Exact Width Dado & router template jig - Router Forums
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post #1 of 17 (permalink) Old 12-11-2016, 10:24 AM Thread Starter
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Default Exact Width Dado & router template jig

A few months ago I made a template jig, following this design.

One issue I had with this design is that my pocket holes didn't exactly line up with my dado so there was a little lip at the end/joint. After building this one I thought it would be a better design to drop the pocket holes, run everything on 90degree corners and put a tenon on the end of each piece that would ride in the t-slot cut for the set bolt.

This weekend I started another project where I need to cut some dados so I started looking at posts and videos for zero clearance dado jig. I've watched this video several times now
and then Ron Paulk has a couple of videos touching on his version of this one. In Marc's video he challenges his viewers to design a version with the knobs on top. This seemed quite simple, just make the rails or tails a bit larger so the knob and router could fit on top.

While pondering this it it occurred to me that perhaps these two designs could be combined into one. So here's what I came up with. Right now my router table is down because I'm in the middle of building a router lift and don't want to wait until that's done before making these shelves. I have some 1/2" baltic birch left from my truck drawer build, so I've designed this out of two layers of 1/2" ply glued together. The sketchup doesn't have the seam in the middle because it was easier to draw as a single 1" heigh block. But imagine this is two pieces of 1/2" with the dados and rabbits cut before glueing it together.

What do you think, will this work?
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post #2 of 17 (permalink) Old 12-11-2016, 10:38 AM
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Interesting idea. Looks a little frail to me though, and maybe a challenge to store. Proof is in the making though. Let us know how it works.
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post #3 of 17 (permalink) Old 12-11-2016, 10:42 AM
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I have a Dado Wiz for this purpose. Attaches to a track. Really like it, but you have to remember to put a slip of paper in to allow space for glue. I have a little gash in mine from learning the lesson to NOT lift the router up while it is still running.

The more I do, the less I accomplish.
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post #4 of 17 (permalink) Old 12-11-2016, 12:48 PM
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Here's mine. Works great.
http://www.routerforums.com/jigs-fix...-dado-jig.html
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post #5 of 17 (permalink) Old 12-11-2016, 12:51 PM Thread Starter
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Quote:
Originally Posted by DesertRatTom View Post
I have a little gash in mine from learning the lesson to NOT lift the router up while it is still running.
I think everyone has to learn that one the hard way. It's funny how often I've forgot that lesson.
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post #6 of 17 (permalink) Old 12-11-2016, 01:00 PM Thread Starter
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The one question I'm pondering is if this will work well enough as the exact width Dado jig or if I'd be better off building both.
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post #7 of 17 (permalink) Old 12-11-2016, 01:12 PM
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Looks good if stiff enough as mentioned Everett but a point to remember is that unless you are using it in some way for lap joints the the amount of adjustment needed will typically only be between 1/4 and 3/4".

Someone I consider a master woodworker once told me that a master woodworker is not someone who never makes mistakes. He is someone who is able to cover them up so that no one can tell.
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post #8 of 17 (permalink) Old 12-11-2016, 01:20 PM
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Here is some more thinking...and action. I built a simple one time use jig for cutting shelf dadoes for kitchen cabinets. Actually, if I need to use it again, all I have to do is remove the screws, adjust the width for the next work piece, and screw the block back in place.

Lots to read on a cold day! :-)
http://www.routerforums.com/jigs-fix...-dado-jig.html

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post #9 of 17 (permalink) Old 12-11-2016, 01:21 PM Thread Starter
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In the picture all four sides are the same length because I just made one side, made it a component and made three copies. In reality I'll make two sides shorter.

For storage one could separate the joints and set the pieces on a shelf in parallel.
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post #10 of 17 (permalink) Old 12-11-2016, 01:58 PM Thread Starter
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Here's another pic with sizes.

There is a 1/2"x3" vertical mating surface and 1/2" horizontal mating surface on the tenon in the tslot. With 1/4-20 bolts holding it tight into the t-slot, I expect it will be quite stable.

Off to the shop, I'll post again when I get it built!
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