Auxiliary TS/Router Fence and FB Rail

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Project by HillbillyShooter posted 10-05-2014 09:54 PM 3673 views 22 times favorited 22 comments Add to Favorites Watch

The subject of an auxiliary fence and safety came up in response to my recent Magic Molder product review ( ) and I indicated I would share mine. So here is my Auxiliary TS/Router Fence and Feather Board Rail system that has evolved over the past 20-years to provide both vertical and horizontal feather boards (FB), reduced clearance inserts (RCI) for my router bits plus various specialized fences.

Obviously, the vertical and horizontal feather boards provide safety in preventing kick back and provide constant downward/inward pressure to insure consistent cutting. The FBs are fully adjustable as you can see from the slots and star-wheels. The constant vertical and horizontal pressure allows you to push (feed) up to the first FB, stop and move to the back, pull (out feed) end to finish a cut without any problems. These feather boards and the rail can be seen in the first photograph (above) where the set up is used to cut the 5/16” round molding with the Magic Molder on the edges of a 1”x2” board.

This fence system started life using the Biesemeyer T-Square Auxiliary Fence that used to be available in PM gold before Biesemeyer was sold to Delta and subsequently became available only in Delta gray (if at all now). You can see the back of the original Biesemeyer Auxiliary Fence in Photo 2 (above) which shows how it attached to the original TS fence with two round knobs that raise the back of the “L” bracket and transfer pressure to the side of the original fence. Photo 2 also shows the four horizontal slots I cut with four-star wheels to add my supplemental fences (which are also shown). The supplemental fences shown are the one next to the original fence, which has the slots, and a second fence which has the bolts that ride in the first fence slots and are tightened using the star wheels. Also shown is the 2-1/4” vacuum hose outlet, which collects sawdust from the router outlet inside as limited by the RCI on the second fence (outside). The RCI inserts for the router bit are shown in Photos 3, 4, 5 and 6.

The next photo shows the vertical FB in place over the router bit.

Next is the FB rail added to the router set up to utilize the horizontal FBs.

Following is a close up of the front of the FB rail showing how the rail clamps to the front Biesemeyer fence rail:

And, this is a close up of the back of the FB rail showing how it clamps to the back of the Biesemeyer “L” rail:

This is an edge-trimming fence that is adjusted around a flush trim bit to trim the proud edge of a solid stock, which I often glue to a plywood edges to provide a finished look of solid wood. The front fence is raised to provide clearance for the proud solid wood up to the router bit (in feed fence); and, the back fence is lowered to the table top, much like a vertical joiner out feed fence. The plywood is run vertically against the fences. Both fences attach to the second auxiliary fence by means of the “t” bolts and “t” slot in the auxiliary fence.

This is the original Biesemeyer Auxiliary Fence that I ran a groove 1/8” from the bottom and 1/8” deep so I could use it to make a controlled rip on Formica and similar thin stock.

This is a spacer fence to insert between the first and second fence shown in Photos 2 and 3 above when extra thickness is needed for a large diameter router bit (such as a raised panel bit):

This is an extra tall, 12” fence (which I was sure I would need, but haven’t found occasion to use):

This is the out feed view of both the horizontal and vertical FBs in use to control the trim cut of a 1”x2” molding piece:

And, this is the in feed view of the same horizontal and vertical FBs in use to control the trim cut of a 1”x2” molding piece:

This is my auxiliary fence system as it has evolved over the past two decades, and I am sure will continue to evolve.

As always, comments (good, bad, critical or whatever) are greatly appreciated. Thanks for looking.

-- John C. -- "Firearms are second only to the Constitution in importance; they are the peoples' liberty's teeth." George Washington

22 comments so far

View Roger's profile


19714 posts in 2224 days

#1 posted 10-05-2014 10:14 PM

Super fine John. Your fabrication is amazing. Deluxe in my book. :)

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed.

View luv2learn's profile


2409 posts in 1723 days

#2 posted 10-05-2014 10:47 PM

What a well thought out professional looking fence John. I don’t see how it would be possible to make making molding any safer with the all the FBs in place. Is that another anti kick back device in front of your blade?

-- Lee - Northern idaho~"If the women don't find you handsome, at least they ought to find you handy"~ Red Green

View AnonymousRequest's profile


861 posts in 969 days

#3 posted 10-05-2014 10:53 PM

Wow John! A lot of thought went into this, great design. The safest setup I’ve seen for sure.

View HillbillyShooter's profile


5811 posts in 1712 days

#4 posted 10-05-2014 10:54 PM

Roger—Thanks, it’s always great to hear from you!

Lee—Thanks, and yes, in front of the blade is an old Biesemeyer splitter with anti-kickback pawls. It’s pre-riving knife, but is a great safety device in my opinion for ripping, etc.

-- John C. -- "Firearms are second only to the Constitution in importance; they are the peoples' liberty's teeth." George Washington

View doubleDD's profile (online now)


5057 posts in 1463 days

#5 posted 10-05-2014 11:07 PM

Very well thought out system. Nice job on building this. I may be adding some of this to my table saw. Great work John.

-- Dave, Downers Grove, Il. -------- When you run out of ideas, start building your dreams.

View Jim Jakosh's profile

Jim Jakosh

16797 posts in 2525 days

#6 posted 10-06-2014 12:25 AM

WOW!!!!!!!!!!!!!! That is the ultimate fence! You sure put a lot of thought into it, I can tell!!!!!!

Thanks for sharing!!.....................Cheers, Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View TopamaxSurvivor's profile


17575 posts in 3096 days

#7 posted 10-06-2014 12:42 AM

Awesome work and well planned!

-- Bob in WW ~ "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence

View tyvekboy's profile (online now)


1307 posts in 2433 days

#8 posted 10-06-2014 12:58 AM

Interesting safety devices. Thanks for sharing.

-- Tyvekboy -- Marietta, GA ………….. one can never be too organized

View kiefer's profile


4873 posts in 2087 days

#9 posted 10-06-2014 02:07 AM

Boy you got some interesting setups their and it makes for some good precices results .
I will have to keep them in mind and I also like the replaceable inserts you have for different router bits .
Thinking ahead never is a mistake because you never know but it’s sure nice to have that fence or whatever ready to go .
I build all kinds of stuff because I have an idea and when the time comes there it is .
Keep passing along those innovations because it helps all of us .


-- Kiefer

View HillbillyShooter's profile


5811 posts in 1712 days

#10 posted 10-06-2014 04:04 AM

Jeff, Dave, Jim, Topamax, Alex and Klaus—Thank you all for taking the time to look and comment on this project that has been in the making for some time. Coming from you gentlemen who have all contributed such high levels of craftsmanship and innovative design, it is a humbling experience. Best, John.

-- John C. -- "Firearms are second only to the Constitution in importance; they are the peoples' liberty's teeth." George Washington

View Blackie_'s profile


4527 posts in 1932 days

#11 posted 10-06-2014 11:57 AM

Thanks for sharing this John.

-- Randy - If I'm not on LJ's then I'm making Saw Dust. Please feel free to visit my store location at

View Scottlj's profile


67 posts in 1138 days

#12 posted 10-06-2014 12:43 PM

Definitely motivates me to make a better / longer horizontal feather board for my table saw.

One question… is there a functional purpose to the bits of dowels that are sticking out on a couple of the boards?

View eddie's profile


8345 posts in 2034 days

#13 posted 10-06-2014 07:17 PM

thanks HillbillyShooter for sharing awesome set up

-- Jesus Is Alright with me

View HillbillyShooter's profile


5811 posts in 1712 days

#14 posted 10-06-2014 09:02 PM

Randy—thanks for looking and commenting. I regret not being around last Friday when you posted your latest design evolution to your Valet Box, but with the nice weather I’ve been fishing and playing hookie from my shop and LJs—great work!

Scott—thanks, and to answer your question, those dowels are alignment pins for double FBs. If you look closely at the 8th picture, you can see the double FBs on the FB Rail. I also have a double FB for horizontal positioning.

Eddie—thanks, and it is my pleasure to share since I receive so much more from LJs than I’ll ever be able to repay.

-- John C. -- "Firearms are second only to the Constitution in importance; they are the peoples' liberty's teeth." George Washington

View gfadvm's profile


14929 posts in 2110 days

#15 posted 10-07-2014 12:16 AM

What a nice shop made set up! You would have to try pretty hard to get hurt with that.

Hope you are catching as well as fishing.

-- " I'll try to be nicer, if you'll try to be smarter" gfadvm

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