Jerry, you can use any thickness of wood with the jigs. I suggest that you get a piece of 4" x 4" wood 8" long to use as a push block. Set up your 1/4" jig with a 1/4" bit adjusted 1/4" away from the fence and slightly over 1/4" above the table. Hold the block against the fence and run it completely over the bit. Now mark the top: "1/4" cut with this side up." Change your set up to the 3/8" jig and bit, rotate the block 90°, make the cut all the way through and mark "3/8" cut with this side up." Repeat and mark with the 1/2" jig and bit. Now you have one very stabile push block to use with each of your set ups. You will use this block when the bit height is a hair over the bit diameter. Now let say you want to use the 1/4" jig and bit with wood that is 1/2" thick. Use a different push block for this type of set up because the bit will be a hair over 1/2" high and you want the block to fully support the wood so you do not get any tear out. Think zero clearance. You can use a piece of 2" x 4" for this but I prefer the added control you get with a 4" x 4". Now for something you can not do easily with most other jigs: if you want to cut your box joints on an angle simply cut a push block on that angle and run your wood through with it.
"Living in the D" (this means Detroit!)
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Last edited by Mike; 12-15-2011 at 03:27 PM.