How to Make a Jig for Cutting Dado Joints
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Step 1: Position and Cut the Hardwood
Position the two 20" x 4" x 1" pieces of hardwood so that the base of the router will fit snugly between them. Measure the distance between the outside edges of the two pieces of hardwood.
Step 2: Attach the Boards
Use 1-1/4" drywall screws to attach those two boards perpendicular across either end of the longer two boards (Image 1). Use a framing square to make sure the boards are perfectly perpendicular (Image 2). The four pieces will create a hollow rectangle.
Step 3: Mount the Rectangle, and Cut the Plastic
Mount the rectangle to a worktable with the two shorter strips of wood facing down. Using a table saw, cut the 3/16" thick piece of clear plastic or Plexiglas the width of the router base and the length of the rectangle's inside length. Place the plastic in the center of the rectangle.
Step 4: Scribe a Center Line in the Plastic
With a V-bit in the router, scribe a center line through the length of the plastic. The line will act as a guide. You'll place the work piece underneath the plastic and line up the spot on the work piece to be cut with the center line of the plastic.
Step 5: Clamp the Rectangle, and Make the Cut
Once the work piece is aligned, clamp the right and left sides of the rectangle in place. Remove the plastic. Insert the appropriate bit into the router, and make the cut, using the rectangle as a guide for the router.
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