Synopsis: Get protected, clear cuts in your router desk with this shopmade auxiliary fence with detachable spacers. The spacer system means that you can set the space between fence and bit simply as soon as, whilst you make a collection of incremental passes with the router, eradicating spacers one after the other till you’ve reached your remaining dimension.
From joinery to shaping, I take advantage of my router desk a bunch. I’ve come to count on rather a lot from it, however I’ve additionally discovered the way to work effectively inside its limitations. For instance, eradicating loads of materials in a single cross with a router is a nasty concept. Not solely is it unsafe, however it could actually additionally injury your router, bits, and workpiece. To keep away from these heavy cuts, it’s typical to maintain adjusting the fence away from the bit between passes. This typically means making small and deliberate modifications slowly to be sure you don’t blow previous your required dimension. Plus, for those who’re measuring every time you progress the fence, the routine can disrupt your workflow much more.
That is the place an auxiliary fence with spacers is useful, permitting you to measure the space between the fence and your bit simply as soon as. After that, all you should do is take away a spacer between passes. The setup additionally ensures protected, clear cuts. Because of this, this jig, which is a breeze to make, will save loads of time. It will possibly additionally assist in a pinch when you should make a rabbet, groove, or dado larger than your accessible bits.
A breeze to construct
The jig contains just a few easy components. First, there’s the auxiliary fence. That is what the inventory rides towards, so I make it from melamine. Second are the spacers. You don’t need these thicker than half the diameter of the bit’s shank. I usually use 1⁄2-in.-shank bits, so 1⁄4-in.-thick MDF works nice. Having some 1⁄8-in. spacers is sweet for smaller bits, in addition to for general versatility. I additionally wish to resaw extra-thin spacers, about 1⁄32 in. thick or so, for once I need to use lighter cuts for a superior end.
Lastly, there are the T-bolts and knobs, which safe the auxiliary fence and spacers to the primary fence. These must be lengthy sufficient to increase via each fences and the spacers whereas nonetheless having sufficient size left over for the knobs to have interaction the threads.
The auxiliary fence and spacers must be constructed to suit your specific router desk. When sizing the auxiliary fence, merely rip the melamine to the peak of your important fence. The size of the auxiliary fence entails slightly extra thought. I mount it (and the spacers) utilizing solely two T-bolts, one on both facet of the cutter, and I don’t need it so lengthy that it’ll bow if it isn’t supported by extra bolts. So, to determinethe size, I open the primary fence all of the. manner and line up the melamine in order that it extends previous the bolts by about 31⁄2 in. on both facet. Then I lower it to that size.
Rip the spacers to the identical width because the auxiliary fence, however crosscut them barely longer. This can make them simpler to put in and take away whenever you use the jig.
Subsequent, find the holes for the T-bolts. Measure the center-to-center dimension between the 2 bolts on the primary fence and switch that to the auxiliary fence and the spacers. Because the spacers are longer than the auxiliary fence, mark your items primarily based on a centerline. For instance, if the bolts are 10 in. aside center-to-center, make your marks 5 in. on both facet of the centerline. Additionally use the primary fence to find out the peak of those holes on the auxiliary fence. The T-bolts’ heads should be recessed within the auxiliary fence in order that they don’t intrude with feeding the inventory. So, earlier than I drill for the T-bolts, I plunge-cut quick, shallow grooves on the router desk to suit the heads. After that, drill through-holes for the bolts.
You may take just a few steps to make the spacers straightforward so as to add to and take away from the auxiliary fence. First, drill the bolt gap about 1⁄2 in. decrease, which is able to go away a slight hole beneath the spacers once they’re put in. This hole will make them simpler to carry up and take away. Second, for a little bit of wiggle room, the spacers’ gap must be bigger than the diameter of the T-bolt. After drilling these holes, take away the waste beneath them on the bandsaw, making a slot that can slide over the T-bolts.
Now that the auxiliary fence and spacers may be connected, you should make room for the router bit. You’ll most definitely be utilizing this jig with giant router bits, so use your greatest ones to put out this opening within the auxiliary fence and spacers. To simply lower out the opening, drill out the corners on the drill press, then filter out the waste on the bandsaw.
As a final step, I put a really slight roundover on the opening’s outfeed facet to forestall workpieces from getting caught on it.
From Fantastic Woodworking #291
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