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PUZZLE PIECE JOINT JIG.....

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Project by indplswoodworking posted 05-18-2014 06:23 PM 5859 views 13 times favorited 15 comments Add to Favorites Watch

This project was way more challenging than I expected. I took me three tries to finally get it right and I had to make a slight alteration to the final version. A great way to lock together long pieces of 4mm okoume plywood and instead of trying to disguise the joint you showcase it. In addition it locks together and minimizes the amount of clamping required. The secret to this jig is using an inlay cutter bit and bushing in your router. The first uploaded photo above shows the guide and bushing atop the router. Very difficult to create but provides a awesome looking seam. I intentional mismatched the grain on the joint to better showcase it once it is lacquered and finished.

Side note , I am building a 15ft kayak and this is required to join two 8ft pieces of plywood together for the hull of boat. I tried to do a traditional 8:1 scarf joint with a block plane and I have the UTMOST respect for the hand-tool guys out there. Give me something with a cord on it any day!

-- https://www.facebook.com/MccloudsCreativeConcepts





15 comments so far

View a1Jim's profile

a1Jim

115201 posts in 3037 days


#1 posted 05-18-2014 06:52 PM

Wow this is a great idea,did you make the templet yourself ? great job.

-- http://artisticwoodstudio.com Custom furniture

View indplswoodworking's profile

indplswoodworking

317 posts in 1753 days


#2 posted 05-18-2014 07:10 PM

Yes, this is a photo of me laying out the first version.

-- https://www.facebook.com/MccloudsCreativeConcepts

View a1Jim's profile

a1Jim

115201 posts in 3037 days


#3 posted 05-18-2014 07:23 PM

Very cool it sure takes a creative mind to imagine this joint and a real talent to accomplish making it.

-- http://artisticwoodstudio.com Custom furniture

View MarkTheFiddler's profile

MarkTheFiddler

2053 posts in 1648 days


#4 posted 05-18-2014 07:41 PM

I’m super impressed by your ingenuity and steady hand. Beautiful joinery. I agree that it’s an excellent way to make a seam, that you can’t make disappear, into an amazing point of interest.

-- Thanks for all the lessons!

View indplswoodworking's profile

indplswoodworking

317 posts in 1753 days


#5 posted 05-18-2014 08:05 PM

I got the idea from a friend and then modified it. The original version had very small interlocking pieces and was very difficult to make a template on the scroll saw. It may have had 25 interlocking pieces and I would cut out 20 perfectly and would always make one mistake before reaching 25. The scroll saw is a very simple looking tool but the most difficult to master.

I think we spend to much time trying to hide joinery when sometimes we should showcase it. This was my first experience with a inlay bit and this type of joinery. I will definitely be using it again.

Thanks for all your great feedback!

-- https://www.facebook.com/MccloudsCreativeConcepts

View waho6o9's profile (online now)

waho6o9

7167 posts in 2037 days


#6 posted 05-18-2014 09:15 PM

Very innovative, thanks for posting!

View Spoontaneous's profile

Spoontaneous

1333 posts in 2790 days


#7 posted 05-19-2014 12:11 AM

There is no way I would even attempt a project like this. Nice work!!

-- I just got done cutting three boards and all four of them were too short. (true story)

View Monte Pittman's profile

Monte Pittman

21986 posts in 1798 days


#8 posted 05-19-2014 01:52 AM

Very cool idea. Very creative.

-- Mother Nature created it, I just assemble it.

View NormG's profile

NormG

5499 posts in 2464 days


#9 posted 05-19-2014 02:43 AM

Great job

-- Norman - I never never make a mistake, I just change the design.

View majuvla's profile

majuvla

9097 posts in 2328 days


#10 posted 05-19-2014 04:04 PM

Verry nice template!

-- Ivan, Croatia, Wooddicted

View steve_in_ohio's profile

steve_in_ohio

1195 posts in 1071 days


#11 posted 05-19-2014 05:48 PM

very cool template jig, great job

-- steve, simple and effective woodworking---etsy.com/shop/SussmanWoodworking--

View mcoyfrog's profile

mcoyfrog

3800 posts in 3054 days


#12 posted 05-19-2014 06:23 PM

Awesome

-- Wood and Glass they kick (well you know) Have a great day - Dug

View indplswoodworking's profile

indplswoodworking

317 posts in 1753 days


#13 posted 05-20-2014 12:05 AM

Thanks for all the great feedback guys. It is once of my favorite joinery techniques.

-- https://www.facebook.com/MccloudsCreativeConcepts

View Ken90712's profile

Ken90712

16951 posts in 2649 days


#14 posted 05-20-2014 02:59 PM

Wow great idea, cool way to lay it out. Not sure I would have thought of that.

-- Ken, "Everyday above ground is a good day!"

View indplswoodworking's profile

indplswoodworking

317 posts in 1753 days


#15 posted 05-20-2014 03:04 PM

It was not my original idea but I heavily refined the original design to better fit my skil set. Why reinvent the wheel?

-- https://www.facebook.com/MccloudsCreativeConcepts

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