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Spline Cutting Jig

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Blog entry by Karson posted 12-31-2011 09:10 PM 6520 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 karson_morrison@bigfoot.com †



18 comments so far

View dustyal's profile

dustyal

1196 posts in 2113 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

lew

10007 posts in 2393 days


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

Cool Idea, Karson!

I like the appearance of the “interlocking” splines.

Lew

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

View cajunpen's profile

cajunpen

14381 posts in 2703 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." http://www.cajunpen.com/

View Karson's profile

Karson

34871 posts in 3038 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 karson_morrison@bigfoot.com †

View therookie's profile

therookie

887 posts in 1465 days


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

very cool i like the idea

-- http://aewoodworks.webs.com

View Joe Lyddon's profile

Joe Lyddon

7693 posts in 2690 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: http://www.WoodworkStuff.net ... My Small Gallery: http://www.ncwoodworker.net/pp/showgallery.php?ppuser=1389&cat=500"

View Karson's profile

Karson

34871 posts in 3038 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 karson_morrison@bigfoot.com †

View Lee A. Jesberger's profile

Lee A. Jesberger

6647 posts in 2617 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.

Lee

-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com

View Dan'um Style's profile

Dan'um Style

12939 posts in 2620 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

EMVarona

437 posts in 1473 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

helluvawreck

15661 posts in 1504 days


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

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

helluvawreck
http://woodworkingexpo.wordpress.com

-- 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

Roger

14447 posts in 1441 days


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

oh yea. nice idea Karson

-- Roger from KY. Work/Play/Travel Safe. Kentuk55@bellsouth.net

View Edward E Nock II's profile

Edward E Nock II

90 posts in 2782 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.

ED

-- ED NOCK

View jockmike2's profile

jockmike2

10635 posts in 2884 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

7693 posts in 2690 days


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

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