A Mystery Project
So, what might this be? Something to do with a router, obviously.
The other day, while browsing one of my Woodworkers magazines, I came across an article about a jig for making mortise and tenon joints with much more additional functionality. The article took an old idea and updated it and concluded that it was a very good idea, not too expensive to build and more uses to be discovered every day.
I bought some oak pieces from Lowes for about $65. I ordered some T-tracks and other bits and pieces from Lee Valley and Veritas, and the Jorgensen hold-down clamps from Woodworkers Supply for an additional $120 or so.
Laminated the oak to make the beam; cut the trough pieces for the router guide, the base pieces etc. Drilled the holes for the screws to hold the Jorgensen clamps and finally, the moment of truth arrived when I had to lug out the ancient Craftsman radial arm saw to cut the dados for the T-track. About 90% satisfied with the result of this forgotten machine. Screwed in the T-track with tiny brass screws and cut the stop blocks for router travel and workpiece positioning. Only parts left to make were the cauls to partner with the clamps to hold the workpiece firmly without marking. The cauls have lengthwise steel inserts to attach magnetically to the clamps. Steel was acquired from Ace Hardware for $7.95 equal to $14,000 per ton--not bad... Finally, to allow the router edge guide to slide smoothly in its groove, I had acquired some beeswax and turpentine, a small portion of which dissolved a small portion of beeswax for application.
Almost ready to test... total cost for materials: about $200. Time invested: maybe 15 hours.
Calibrated the center of router to edge of beam. Vernier edge guide adjustment is one full turn of screw for 1/16" travel; there are eight divisions per turn, so it should be possible to set the edge guide accurately enough for most non-aerospace work...
Did a test cut using a 1/4" diameter bit along the center of a piece of 3/4" stock: perfect! Good project. Good tool!
The other day, while browsing one of my Woodworkers magazines, I came across an article about a jig for making mortise and tenon joints with much more additional functionality. The article took an old idea and updated it and concluded that it was a very good idea, not too expensive to build and more uses to be discovered every day.
I bought some oak pieces from Lowes for about $65. I ordered some T-tracks and other bits and pieces from Lee Valley and Veritas, and the Jorgensen hold-down clamps from Woodworkers Supply for an additional $120 or so.
Laminated the oak to make the beam; cut the trough pieces for the router guide, the base pieces etc. Drilled the holes for the screws to hold the Jorgensen clamps and finally, the moment of truth arrived when I had to lug out the ancient Craftsman radial arm saw to cut the dados for the T-track. About 90% satisfied with the result of this forgotten machine. Screwed in the T-track with tiny brass screws and cut the stop blocks for router travel and workpiece positioning. Only parts left to make were the cauls to partner with the clamps to hold the workpiece firmly without marking. The cauls have lengthwise steel inserts to attach magnetically to the clamps. Steel was acquired from Ace Hardware for $7.95 equal to $14,000 per ton--not bad... Finally, to allow the router edge guide to slide smoothly in its groove, I had acquired some beeswax and turpentine, a small portion of which dissolved a small portion of beeswax for application.
Almost ready to test... total cost for materials: about $200. Time invested: maybe 15 hours.
Calibrated the center of router to edge of beam. Vernier edge guide adjustment is one full turn of screw for 1/16" travel; there are eight divisions per turn, so it should be possible to set the edge guide accurately enough for most non-aerospace work...
Did a test cut using a 1/4" diameter bit along the center of a piece of 3/4" stock: perfect! Good project. Good tool!
