portable handheld mortising jig "build blog"

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Blog series by hobby1 updated 11-28-2013 07:26 PM 13 parts 19962 reads 48 comments total

Part 1: Building the router base sub assembly

10-10-2013 04:39 AM by hobby1 | 8 comments »

Hi Guys,Every Christmas, I use the money I get for Christmas to put towards a shop tool, either machining, or electronics,or woodworking, 3 years ago, I put it towards a benchtop woodworking bandsaw, then the next year it was a bench top jointer from grizzly, last year it was a newer version of workmate, Now that I am taking my woodworking from a hobby level, to a God given career level, doing commision work, I realized I need to add to my woodworking tool collection,so this Christmas coming...

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Part 2: building angle brackets for base subassembly

10-11-2013 01:47 AM by hobby1 | 3 comments »

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 ...

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Part 3: the determining and building of the guide rails

10-12-2013 09:44 PM by hobby1 | 3 comments »

At this point I have everything screwed together for the first subassembly.It’s time to work on the axis travel arrangement. I thought about 3 ways to do this, first was with a linear bearing approach, where I would ream a hole through a piece of steel to be the bearing, and make 4 of them, then make some sort of rail system out of round bar stock for the bearings to run on, however, that would mean some elaborate bracket sytem to hold the rails up, which would mean 4 rails 2 for eac...

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Part 4: the finalizing of the dovetail slides, and prefit everything together

10-14-2013 05:00 AM by hobby1 | 5 comments »

Hi guys Please:If you get tired of all this technical stuff I’m showing here, please let me know, and I’ll just post the highlights of the build with much less play by play details. The next thing I worked on was, assembling one set of dovetailed slide rails on the main baseplate, that will allow the router to travel in the “Y” axis direction. Here I’m using again my surface plate as the datum, to ensure the fixed slide is assembled perfectly square wit...

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Part 5: the lapping of slides and start of front fence assembly

10-15-2013 02:44 PM by hobby1 | 9 comments »

I got a couple hours in yesterday afternoon, I started by lapping in the central dovetail block into both the subassembly guide rails, and the base guide rails, respectively, here is one side of the block without any lapping done to it, it is rough on the top inside of the dovetail, this could have been prevented if I would have taken light cuts on the mill, however. I knew I would lapp this in, so I took substantially deep cuts, around 0.200” at a time, so the reason for the roughn...

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Part 6: starting the front fence system

10-17-2013 10:39 PM by hobby1 | 5 comments »

Couple hours in this evening, Here is where I’m starting working on the front fence, I need to first cut a thru hole through the router baseblate subassembly, so I do some guaging and measuring and marking off to locate the approximate center of the router shaft. then drill a 1/2” hole for the router cutter to come thru. Now I can put some marker on the front fence in preparation for marking and measuring, this will be the slot in the fence to allow the cutter...

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Part 7: finalizing front fence and start on clamping system

10-22-2013 05:08 PM by hobby1 | 3 comments »

A couple hours more in the last couple of evenings, Here is where I left off at after the last machining session, I was able to get some slots machined for and adjustable depth positioning fence, this allows me to adjust the depth of where to cut the mortise in the edge of a board, for example, set it 3/8” off of center to put a mortise in the edge of a 3/4” thick board ect… Now, I’m now finishing up the details on this project, so I drew up a punch list, to sta...

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Part 8: begining to machine the stop blocks with procedural steps to make one part

10-28-2013 04:23 AM by hobby1 | 2 comments »

I needed to make a latching stop block to keep the router from slipping off the back, its not only a stop block, but also a latching block, because later I will attach some sort of a latchng mechanism, on this block to keep the router elevated above the workpiece while repositioning the router for the next mortise. Started out with a quick sketch with some dimensions that later got changed during the machining process. I also worked on making an arrangement for a “...

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Part 9: few hours this week, making the mortise length stop blocks.

11-03-2013 02:32 AM by hobby1 | 2 comments »

I was able to get a few hours in this weekend, I fabricated all the parts to make the “X” axis stop blocks, this will allow me to set the length of a mortise. I now need to measure out and secure accurate dimensions on the stop block now, to know at what locations to do the operations on. I first use my heigth guage to reference off of the surface plate the height of the sub base, which will be the top of the stop blocks, then I get the heigth of the bar and with a l...

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Part 10: couple more hours this evening, building mortise depth stop block and starting the handles.

11-07-2013 03:47 AM by hobby1 | 2 comments »

couple hours yesterday evening, allowed me to start working on making the adjustable ‘mortise depth’ stop, It is machined with a small flange to ride in the groove at the bottom of the subbase, when I have it set where I want it, for depth of cut, I tighten it with a screw that comes through the slot in the subbase. However I don’t want to thread the stop block itself, seeing it is a very thin piece of aluminum stock left over after machining it to final thickness, to fit un...

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Part 11: making the handles complete with tapers, using my tapering jig.

11-12-2013 01:49 AM by hobby1 | 2 comments »

Now I will first machine a small taper on the handle top, I will use one of the bars I just threaded as a mandrel to hold a handle top onto, then I will set up to machine a taper.Because I don’t need to use the tailstock to support the workpiece, I can adjust the compound slide to the desired angle, a person aquainted with machining, will see in this setup the taper is being cut the opposite way it is usually done on a lathe, however it still works. now instead of machining a lar...

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Part 12: adding the latch, and upgrading the length stops.

11-16-2013 04:01 AM by hobby1 | 2 comments »

I was able to get a couple hours in this evening for machining parts. I’m using a cabinet door bullet catch latch,———————- to lock the router subbase assembly, should I use the jig in a upright position, this latch will allow me to latch the router while I move the jig to a new location to make another mortise, on the board. Now I’m not happy with the smallish rod I was using for the mortise length stops to fasten onto, the rods w...

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Part 13: short video mortise jig

11-28-2013 07:26 PM by hobby1 | 2 comments »

Hi guys here is a short video of the jig, cutting a mortise. have fun in the shop.

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