Well I made the jig, but my old small bandsaw just wasn’t up to the task. I wasn’t about to quit, so I decided to try to make a jig that I could use with my router. It took me awhile to figure it out (using Sketchup), but once I did, it was rather easy to make the jig.

Here is how to make the jig.

Picture 1.

1. Cut a 3/4” thick piece of MDF or Plywood, 10” X 15”.
2. Draw a line down the middle of the board as shown in the drawing.
3. Draw a short line 1” from the edge of the board. This line must cross the first line.
4. Draw another short line 10-1/2” from the edge of the board.

Picture 2.

Using drafting triangles, draw the lines as shown on the picture. Make the 30 and 45 degree angles as accurately as possible.

Picture 3.

Drill the two 3/8” diameter holes as shown in the picture. These two holes will be used later as the center of the points for making the radius cuts with the router.

Picture 4.

This picture shows how the two 3/8” holes will be used. The router trammel shown in Picture 7 will be used with this board to make the two radius cuts. A 1/2” router bit is used.

Picture 5.

1. Cut another piece of wood 9-1/8” X 10”. This board should be the same thickness as the wood used to make the “Lazy Larry”. This board is used as a fence to help align the boards used for the “Lazy Larry”. It is also a spacer to raise the router to the same level as the boards.
2. Attach this board as shown in the picture using double sided tape.
3. Flip the boards over and drill the 3/8” holes through this board using the original holes as a guide. These two holes will be used as pivot points using a 3/8” dowel.

Picture 6.

The jig should now look like this.

Picture 7.

This picture shows the router trammel. The 5/8” diameter hole is for a router bushing. The internal diameter of the bushing must be large enough to accomodate a 1/2” diameter router bit.

I hope that this information is useful for the JOCKS who would rather use a router than a bandsaw.

Next time I will show how the jig is used.