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Web Extra: Building a Jig

From "Freeform Furniture"
episode DFFF-207

Host Amy Devers demonstrates how to build a table-saw jig for your woodworking projects. And she makes a dipping container.

Amy builds a jig.

Building a Jig

A table saw tenon jig is easy to build and easy to use on any saw with a plain, unencumbered rip fence. The jig is designed to ride along the fence, offering sliding movement accurately parallel to blade as well as easy positioning for cutting centered or offset tenons, lap joints and bridle joints.

The first thing to do when making your own tenoning jig is to get all your tools together. You will need a table saw, tape measure or steel ruler, drill with bits, clamps, precut tenon, dust mask, and goggles for safety.
After you have your materials together, you need to set up the saw. The accuracy of the jig will be determined by the saws setup as well as the fit of the tenon. For the saw's set up, you will first set the blade height equal to the length of your tenon. Then, center the tenon's cheek against the right side of the blade and make sure the fence is against the right side of the tenon stock. Make sure the fence is locked and set the miter gauge to 0.
Once the saw and tenon have been set up, it's time to cut. Use a pre-arranged cut list to determine which cuts to make and to ensure accuracy. Glue then clamp both the horizontal and vertical rail pieces together, then make sure that each laminated face on each rail is flat. Stand the miter gauge extension on its edge and scoot one edge against the fence, then make sure the face is touching the back side of the extension by moving the miter gauge forward. Now you can drive a screw through the slots in the miter gauge into the extension.
Take your tenon and stand it on one end and move a laminated face of the vertical rail up to the face of the tenon stock. Drill screws into the back of the extension of the vertical rail then on the right side of the vertical rail, then clamp down your tenon. A handle mounted on the bridge makes the jig easy to handle. Now your jig is complete.

Amy puts together a dipping container.

Dipping Container

First, mix a ratio of 10 percent thinner in the can with the plastic compound. The thinner is included with the plastic dip and its solvents form a vehicle for the plastic to dry to it. The thinner will evaporate after the plastic dip dries.
Then pour the mixture through a paper funnel and into a custom-made melamine box. Melamine is a type of laminate with a thin, plastic coating on the substrate. Those plastic resins create a non-stick surface. This surface makes it perfect for plastic dipping because it won’t dry up inside the box.

RESOURCES :

Festool
Website: www.festoolusa.com

Stanley Tools Product Group
Website: www.stanleytools.com

Lie-Nielsen Toolworks, Inc.
Website: www.lie-nielsen.com

Power Tools
Porter Cable Power Tools
Website: www.deltaportercable.com

Gladiator GarageWorks
Website: gladiatorgarageworks.com

Hand Tools
Garrett Wade Co., Inc.
Website: www.garrettwade.com

The Peck Tool Company
Website: www.pecktool.com

Biesemeyer
Website: www.biesemeyer.com

Saw Blades
Forrest Manufacturing Company
Website: www.vacupress.com

Jogensen Adjustable Clamp Company
Website: www.adjustableclamp.com

Adhesives, Abrasives and Safety Equipment
The 3M Company
Website: www.3m.com