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SCREWS ARE NOT TIGHTENED ON SPACERS
BASEPLATE (9 x 12 - '/* ACRYLIC)
#6 x Rh SCREWS AND WASHERS SECURE EDGE y GUIDE
CENTERLINE SCRIBED ON BOTTOM OF BASEPLATE
As I mentioned, this jig only has a few parts (drawing at right). The main component is the baseplate that's made to accept a palm router (or laminate trimmer).
The Jig Baseplate. After cutting the baseplate to size, I routed the slots for a pair of outside edge guides and a set of spacers. These slots let you reposition the guides and spacers for rout- 3 ing the flutes. I drilled the end holes for the slots first. Then a couple of passes with a Vi"-dia. straight bit finished the slots (Figure 1). \
Now you can use your router's baseplate as a template to mark the mounting V_
hole locations. Then, drill and countersink the holes. A hole saw will create a nice center hole for the bit. After you attach the router, scribe a centerline on the bottom of the baseplate in line with the center of the collet.
Edge Guides and Spacers. The two edge guides and the spacers are all identical except for their width. You can make them from a single piece of extra-wide stock, like you see in Figure 2.
After cutting the blank to length, I routed a roundover on one side of each end. Then I cut a deep dado on the opposite side.
countersunk mounting holes for router
AFTER EACH CUT, A SPACER IS MOVED FOR THE NEXT CUT (SEE INSET PHOTO ON OPPOSITE PAGE)
SPACER WIDTH DETERMINES SPACING BETWEEN CENTER OF FLUTES
f'-WIDE DADO 14" DEEP (SEE FIGURE 2)
EDGE GUIDES ARE LOCKED IN POSITION FOR ALL CUTS
This dado /
allows you /
to slide the spacers past the router bit without having to adjust the depth of the bit.
The last step is to rip the piece to width (Figure 2). The spacers determine the center-to-center
distance between the flutes (detail 'a' above). I've found that %"-wide spacers work well with a %"-dia core box bit. But what's nice is you can make sets of spacers of varying widths, depending on your needs. Finally, you can fasten the edge guides and spacers, as shown above.
drill start and
stop holes before routing slot to establish ends of slot
vv'-dia. straight bit
CUT SLOT IN TWO PASSES
ROUNDOVER5 AND CUT DADO BEFORE RIPPING PIECES > TO WIDTH