portable handheld mortising jig "build blog" #2: building angle brackets for base subassembly

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Blog entry by hobby1 posted 10-11-2013 01:47 AM 1225 reads 0 times favorited 3 comments Add to Favorites Watch
« Part 1: Building the router base sub assembly Part 2 of portable handheld mortising jig "build blog" series Part 3: the determining and building of the guide rails »

I got a couple hours in today,
this afternoon, I started laying out the cut lines for the two angle braces to support and make square the two plates when everything is tightened permanently.

after I cut them out, I used a flycutter to clean up the cut lines on both pieces simulataeously.
Now I need to start looking at squaring up the 90 deg. angle I first used the factory sides of both pieces as a reference, against a precision square block, to orient the pieces square with the table as they are clamped in the vise.

Now I used this fresh cut edges to reference against the precision block, to true up the factory edges.
here are the two factory edges with there beveled edges, just like the factory edges of 2×4 lumber, I need to edge joint these to make a nice flat surface, on the edges.

after flycutting the edges, here is the result

a quick check against the surface plate and precision block, to assure all is machined square.

Now I am going to screw these brackets to the plates, but in order to make it easier to hold the angle brkts, when I transfer punch holes, I need to mill out a dado, in the router base plate to recieve the bottom of each angle brkt.

I need to be careful to not go too deep, or I risk cutting into the screw holes on the side,of the plate, So I set a depth to cut.

The angle piece is 1/2” thick so I use a 3/8” endmill to make two X axis adjustments to sneak up on the final width of the slot.
Using the workpiece itself as a guage.

Now they both fit, so I can move onto drilling and tapping holes to bring the base X axis plate assembly together.

Next I can start drilling and tapping holes to assemble these brackets on, then move back to the router sub base plate, to start laying out the guide rails ect..

3 comments so far

View stefang's profile


15881 posts in 3359 days

#1 posted 10-11-2013 07:48 AM

That is looking very good and precise. I have to admit that I’m not entirely sure how this is going to work, but that makes it all the more interesting.

-- Mike, an American living in Norway.

View Boatman53's profile


1056 posts in 2221 days

#2 posted 10-11-2013 12:15 PM

Looks very interesting. I got a small mill last Christmasand love those Colt routers. Can’t wait to see where this project goes. Looks like you are off to a great start.

-- Jim, Long Island, NY home of the chain leg vise

View hobby1's profile


335 posts in 2322 days

#3 posted 10-11-2013 02:27 PM

I know what you mean Miike, I have a general idea, in mind, but this is definately a design and build sequence, usually when I machine parts for my model projects, I’ll CAD everything, make sure everything fits, have all the detailed dimensions, right down to the thou. and then build.
This project is like my woodworking projects, I build as I go along.

Thankyou, I really enjoy using those benchtop mills, they really open up oppurtunites to fix and fabricate parts, that otherwise could not be found comercially.

My colt palm router, is my goto router, for majority of routing needs, especially edge routing small workpieces, its base plate is small enough where I could hold the workpiece down by hand and do a quick profile with ease.

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