I’ve been having trouble with the 45 degree miters for my walnut veneered box, and I thought I had this very clever idea for a box miter jig on the table saw. It works the same principle as a picture frame type miter jig works. As long as your total angle is 90 degrees, the rest of the alignment isn’t as critical, so if you have a 44 degree and a 46 degree miter it will all work out in the end.
Here is a picture of the jig, the idea is the wood can sit on the left or right side (depending which part of the angle needed to be cut). I had thought I’d be able to just hold the wood onto the jig but I couldn’t get a good grip on it and that was before I even tried to make a cut.
I tried to figure out a clamping solution to clamp the work piece down, the only clamps that I had with a deep enough was a spring clamp. I was cutting through some 1/2’’ plywood test pieces when I heard the wood get caught into the blade, I immediately stopped the saw and stopped the jig.
I think the problem is that the sawblade, and gravity are pulling the piece into the blade, which causes it to pinch and could cause a huge kickback problem worse case scenereo, but it also negatively effects the mitered cuts, they are extremely inaccurate.
Unfortunatly the way it was built I can’t really get any good clamping pressure on the piece, it should be an easy fix, I can cut down the sides of the V to allow the clamp to reach the piece being cut, but in all true irony fashion. A few days before I finished the jig, I saw a tip about using a 45 degree chamfer bit to cut perfect miter corners for boxes and I just smacked my forehead and said well duh! .. (it was either in woodsmith magazine, shop notes, or one of the woodworking tv shows I don’t remember).
I finished the jig anyways, because I don’t have a chamfer bit large enough to handle a 1/2’’ miter and plus I had thought I created some brilliant jig (I was wrong).
I doubt I’ll be working to fix the jig, I haven’t thrown it away yet, who knows but it seems more likely I’m going to get a bigger chamfer bit and use my router table it seems to be a much better approach to the situation.
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