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Auxiliary Fence

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Project by Lenny posted 11-12-2009 01:41 AM 6059 views 15 times favorited 26 comments Add to Favorites Watch
Auxiliary Fence
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Apparently I am in a table saw accessories mode. I recently completed a thin strip ripping jig and then moved on to this auxiliary fence for making rabbets on one side and for use with tall pieces (cutting a bevel on the underside of a tabletop for example) on the other. I got the idea for this on a Woodsmith Shop show. The auxiliary fence is made to snugly fit over my existing TS fence. As you can see from the end view, a notch was needed to allow use of the fence’s lock knob. The material is a phenolic covered plywood purchased from Woodcraft. It has a thin phenolic resin on both sides and ends up at a full 3/4”. It is sold in a 2’X4’ sheet for $60. I bought it on sale at 10% off. It is flat, straight and perhaps most importantly, smooth. It took just under one full sheet to make this accessory.

The first picture shows the contstruction. It’s essentially a short fence for rabbets, a cross piece or saddle, a second cross piece to support taller side, the taller side and a “gusset” on each end that is notched over the locking mechanism. I used Titebond melamine glue and countersunk screws to put it together:

This photo shows the rabbet side before I made the first cut. I drew a line 1/2” above the table:

This is after I made the cut which is just shy of the full 3/4” thickness:

So now it was time to cut my first rabbet. I took a piece of “3/4 inch” plywood. I placed the ply on top of the dado blades and brought the fence over until the outside tooth was even with the outside edge of the ply:

Here’s the end result, a 1/2” deep rabbet that fits the 23/32” ply perfectly:

I haven’t actually made a cut using the other side but here is a photo of how it would work. The stock would rest against the tall fence and be safely pushed through the blade. The stock shown in this photo is a bit too narrow for my liking but you get the idea:

I expect to get lots of good use out of this. I”ve had the table saw for 6 months now and can finally make rabbets on it. That should be a lot faster than the router table in many applications.

-- On the eighth day God was back in His woodworking shop! Lenny, East Providence, RI





26 comments so far

View blockhead's profile

blockhead

1455 posts in 2054 days


#1 posted 11-12-2009 01:53 AM

Great job Lenny! That will be a very useful addition to your shop.

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

View Dadzor's profile

Dadzor

57 posts in 1865 days


#2 posted 11-12-2009 02:07 AM

Great fence, Lenny.

Not only does it look great, but it will make end cuts on longer stock much safer.

Very impressive.

Matt

-- You don't have to burn books to destroy a culture; just get people to stop reading them. -- Ray Bradbury

View John Gray's profile

John Gray

2370 posts in 2631 days


#3 posted 11-12-2009 02:13 AM

Nice job Lenny. I’m jealous…..I want plywood walls in my shop. 8-)

-- Only the Shadow knows....................

View Beginningwoodworker's profile

Beginningwoodworker

13347 posts in 2419 days


#4 posted 11-12-2009 03:06 AM

Great job, Lenny.

-- CJIII Future cabinetmaker

View Napaman's profile

Napaman

5365 posts in 2823 days


#5 posted 11-12-2009 03:23 AM

i dont care how it works…it just looks awesome!!!

so…when is retirment>>>getting clooooose???

-- Matt--Proud LJ since 2007

View Lenny's profile

Lenny

1295 posts in 2273 days


#6 posted 11-12-2009 03:29 AM

Thanks guys. John, it’s T-111 on the walls. I usually find at least one stud but it makes it nice to hang things even when no stud is near. Napaman, how are you doing? Thanks for asking about the retirement date. I will answer that question anytime: 8 months and 18 days…but who’s counting?

-- On the eighth day God was back in His woodworking shop! Lenny, East Providence, RI

View Dusty56's profile

Dusty56

11684 posts in 2434 days


#7 posted 11-12-2009 03:33 AM

Excellent job on the fence , Lenny….how much are you loving that Powermatic ?

-- I'm absolutely positive that I couldn't be more uncertain!

View RickL's profile

RickL

245 posts in 2686 days


#8 posted 11-12-2009 03:37 AM

Lenny, looks great, and almost too good to use :) Good Job, Rick (152 working days not counting weekends, holidays, and 6 weeks vacation I have to use up in 6 months)

-- Rick, Union,KY firstlightwoodworking.blogspot.com

View Lenny's profile

Lenny

1295 posts in 2273 days


#9 posted 11-12-2009 03:45 AM

Thanks Dusty. I love the saw so much I am adorning it with all these accessories! Again, I have nothing to compare it to as it is my first (and last) TS but it’s awesome! Makes woodworking even more enjoyable than it has been for nearly 30 years. Heck, I have a picture of it as my desktop on the computer! That’s fine but it replaced a picture of my wife! Just kidding. Thanks Rick. Gotta love that Woodcraft green huh? It appears you are even closer to “release” than me. Good for you!

-- On the eighth day God was back in His woodworking shop! Lenny, East Providence, RI

View Dusty56's profile

Dusty56

11684 posts in 2434 days


#10 posted 11-12-2009 03:56 AM

Good for you …glad to see that you’re enjoying your hobby , now get the wifes’ pic back on your screen before you get caught ! LOL

-- I'm absolutely positive that I couldn't be more uncertain!

View Roz's profile

Roz

1661 posts in 2532 days


#11 posted 11-12-2009 04:37 AM

I LIKE IT! The green color is especially cool. The high face looks like a real safety improvement. Well, I got to go. I have to go make a new fence for my saw.

-- Terry Roswell, L.A. (Lower Alabama) "Life is what happens to you when you are making other plans."

View ChunkyC's profile

ChunkyC

856 posts in 2000 days


#12 posted 11-12-2009 05:20 AM

That’s nice! I have one two but it never crossed my mind to add a tall fence to the other side. I like yours much better.

-- Chunk's Workshop pictures: http://spadfest.rcspads.com/thumbnails.php?album=135

View Karson's profile

Karson

34912 posts in 3146 days


#13 posted 11-12-2009 05:23 AM

Nice looking jig. They are very handy.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware karson_morrison@bigfoot.com †

View blackcherry's profile

blackcherry

3201 posts in 2569 days


#14 posted 11-12-2009 05:41 AM

Great looking jig Lenny, it will do wonderful panel for cabinet doors. Enjoy and stay safe and Congrat on signing V-Mart he’s a class act.

View a1Jim's profile

a1Jim

112828 posts in 2323 days


#15 posted 11-12-2009 07:32 AM

nice work on the fence

-- http://artisticwoodstudio.com Custom furniture

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