e nut,
Refert o Sources on page I I for hard- end of the blank, where showno n Draw- screw,a nd washera s shown. Adjustable
waref or this project. ing la. Now, drill two holest o form the up or down in the slot, this screw serves
ends of the adjustments lot, remove the as an indexingp in. Onces etf or a partic-
Buildt he jig materialb etweent he holesw ith a coping ular workpiece, it guaranteest hat every
@ For the base.c ut a piece of zA" ply- saw or scrollsaw,a nd clean up the slot cut in the sequenceis an equal distance
& wood to the size showno n Drawing with a file. Cut aVq"s roovec enteredo n the from the centero f the workpiece.
1, then cut a pieceo f t/q"h ardboardt o the
samed imensions.
ffiCut s/s"d adoes3 Ao"d eepi n one face
&of the plywood, whered imensioned.
Glue the hardboard to the dadoed face
with yellow glue. Now, clamp the as-
sembly between two scrapso f plywood
to ensure even pressure.A fter the glue
dries,r emovet he clamps,s et your dado
blade for a t/+"-widec ut, put an auxiliary
fenceo n your miter gauge,a nd cut a slot
throught he hardboardc, enteredo vere ach
plywood dado,a s showni n Photo A.
a piece of maple to r/qx3/8x12",
ffiCut
ffi1fen cut two 3" pieces and one 3t/2"
piecef rom this blank for the guide bars.
For the hold-downb ases,c ut a piece of
7+"p lywoodt o lv2xl2". Cut a t/q"g roove After cutting dadoes in the plywood base, Diagonal lines on the end of the workpiece
glue the hardboard to the dadoed face. locate the hole that fits onto the indexing
down the center of one face of this ply-
Mount the two outside blades of a dado pin. Drawt he cutline for the final shape,
wood,w hered imensionedo n thed rawing. set in your tablesaw,a nd cut slots through and extend the lines to the edges to help
Drill two /+" holesn earo ppositee ndso f the hardboard centered over each dado. you position the workpieceo n the jig.
8 Best-Ever Woodworking Jigs, Homemade Tools, & Shop Organizers 2008
IexeloDED vtEW
Four-armk nob
Plastick nob wilh th" inseft
@''-'" flal washer
H'LDDo wL/.-' t/+"
tr;,lrilL.
",,
17/zz ' 4J-*/
s/qx1|/zx '3" plywood
)>-@
343/s'
tZ" slots
1/q"d eep,
centeredo ver
Te"d adoes
1/+x 3" panhead
machine screw
l/qx 12 x 36" hardboard
7e"d adoes
s/o"d eep BASE 3/+x 12 x 36" plywood
3411/ta"
lE PtvorB LocK
Tap into tapering
31/2"
To taper a leg, cut your workpiecet o its Thisj ig alsos ervesa notherp urposea, s " rabbets /ro"d eep
finishedl ength,t hen rip it to the square showni n Photo D. When you needt o cut a
dimensionst hat you want for the unta- singlet aper,m ark its start and stopp oints
pereds ectiona t the uppere nd.D raw a line on the end and edge of your workpiece.
on all four facest o mark wheret he taper Remove the indexing pin from the end
will begin. Drill a t/q"c enteringh ole 3/s" block, andn estt he endo f the workpiecei n
deepa t the centero fthe bottom end, and the notch.A lign the marksw ith the edge 3/1"
add cut lines to show the final dimen- of thej ig, andc lamp.P lacey ourhold-downs
sionso f that end, as showni n Photo B. againstt he workpiece.T ighten the pivot e/szs" lot
Draw cut lines on the face connecting block in place,a nd make the cut. i
the leg-bottom marks with the taper- ' t/+"w asher,
th" gloove filedt o allow
start marks. This helps you visualize the i 3/a x 31/2" 3/6" deep, nut to engage
final shapea, nds ervesa sa safetyr eminder IDEB AR centered the rabbet
as you pusht hej ig acrosst he saw.
Mount the leg-centeringh ole on the
indexingp in. Slide the pivot block until
the plannedo utsidef ace of the leg aligns
with the edgeo f the jig. Thrn the knob to
lock the pivot block in place. Now, near
the upper end of the leg, align the taper-
startc utline with the edgeo f thej ig. Slide
the hold-downb locks againstt he leg, and
tightent he nylon nut on eacho net o sett he
block's position.T ighten the top knob on
eachh old-downt o clampt he leg in place.
Raise the saw blade t/q"a bovet he leg.
Butt the jig to the fence,m ove the fence
until the saw blade just clears the left
side of the jig, and then make the cut, as
shown in Photo C. To make each of the
three remaining cuts, loosen the hold-
down knobs, rotate the leg one-quarter Hold the taper jig tightly againstt he The width and adjustability of the taper
tablesaw rip fence as you cut. Before jig allow you to handle a wide range of
turn clockwise( asv iewedf rom the pivot- starting each pass, make certain that angle cuts. Here,w ith the jig flipped end-
ing end),r eclamp,a nd cut. your left hand is well away from the line. for-end,w e're shaping a simple leg.
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"f
g0o
Dead-0n
CrosscSulte d
Wheny ou build this sled,Y our
accuracya nd efficiencya t the
tablesaww ill soar.
ieliable tablesaw miter gauge After the glue dries, cut a Vq"g roovec en- fence is parallel to the miter gauge slot
t
handles a lot of crosscutting teredo n the s/s"g roove.T hen, cut a rabbet before proceeding.)A pply double-faced
tl
but not all. It rides in just along the front of the bottom edgea nd a tape to the top of eachg uide bar, and at-
afl tutkrso,n. e slot, and suPPortst he work- t/2"g roovec entereda longt he top edge. tach the barst o the platform, as showni n
pieceo n just one sideo f the blade,a llow- flFrom 3/+"m aple, cut the blade guard Photos A and B. Removet he assemblY
ing for slop. This problem disappears, Usides and end.G lue and screwt he end from the saw,a nd permanentlya ttacht he
however,w ith an accuratec rosscuts led. to the sides.N ow, screwt he blade guard bars with screws.
Our designi s both inexpensivea nd sim- to the fence,w heres howno n Drawing 1. JCut a piece for the stopblock,a nd cut
ple to build. Plus, it includes reliable, f, Cut the front rail from:/+" maple.U se f a dado in the back, where shown.C ut
adjustables topsf or repeatablec uts.F rom rfa jigsaw to cut a notch, where shown, a guide bar, and glue it into the dado.
the momenty ou put this jig to usea t your for the blade to passt hrough. Attach the Drill a shankh ole through the block and
tablesaw, you'll discover that making front rail and the fence to the platform bar, wheres hown.N ow, cut a pieceo f Vq"
right-anglec uts is easiera nd safer. with screws. acrylic plastict o sizef or the stopblocki n-
sand, and finish two toP blade dicator.S eeD rawing 1b. Drill, saw,a nd
frCut,
Build a real workhorse tfguard supports.U sing a fine-toothed file smootht he slot, where shown.M ake
rf Selecta flat pieceo f 3/qp" lywood, and tablesawb lade, cut a piece of Vq"c lear a cursorl ine, as showni n Photo A.
I cut the platform to the dimensions acrylic to size for the blade guard cover. QRemove the top bladeg uard, sandt he
showno n Drawing 1. Attach the cover to the supportsa nd the l0iig, and apply three coats of finish.
f)Cut two 72x3x30"m aplep iecesf orthe front rail. Reattachth eb ladeg uard,a ssemblea ndi n-
&fence, and cut a s/a"g roove% e" deep ftFrom 3/q"m aple stock, cut two strips stall the stopblock,p lacet he crosscuts led
in the face of one piece, where shown [Jto servea s miter-slotg uide bars.S et on your tablesaw,a nd make a cut from
on Drawing 1a. Glue the two blanks your tablesawr ip fence 8%" to the right the front edge through the fence. Use a
together,k eepingt he edgesf lush and the of the blade, and lower the blade below rule to sett he stopblock4 " from the kerf.
groove on the interior of the lamination. the table'ss urface.( Note:M ake surey our Mark the centero f the stopb lock on its top
Two pennies shim the miter-slot guide Keepingt he rightend of the platform against Hold the workpiecef irmly againstt he
bars slightly above the tablesaw surface. the rip fence, set the sled assembly on fence as you make a cut. Keep your hands
Place a couple of these stacks in each the guides. Press down firmly to stick the outside the blade guard, and don't cut
miter-gauges lot, and set the bars on top. bars to the platform. through its end.
10 Best-Ever Woodworking Jigs, Homemade Tools, & Shop Organizers 2008