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Jigs and Fixtures for the Table Router and Plunge Router From "Wood Works" episode WWK-613

In Wood Works episode 408, specialized jig was used to create the intricate finger joints for these magazine boxes at the router table.

In this special episode of DIY Wood Works, host David Marks discusses and demonstrates the uses of jigs and fixtures in woodworking. In this segment, he demonstrates the use of some jigs for the table router. He also creates a specially made jig that can serve as an inexpensive alternative to the multi-router.

Note: The online summary of this special Wood Works episode on Jigs and Fixtures contains a number of references to past episodes of the program. You may click on the boldfaced episode numbers in order to link to the online summaries of those particular shows.

Some of the tools and jigs featured in this episode:

Trammel-arm jig
Miter jig
Miter gauge
Tenoning jig
Tapering jig
Table-saw cradle jig
Dovetail jig
Mortising jig
Dado jig
Drill-press jig
Table saw
Table router
Plunge router
Band saw
Drill press
Clamps
Safety glasses and ear protection

Safety Alert: Always wear safety goggles or safety glasses, and follow proper safety precautions, when working with wood, power-tools, saws, drills, routers, etc.

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Figure A

Router Jigs and Fixtures

• For this segment, David begins by moving the ripping fence to the table-router side of his combination table-saw/table-router. He specially designed this dual-purpose table (figure A) to take advantage of the extra flat surface and the common fence when working with bigger pieces.

• The movable fixture used as the ripping fence on the table saw can also be used as the primary fence on the table router. It guides the stock to the blade in a safe manner, and has a lot of versatility. It is this fence that enables the accurate cutting of through-dados and through-rabbets. And with stop-blocks clamped to the fence, stop rabbets can easily be cut as well.
  

• Another useful jig David custom-made for the router table is the one used to make finger-joints (figure B).

• This jig has an indexing pin that positions the stock to make perfectly spaced fingers for the joints (figure C).

• It was this jig that was used to cut the finger joinery for the wooden magazine-boxes made in Wood Works episode 408.

  Figure B

  Figure C

  
  

  
  

• The real versatility of the plunge router is a function of the various accessories that are available for it. They enable the woodworker to perform cutting, shaping and smoothing tasks quickly and accurately. For example, a trammel-arm jig is ideal for cutting perfect circles at the router table.

• Also known as a circle-cutting jig, the trammel arm is made by attaching a straight piece of plywood to the center -- or pivot-point-- of the stock (figure D), while the router is attached to the end of the board at the desired radius.

• With the bit plunged into the stock, the trammel-arm pivots off the center to make a perfect circle (figure E).

  Figure D

  Figure E

  
  

  
  

• Another jig that's been used in previous episodes is a guide called router rails. These can be used to level the end-grain of several large boards. The rails we used are flat, cold-rolled steel (figure F).

• The extended fence of the router straddles the rails (figure G) and routs the surface flat with a steady back-and-forth motion.

• This technique was essential in leveling two base sections of the coopered hall-table in.
  Wood Works episode 509

  Figure F

  Figure G

  
  

  This mortising jig can be used to achieve the same basic results as a the multi-router.

  
  

Typically, David uses the multi-router for batch-cutting mortises. This is the ideal tool for the repetitive task of making multiple mortises, but it is highly specialized and expensive. There is an alternative for those who don't have access to a multi-router. It's a jig that, like the multi-router, helps the woodworker maintain accuracy and repeatability in cutting mortises.

Here's how the jig works:

• With the stock clamped in the vise of the workbench, align the center-line of the jig with the layout marks on the stock (figure H) and clamp the jig in place. You may need to add wood spacers to get the jig in precise alignment.

• Lock the adjustable stops for the correct length of the mortise, then rout between the stops to cut the mortise (figure I).

  Figure H

  Figure I

  
  

• One 16" x 9" piece (for the bed);
  
• Two 9" x 4-1/2" (for the adjustable stops).
  

• Lay out the wide opening on the bed and smaller mortises on the adjustable stops. Cut out those openings, along with some pilot holes and slots in the shims as shown (figure K).

  Figure J

  Figure K

  
  

• Attach the 2x4 spacing block, and slide in some of the spacers.

• Turn the assembly over and attach each of the adjustable stops using a screw, washer and wing-nut. The assembly is now ready to use.

• Always use a guide bushing on the base of the router. The bushing should be slightly less wide than the width of the opening (figure L). This will ensure a straight, consistent cut while allowing the bit to clean up the walls of the mortise.

• The slotted shims allow you to customize the cut for a variety of different-sized materials. Simply add the proper amount of shim (figure M) to move the cut in the proper direction. This feature makes the jig more versatile.

  Figure L

  Figure M

  
  

A variation of the mortising jig is one that is used to rout dados (figure N).

• To make this jig, use five pieces of 3/4" plywood: Two side pieces each cut 28" long, and two cross pieces each cut 20" long (figure O). Also cut a third cross piece 20" long. The extra is a sacrificial piece -- an indicator -- that will be changed out with each different-sized bit.

• Assemble the plywood pieces into a rectangle using counter-sunk screws.

• Cut an alignment piece in the sacrificial cross-piece with the bit that you'll be using to cut the dados.

  Figure N

  Figure O

  
  

• Install a 1/4" base-plate, cut to fit inside the jig, on the router (figure P).

• Make a dado cut in the sacrificial piece (figure Q) to confirm your line. You can change this piece as you cut a new dado, and use it for different projects. The router should slide within the track to cut a perfect dado every time.

  Figure P

  Figure Q

  
  

  A bed-extender fixture was used to create the base pieces for this coopered hall-table at the band saw. Steel router-rails were then used to enable the tops of the base-pieces to be leveled using a hand-held router.

RESOURCES :

Woodworking Techniques: Best Methods for Building Furniture from Fine Woodworking
Author: Editors of Fine Woodworking magazine
Publisher: Taunton Press
ISBN: 1561583456

David Marks Website
David Marks, DIY's Wood Works host, is a master woodworker. For more information on cut sizes and project details, please contact him via his Website at www.djmarks.com

Woodworker's Guide to Wood: Softwoods, Hardwoods, Plywoods, Composite, Veneers
Model: 080836878
Author: Rick Peters
(2000)
Sterling Publishing Co. Inc.
Website: www.sterlingpub.com

Fine Woodworking
A magazine devoted to high-quality craftsmanship in woodworking.
The Taunton Press Inc.
Website: www.taunton.com