Friday, February 20, 2015

Spline jig with an adjustment stop



                                        This is an easy to make jig and gives me really  accurate
                                         and interesting  cuts. I do have a couple other  sleds but
                                        none like this. Here is a step by step on how I made it.                                              

                                Here is my Spline cutting jig I designed in July 2014. It was made
                                very simply by using a piece of 2x4, piece of plywood and a runner. 
                                The stop block I made slid along the top and was clamped into 
                                position. This is worked very nice but I thought I would like to
                                make an adjustable stop block and upgrade this jig.

                                       I will start by making a rail that will be attached to the front 
                                      base of the sled.

                                      The sled is turned over and the rail  is attached to the sled, first 
                                       drilled then countersunk and screwed together.

Baltic birch is used to make a block which will slide on the rail...

                                         I use my miter gauge to cut the pieces. The sandpaper
                                         holds the wood firm giving me exact clean cuts.

                                         The blocks are tested for fit and ready to be glued

                                          Everything fits nicely and slides along the rail.

                                         A strip is added to the block that will ride on the top
                                        of the v-track.

                                          The blocks are drilled to fit a threaded rod.

                                        A T-nut is installed on this end for the rod, this will
                                        move the block when the rod is turned.

                                         Nuts are put on the right side. There is two on each
                                        side of the block and tightened having a locking effect
                                         so the rod will turn freely in the hole.

                                         A handle is made using a wheel and a dowel. The dowel
                                         is drilled and a nut and  bolt are used so the dowel spins

                               I test a piece using a scrap 2x2 and am happy with the results.
                              Some are cut at 45 degrees and some at 90. I also sampled different

                                                  Now I will make a small box, I cut
                                                  some 3/8" Baltic birch and cut them
                                                  at 45 degrees.

                                           Glue is spread on the four pieces and tape is
                                          used to hold it together.

                                         Waiting for the glue to dry.........

                                         The cuts were easy to make and I did not have to
                                         clamp anything. After I cut four sides I turned the
                                         handle 8 times and cut again. This was done 7 times.

                                          Splines are glued in.....

                                          .....the splines are now carefully trimmed with the
                                          band saw and sanded smooth with a belt sander.

      Box complete and looks good, and I have many other designs in mind, if you have any
      suggestions for designs let me know.

 see also:

Leonardo da Vinci hammer                Make a screwdriver                           Make a table clamp


No comments:

Post a Comment