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Zero Clearance Router Table Miter Spline Jig

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Project by PaulfromVictor posted 1802 days ago 9125 views 13 times favorited 14 comments Add to Favorites Watch

...that’s a mouthful.

So, as I am in the shop working on this my wife comes in and asks, “what are you making?” To which I reply, “Do you really want to know?”. She said “Yes” So, I told her I was making a router table miter spline jig. Her response was a 10 second silent pause as she did her impression of a deer caught in headlights. Then she proceeded to talk to me about what she really wanted to talk about.

Someday I may find the inspiration to start an “Andybox”. When I do, I will use this. I did this as a router table jig instead of a table saw jig for a couple of reasons. First, I do not have a flat grind sawblade, only ATB. Second, using this with a slot cutting bit set I will be able to make spline of various thicknesses, including smaller than 1/8”.

The jig is made out of all MDF. The base is two thicknesses (1.5”) . The right angle portion is made out of 1/2” paper coated MDF (because I had plenty of scrap of this). These pieces are replaceable. I made a batch of 8 of them to last me for a while. Also, the 45 degree bevel is cut on each end, so after one end is used, you can swap sides and have a fresh end for a new zero clearance. The replaceable pieces are attached with quarter inch bolts and phenolic knobs. A quarter inch grove is cut into the pieces that runs almost the full length of the piece so they can be adjusted as needed. An additional grove of a half an inch is cut over the top of that groove as a counter sink for the bolt head.

There are a couple of downsides I see to this jig. One is that the height of the slot cutting bit will limit how far up a box a slot can be made. The other issue is that it will be neccessary to slide the removable pieces out to capture the bit, then adjust them in to cut out for the zero clearance.

Next time I make replacements for the disposable part, I will make them taller, so I can put two sets of grooves, and they can be flipped for a second cut, and then switched to the other side for two more cuts. 20/20 hinsight.





14 comments so far

View papadan's profile

papadan

1125 posts in 1993 days


#1 posted 1802 days ago

Jig looks well made. I just don’t understand what you do with it. I need a picture of a splined miter from the jig. LOL

-- Carpenter assembles with hands, Designer builds with brains, Artist creates with heart!

View bobthebuilder647's profile

bobthebuilder647

128 posts in 1877 days


#2 posted 1802 days ago

Nice jig. I never thought of doing this on a router.

-- Rick, Pa. Courage is what it takes to stand up and speak; courage is also what it takes to sit down and listen.

View a1Jim's profile

a1Jim

112008 posts in 2201 days


#3 posted 1802 days ago

Cool Idea how about some photos of how well it works.

-- http://artisticwoodstudio.com Custom furniture

View cabinetmaster's profile

cabinetmaster

10874 posts in 2182 days


#4 posted 1802 days ago

Great idea. I had never thought of that either. Great thought about the 20/20 hindsight.

-- Jerry--A man can never have enough tools or clamps

View dustyal's profile

dustyal

1196 posts in 2099 days


#5 posted 1802 days ago

I was wondering if someone had a router jig for spline miters. I made a jig for my table saw and it worked, but I really want to use the router since it is quieter and cleaner than my table saw. I do not have a flat top blade for the TS and it shows. Don’t intend to buy blades until I get a new TS.

Nicely done… but I can already see that this jig might get a bit complicated for me.

I didn’t think to go with a slot cutter… I kept thinking straight bit. I had what was an unusual sized bit… a 1/2” shank, 5/32” bit. I broke it… can’t find a replacement. In looking… didn’t see anything smaller than a 1/4” straight bit… but now that you made me look, I see the smaller slot bits. Not important… just drifting off there for a moment.

Thanks for posting.

-- Al H. - small shop, small projects...

View PaulfromVictor's profile

PaulfromVictor

220 posts in 1970 days


#6 posted 1802 days ago

I don’t have anything milled up for current projects just yet. It will probably be a couple weeks till I have a chance to try it out.

You could make a vertical form of this jig for traditional router bits and dovetail bits (for Dovetail Keys). Straight router bits would be a bit thick for most applications though.

View PaulfromVictor's profile

PaulfromVictor

220 posts in 1970 days


#7 posted 1802 days ago

One thing that may not be clear in the photo is that the part clamped to the fence has a portion hollowed to make room for the spinning arbor of the slot cutter.

View papadan's profile

papadan

1125 posts in 1993 days


#8 posted 1802 days ago

OK, now I understand what you do with it. I was thinking of the bit coming up into the wood, didn’t catch the slot cutter part.

-- Carpenter assembles with hands, Designer builds with brains, Artist creates with heart!

View Innovator's profile

Innovator

3584 posts in 2038 days


#9 posted 1802 days ago

Nice looking jig, it looks great.

-- Whether You Think You Can or You Think You Can't, YOU ARE RIGHT!!!

View Splinterman's profile

Splinterman

23058 posts in 1985 days


#10 posted 1802 days ago

Sweet jig…...good job.

View blockhead's profile

blockhead

1451 posts in 1933 days


#11 posted 1793 days ago

Now that’s a sweet jig! Great job!

-- Brad, Oregon- The things that come to those who wait, may be the things left by those who got there first.

View Rich99's profile

Rich99

60 posts in 1796 days


#12 posted 1778 days ago

looks great, paul, but i just can’t visualize how it works.

so the bit is partly buried in that block that’s clamped to the fence? and the workpiece sits right in the ‘v’?

you’re putting the spline across the miter?

yeah, i really don’t get it. but it looks good… see my sander-mounted chamfer jig… my first attempt at an original jig.

-- Far-North Wood-Works (a fantasy company)

View PaulfromVictor's profile

PaulfromVictor

220 posts in 1970 days


#13 posted 1777 days ago

It is used with a slot cutting bit. The blade spins on a plane parallel to the table. A traditional bit will not work because it is vertical. The spline goes accross the miter

A picture of a slot cutter might help visualize. Here is one on Amazon:

http://www.amazon.com/Freud-63-154-64-Inch-Cutter-16-Inch/dp/B0002TUD06/ref=sr_1_8?ie=UTF8&s=industrial&qid=1254960714&sr=8-8

View Blackie_'s profile

Blackie_

3374 posts in 1137 days


#14 posted 497 days ago

I’ve been wanting to do 1/4 splines as I already have a thick kerf flat bottom 1/8 TS blade so this would work great and I see you’ve already touched on the spline placement limit, Andy mentioned a spiral bit so I’m assuming the box would ride the router table as does a TS thus giving you more flexibility on placement, I don’t have a spiral in my inventory but I do have slot cutter. Nice jig.

-- Randy - If I'm not on LJ's then I'm making Saw Dust. Please feel free to visit my store location at http://www.facebook.com/randy.blackstock.custom.wood.designs

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