Jigs

A jig has been defined as custom built tool to hold the work surface or tool.  Generally used for repetitive  work.  I usually work off a solid base where the work surface is clamped to upright posts or blocks.   

Hinge Mortising Jig

The hammer and chisel just was not working to make a mortis for a hinge.  It always looked like I took an axe to it.  TV Home improvement show several commercial hinge mortise jigs and pointed me investigate buying one.  After reviewing my options, I decided the few times I would use the jig did not justify the cost.  The next option was to make my own.

For many years, I have owned a Dremel tool with a router attachment.  The tool seamed perfect for cutting the mortis.  The jig is made using a scrap piece of 2x2 and a couple pieces of thin plywood cut as 90 degree rectangles.  The first piece of plywood was attached to the 2x2 to form a 90 degree angle.  The router attached plus hinge was used as a spacer to place the second piece of plywood and it was clamped to the 2x2.  The 90 degree angle was checked on the second pieces of plywood and it was screwed down.   Additional stop blocks maybe added if you want to exclude cutting an area with router tool.

The board needing the mortis is sandwiched between the jig and a backer board and clamped.  After cutting the mortis the hinge is placed in the mortis and opened to allow marking the position on the jig and the opposite mortis if two need to be cut.  

Siding Jig

I help maintain historic Cordelia Lutheran Church.  It was built in 1883.  Sections of the siding need to be replaced because flickers have pecked holes or wood is rotten due the west exposure.  Matching shiplap siding is not available but the knot-free wood is available.  I explored using a table saws or router bits to make the laps but found a circular saw and this jig produced the best results.  The jigs allows for edge cuts with a circular saw to make the laps.

The base for my siding jig is a 2x6x16 redwood plank that is straight.  I have used it to support my jigs and construction projects for over 30 years.  The uprights are 90 degree blocks of 3/4" particle board with 3/4" plywood strips attached to allow screwing to the base and clamping to the work surface. 

A circular with a saw guide is used to make the cuts.  

Design/Inlay Router Jig

I use a Milescraft Model 1207 Jig to add a design and inlay to wood.  The jig comes with 4 templates, a pencil guide for tracing your own pattern, a universal router base to hold the guide bushings and 2 router bits. 

If you want to use your router to cut a design or add an inlay accent then the Milecraft is the tool to get.  I used it right out of the box to cut my first inlay on a church door.  

Thoughts and Hacks

1. Bushing selection is sometimes difficult.  Cut the inlay first before making the space for it.  

2. Make some working edges out of 1/4" peg board to act as jig clamps to prevent movement and keep router flat.