|Project by Don Johnson||posted 07-07-2015 01:26 PM||2547 views||7 times favorited||7 comments|
As a subscriber to The Drunkenwoodworker’s channel on YouTube, I naturally viewed his videos on making picture frames: https://www.youtube.com/watch?v=r6fUXRMJ0DI&list=FLACdgVVUaH2fHCbFkc20sWQ&index=1
I was struck by the design ingenuity and ease of use of these two jigs,and would have liked to make both of then, but really could not justify doing so as I had no reason to be producing picture frames. A little while later, whilst discussing the website I am setting up for an artist friend – http://www.angelauren.co.uk/ – she happened to mention that she had a business proposition for me, which would be to make her some picture frames !
So, immediately (as is my custom) I found a source of an aluminium ruler of similar length to that specified, and set about making the frame jig. I did not use the Micro Jig Zero Play Guide Bar (not available in the UK ?) but fitted two oak strips as I did previously for a table saw sled. I found that I needed to attach a washer to mate with the mitre gauge T slot, as otherwise the jig wanted to fall ‘backwards’ due to the cantilever effect of the extended length sticking beyond the front edge of my table saw.
I was lucky that my narrow kerf table saw blade cut just the right slot thickness in the stop block to suit the ruler, but instead of using a toggle clamp, I used a brass thread insert and a steel screw to lock the stop block in position – see picture six. However, as shown by the arrow in picture three, the steel screw marked the soft aluminium ruler, so a new stop block was made with a tapped thread into which was fitted a bolt made of nylon. The ‘sticky’ effect of nylon meant that the bolt did not need to be screwed very tighly, and could be just finger tight, so a knob did not need to be fitted to the bolt head.
I made the spline jig pretty well exactly as the YouTube video, and changed the saw blade to one that creates flat bottomed cuts – which are 3.2 mm wide. There is MDF sheet available which is also 3.2 mm thick, so splines were easy to make and fit into place. Picture four shows the first frame I made, from some pine, and the jigs worked very easily and accurately. I set the stop to 10 inches, and the finished frame rebate was exactly ten inches when measured. No tricky calculations needed.
As a safety feature, I may fit a 45 degree ended block to the first jig so that it will cover the saw blade if it comes past the guides.
-- Don, Somerset UK, http://www.donjohnson24.co.uk