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Blog entry by patron posted 12-23-2010 05:26 PM 4923 reads 4 times favorited 21 comments Add to Favorites Watch

recently i was asked to figure out a way to mount
under table hinges and stops
for a series of square tables to round folded wings (4 each)

when the wings were folded up
they had to lay flat to the underside flush
with the table top
(no room for crumbs or crud to gather)
so had to be inset to both
here is the generic jig i came up with
with the top and wings upside down
and a business card in between them
for spacing i cut out the hinge profile (twice)
and registered the jig to the corners of the top
with stops to hold the wings in place
(under the jig side showing
corner stops with curved ends for the round wings
to register too)

i always use a 1/2”x1/2” long patterning bit
as the offsets for the bushings are to much trouble to get right
and make a direct profile cutout
(start in the field so as not to gouge the edges of the jig)
for depth of cut lay the hinge and jig
with the hinge under the router base
and drop the router to the surface of the top
and lock that depth then remove the hinge
and route

then another jig for the knuckle too
this one to each side separated
so i can just come in from the side

now for the metal ‘holder-open-stops’
(i didn’t design these
the parts were given to me)
it is a series of 3 parts
and 4 routs
this is the ‘master’ jig for that
it has stops under for the top and the wings
the innovation is the ‘cut out’ to accept 4 different profile inserts
all registered to the center line
and all for different width , depth , and length routs
this is the actual metal bar
that holds the wing up
it is deeper and has a finger hole
and corresponding finger slot deeper still

here is the flush metal plate to hold the ‘slider’
screwed to the table top
and a 1/32” ‘rub plate’ clued to the wing
it is 1/8”wider than the ‘slider’

the whole point of this blog
is to show how 1 master jig
can be used with inserts to
make many different routs
that can be re-used and adapted to the same jig
instead of making all dedicated masters
for all the different routs
here are some of the inserts

and here is the one with an insert in it
that made the slider rout
and the finger rout too

well this has been a ‘woodworki-leaks’
i was asked to keep this a secret
as it is ‘proprietary’ to some secret project
(there are no pictures still available
of the actual finished tables
these pictures were taken
with a spy camera
and smuggled out)
but as i was given no instructions on how to do this work
and nobody even looked at how i did it
or asked how the jig worked
i feel that i designed it myself

now i have to go and catch my plane
to sweden (i hope to get a ‘message’)
before i get extradited
back to the states
to stand trial for divulging
this information

merry christmas !

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

21 comments so far

View Dennisgrosen's profile


10880 posts in 3139 days

#1 posted 12-23-2010 05:46 PM

ThankĀ“s fortaking you time to make a very good picture tuturial David :-)

have a nice tour de holydays
Merry Chrismas

View supervato's profile


153 posts in 2953 days

#2 posted 12-23-2010 05:53 PM

very cool bro I’ll save this idea so I can use it when I need it in the future.

View SPalm's profile


5320 posts in 3906 days

#3 posted 12-23-2010 05:54 PM

I, for one, am glad you leaked it.
And I hope the hackers don’t take down your server.

Nice pictorial. You do such clever work.

-- -- I'm no rocket surgeon

View Jim Bertelson's profile

Jim Bertelson

4179 posts in 3189 days

#4 posted 12-23-2010 06:19 PM

Nice work and nice pictures, David…............I don’t have anything to leak…......except the residue of my morning coffee….....(-:

May your Holidays be full of fun, and the New Year be funner…............(-:


-- Jim, Anchorage Alaska

View terrilynne's profile


836 posts in 2918 days

#5 posted 12-23-2010 06:49 PM

Very clean work and nicely done.
Have a Very Merry Christmas!

p.s. do you have any snow there? I was hoping for some here. Guess we’ll have to drive into the mountains Christmas morning to play in the snow!

-- Terri, Rocky Mountain High Colorado!

View patron's profile


13606 posts in 3365 days

#6 posted 12-23-2010 06:53 PM

had 6”
but it all melted
now it is in my water tank
that storm in california
should bring you some

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View Gene Howe's profile

Gene Howe

10530 posts in 3453 days

#7 posted 12-23-2010 06:57 PM

Very neat David! Great planning and execution, as always.
And, here I thought all the great woodworkers were in Santa Rosa! :-)

-- Gene 'The true soldier fights not because he hates what is in front of him, but because he loves what is behind him.' G. K. Chesterton

View patron's profile


13606 posts in 3365 days

#8 posted 12-23-2010 07:04 PM


if all of them were there
there wouldn’t be any wood
in the stores

so God spread them around

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View Joe Lyddon's profile

Joe Lyddon

10118 posts in 4077 days

#9 posted 12-23-2010 07:59 PM

Very good, commandant!

Please feel free to meet in our secret meeting place in filac amol atla

Thank you very much for your devoted attention to the details.

Special and secret agent eoj noddyl.

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

View jack1's profile


2107 posts in 4052 days

#10 posted 12-23-2010 09:13 PM

Nice looking jig and the work it produces. I like it.

-- jack -- ...measure once, curse twice!

View stefang's profile


15881 posts in 3358 days

#11 posted 12-23-2010 10:50 PM

Lumberjocks leaking, well David now I have heard everything. It looks like a good solid solution and nicely done with the jigs. I have to agree with you that guide collars are fussy. I tried to use a guide collar on the project I just finished today and after a 3 failed tries I went and bought a pattern bit which did the job. I appreciate your comment on this, as now I know I’m not the only one who has had an issue with guide collars. Thank you and a very Merry Christmas to you too.

-- Mike, an American living in Norway.

View jockmike2's profile


10635 posts in 4271 days

#12 posted 12-24-2010 12:11 AM


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

View patron's profile


13606 posts in 3365 days

#13 posted 12-24-2010 12:37 AM

i am a modern man

more like ‘droopy drawers’

i dress in the new style
crotch to my knees
pant legs trailing on the ground

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View Todd A. Clippinger's profile

Todd A. Clippinger

8901 posts in 4124 days

#14 posted 12-24-2010 01:53 AM

Hey pro bro I dig your jig

-- Todd A. Clippinger, Montana,

View Monty Queen's profile

Monty Queen

1593 posts in 3276 days

#15 posted 12-24-2010 05:01 AM

Nice looking jig, awesome work.

-- Monty Q, Columbia, South Carolina.

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