Spline Cutting Jig

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Blog entry by Karson posted 12-31-2011 09:10 PM 7648 reads 8 times favorited 18 comments Add to Favorites Watch

I have seen a few spline cutting jigs here on LumberJocks. I was trying to think how I would use such a jig.

I ran across some Freud blades for a skill type saw that are 7 1/4 wide and 1/16” thick. They were made for the battery skill saws where you don’t have a lot of power.

So I decided to put that blade on my table saw.

I measured the max cutting height with that blade and it’s 1 5/8” so I knew that if I used 3/4” ply for the base and depending how I made the side, I wouldn’t have any blade left for make a cut.

So I used 1/2” ply for the base and I cut a 45 deg cut on the sides and then used 45 deg blocks to glue it all together.

It does not have an end on either end of the jig so I’m not limited at to the box height. I used the slots in the table so that I didn’t have to use the fence and this way it is always in the same place. The blade always cuts in the same slot.

I then made the jig reversible so I can cut a straight spline and I can cut an angled spline, I just turn the jig around in the slots. I also did some testing and I felt that I liked 25 deg angle on the spline to be the best angle to cut.

I glued extra blocks between the two cuts so the the base would not fall out and also to be a protector for fingers holding the jig where the saw might cut.

I use a board in the inside that is held with clamps to align the box and register it in the same place for all cuts.

Here is a sample cut on an angle where I move the box 5/16 over and register off the opposite side of the blade.

These boxes will be given as Christmas presents next week at the family Christmas Party. So they will be posted in a different posting.

I double checked again and the cuts are actually being cut at 23 degrees. From when I did the first check and from when I set up the jig My set-up block changed.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware †

18 comments so far

View dustyal's profile


1247 posts in 2413 days

#1 posted 12-31-2011 10:38 PM

Nicely made and nicely presented. I’ll probably remake mine to incorporate your 25º slot idea.

-- Al H. - small shop, small projects...

View lew's profile


10433 posts in 2693 days

#2 posted 12-31-2011 11:53 PM

Cool Idea, Karson!

I like the appearance of the “interlocking” splines.


-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View cajunpen's profile


14506 posts in 3003 days

#3 posted 01-01-2012 12:34 AM

Nice one Karson. I think the 1/16” 25 degree mitered slots will give your boxes a different look. They would be really neat incorporated along with some 1/8” slots.

-- Bill - "Suit yourself and let the rest be pleased."

View Karson's profile


34951 posts in 3338 days

#4 posted 01-01-2012 12:52 AM

Bill: I plan to try some different ideas one where you do a taper in on top and bottom and also a taper out in the same place.

When I did this on a mahogany box I had to do some maple splines because the two-tone splines disappeared in the darker wood.

Id also like to try dyed wood like green and red for Christmas.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware †

View therookie's profile


887 posts in 1765 days

#5 posted 01-01-2012 01:00 AM

very cool i like the idea


View Joe Lyddon's profile

Joe Lyddon

8253 posts in 2990 days

#6 posted 01-01-2012 01:35 AM

I have wondered about that!

I’m glad you proved it out!

It seems like the last time I got that lil blade, it was a Buy 1 Get 1 FREE Deal… So, I have one in by CS and a NEW one hanging on the wall!

Now, I can take it OFF the wall and USE it in my TS!

Thank you for your experimentation proving it works SO GOOD!!

Happy New Year!

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: ... My Small Gallery:"

View Karson's profile


34951 posts in 3338 days

#7 posted 01-01-2012 03:14 AM

Joe: I bought 2 packages so I’ve got 4 blades. I’ve cut 1000’ of Sapele boards. 5/16 X 11” X 1 1/4 with one of these blades.

Not one burn mark on the wood. Because the kerf was so small I got extra boards out of my raw stock.

They cut slick and work great.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware †

View Lee A. Jesberger's profile

Lee A. Jesberger

6772 posts in 2917 days

#8 posted 01-01-2012 03:19 AM

Well done, buddy. I hope the splitter is just removed for this jig!

Happy new years.


-- by Lee A. Jesberger

View Dan'um Style's profile

Dan'um Style

13784 posts in 2920 days

#9 posted 01-01-2012 03:33 AM

good read Karson … hope you are you enjoying the holiday season.

took your lead on a earlier post and bought some of these 7 1/4” inch dia and 1/16” kerf for my table saw and am having excellent results myself

-- keeping myself entertained ... Humor and fun lubricate the brain

View EMVarona's profile


437 posts in 1773 days

#10 posted 01-01-2012 12:02 PM

Excellent! That’s giving me some ideas. I also made a simple spline jig. I plan to make another with some improvements based on yours.

-- Ed "Real happiness is one that you share."

View helluvawreck's profile


17712 posts in 1804 days

#11 posted 01-01-2012 02:52 PM

Karson, that’s a nice jig and the thin splines look really good. Nice work.


-- If a man does not keep pace with his companions, perhaps it is because he hears a different drummer. Let him step to the music which he hears, however measured or far away. Henry David Thoreau

View Roger's profile


17028 posts in 1742 days

#12 posted 01-01-2012 04:17 PM

oh yea. nice idea Karson

-- Roger from KY. Work/Play/Travel Safe.

View Edward E Nock II's profile

Edward E Nock II

96 posts in 3082 days

#13 posted 01-01-2012 05:56 PM

Karson….My spline jig is veyy similar. I extended lines on both sides of the blade up the jig sides & over the edges so I could see where I was cutting w/o measuring. Mine is endexed to the rigth of the blade. See you in Baltimore Friday. Bring som extra $$$$ mor me.



View jockmike2's profile


10635 posts in 3184 days

#14 posted 01-01-2012 07:50 PM

Nice jig Dad. You and Degoose aught to put you heads together, the sky would be the limit with both of your creative minds. LOL. I just bought a new Rigid table saw, the big heavy version. David Craig put it together for me, I’ll bet the top alone weighs 150 lbs. Next a new bandsaw, and back to the lathe. Just finished moving so I have less space and I’m going to need help setting up a shop that was in a 30 X 40 pole barn to a 24 X 24 barn. Btw, I tried to get hold of our old woodsman poet, and got a recording. Left my number but never heard back. God Bless, mike

-- (You just have to please the man in the Mirror) Mike from Michigan -

View Joe Lyddon's profile

Joe Lyddon

8253 posts in 2990 days

#15 posted 01-01-2012 11:34 PM

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