Incra Jig Process Imporovement - Router Forums
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post #1 of 22 (permalink) Old 07-10-2009, 10:23 AM Thread Starter
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Default Incra Jig Process Imporovement








Had trouble with getting the Incra Ultra to cut joints the way I wanted consistantly. Loose joints drive me crazy! Anyway I set to tighten things up with a process approach towards improvement. My system now cuts flawless 1/2 blind and full dovetails about every time now. I'm now looking forward to progressing some of the more advanced joinery thats possible with the Incra system.

Of particular note: replaced the slightly chewed up runners on the base of the Horizontal fixture with custom made plywood/polyethylene replacements. Extended them another 2" out the back from the originals for added support. The polyetylene was cut from a large cutting board purchased from sams club. That stuff even joints nice! The fixture slides much better now.

Here are the steps I took to get it RIGHT!
INCRA JIG Improvements for cutting Dovetails:

DONE - Tighten all Screws on Fence and jig

DONE - Verify Incra Jig Fence is 90 to router table top - shim if needed

DONE - Remove jig from table and blow out dust - blow out and brush incra jig teeth

DONE - Adjust router Table plate to be level with router tabletop height

DONE - Verify Router Base Plate is tightly secured to router table plate

DONE - Measure dovetail router bits with calipers to ensure correct sizing
Mark with Sharpie the size and bit type on bit shaft.

DONE - Clean dovetails bits of pitch and touch up with diamond stone.

Make dovetail rabbeting standup push jig.

DONE - Make new Horizontal jig jig runners from UHMW or Polyethylene Cutting Board.
DONE - Make spares runner part for future use (both 5" and 7")

Add Aluminum or Wood Cross Member to runner extensions.

Add Lead Weight to top of base of Horizontal Fixture.
Add a good handle to Horizontal fixture to push with.

Install UHMW on inside of horizontal fixture Al slide.

Install MDF backer board on Horiz. fixture?

DONE - Test locking the router height. Note: not needed

FUTURE - Install in the table dust collection?
FUTURE - Install a tabletop dust collection catch.

Let me know if any of this is of help.

TJ
Life is too short...this is not a rehearsal.
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post #2 of 22 (permalink) Old 07-10-2009, 10:41 AM
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Thanks for sharing

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post #3 of 22 (permalink) Old 07-10-2009, 12:34 PM
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Nice job on the post TJ. A lot of helpful information provided. I am bookmarking this thread for future use.

Thanks!
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post #4 of 22 (permalink) Old 07-10-2009, 12:59 PM
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Some positive points for improvement there. I have long slippy plastic rails and am making a handle for the RAJ. I support the material with small sacrificial strips. And have precise bits.Carry on.
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post #5 of 22 (permalink) Old 07-14-2009, 09:29 AM Thread Starter
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Mike;
I just addeed a handle and a cross plate for the extended base runners. It feels like it adds control to the cuts by permitting more downward and right pressure to keep base of fixture on the fence. It also adds degree of safety as I use one hand to hold the stock to the top of the fixture to minimize any vibration, and the other hand to push the stock through the bit with the handle. This ensures to a degree that both hands are out of the path of the bit as it moves through the work.
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post #6 of 22 (permalink) Old 07-14-2009, 01:36 PM
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Thats a very nice idea there with the handle!!
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post #7 of 22 (permalink) Old 07-14-2009, 03:59 PM
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My handle is styled on a wood bodied plane handle, and held on with KD dowel fittings. Will post photo when polished and assembled. I need a metalwork lathe to turn down the dowels a bit.
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post #8 of 22 (permalink) Old 07-16-2009, 11:40 AM
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Handle polished, waxed and installed.
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post #9 of 22 (permalink) Old 07-17-2009, 01:54 PM Thread Starter
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Quote:
Originally Posted by Mike Wingate View Post
Handle polished, waxed and installed.
Mike thats a nice handle! It looks to be very effective. The skill of some of you never fails to amaze me.

The handle I installed is set back to permit full clamping along the back of the horizontal fixture with a wood parallel clamps (or whatever they are called). Its funny...my handle reminds of a boat oar handle or something I've seen on sailing ships while yours looks very professional!
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post #10 of 22 (permalink) Old 07-17-2009, 03:59 PM
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Thanks, but it is just a copy of one I did for a fingerjoint jig, with replacable sacrificial, dovetailed inserts. (never used now I have the Incra) copied from an old wooden handsaw I had at school(gone and replaced with plastic rubbish). Nothing is original, just changed a bit. My next project is to make some featherboards using polypropylene cutting board material on the laser cutter (arriving at school on tuesday). Cheaper than buying sheet material. Well done with your jig. Similar but with our "own" style. I saw yours on the Australian wood forum.
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