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Router Pattern Jig - With Plans

Project by Peter O posted 610 days ago 5335 views 61 times favorited 35 comments Add to Favorites Watch

I put this together today. In the past when I’ve used the router to cut a pattern, I’ve either attached the pattern to the workpiece with double-stick tape, or I’ve built an oversize pattern with a toggle clamp so that the pattern becomes a jig. Double-stick isn’t cheap, and can leave gummy stuff, and building a custom jig for every part results in a lot of jigs hanging around never to be used again. I needed to do some pattern routing today, and thought it was time to do it differently!

This jig allows me to clamp the pattern and workpiece together, and the jig can be used for any number of different patterns. The pattern can go above or below the workpiece, depending on which kind of bit I’m using. I put two handles on it for good control, and left the ends open so pattern and workpiece length wouldn’t be restricted. I think it should also work for holding small pieces during routing operations.

The handles, cams, and fence are oak. The baseplate is 1/4” ply and can be replaced when damaged. The jig is 12” long.

[EDIT] Forgot to mention … a series of holes is drilled in the fence to raise and lower the cams so the jig will accept different thicknesses of stock/templates.

—————PLAN ADDED 11/14/2007—————
There seemed to be a lot of interest in this jig, so I’m putting up a few drawings and instructions to help along anyone who decides to build one. You may want to adjust the size of the jig based on the templates you usually use. I tried to duplicate my table saw throat plate and found that my jig was a little too long.

First things first -
Hardware! I’ve had no end of frustration discovering that the hardware I had planned to use for a project was not in my shop and the hardware store was fresh out. For any project – find your hardware first! I used machine screws with wing nuts for the cam pivots and wood screws for assembly.

Construction –
Handles (2): The handles just need to be a place to hold on and they need to set the fence at 90 degrees to the base. A couple of triangles would work, but I like to make my jigs comfortable to hold and use. I’ve found this shape comfortable for my smallish hand:
Handle Diagram
If your hands are largish, you could increase the 3¾” and 4¼” horizontal measurements and the 2.125” radius by ¼” or so. I made my handles out of 3/4” oak, but have used ply and melamine in the past. MDF might work, but I don’t know how well it will hold the screws. If you use wood, the grain should be oriented horizontally. Roundover both sides of the finger hole and the grip area.

Cam levers (1 LH, 1 RH): Cams can be made with an increasing radius, but I just make mine round and drill the pivot hole off-center.
Cam Diagram
The cams on my jig are 3/4” oak, but ply will work fine. Melamine and MDF are not up to this task! Wood grain should be oriented along the length of the cam lever. Drill the pivot hole so the bolt fits snug – too much slop and the cams won’t stay tight against the workpiece. Countersink the hole for the bolt head. When countersinking, the hole should be right of center for one cam and left of center for the other cam – this will give you one RH and one LH cam.

Fence: I used 1/2” oak, but ply or melamine should be fine.
Fence Diagram
Again, drill the holes so the bolts will fit snug. By staggering the holes, you get a pretty fine adjustment for just about any thickness of material.

Base: 8” x 12” x 1/4” ply. This base plate is sacraficial – it will get cut up and chewed up as you use the jig. When it isn’t providing the necessary support any more, just cut another one.

Assembly -
Handles to Fence: Clamp the handles against the fence one inch from each end of the fence. Drill and countersink two holes through the fence into each handle and insert the woodscrews (see diagram below).

Fence to Base: Turn the base plate upside down and set the handle/fence assembly on the inverted base. Trace the outline of the handle/fence assembly onto the bottom of the base. Turn the base over and clamp the handle/fence assembly to the base. Using the lines you just traced, locate and countersink one hole into each handle and two holes into the fence taking care to avoid the screws that are holding the handles to the fence.
Screw Location Diagram

Cams to Fence: Pass the machine screws through the cams and through the fence, and secure them with the wing nuts. By switching the cams from side to side, you can make them tighten either by lifting by pressing down the handles.

I hope this is clear, but if you have any questions, please feel free to ask.

-- http://www.north40custom.com -- http://north40studios.etsy.com --


35 comments so far

View David's profile

David

1972 posts in 889 days


posted 610 days ago

Peter -

Very nice! Great design.

-- http://foldingrule.blogspot.com

View Max's profile

Max

11235 posts in 1024 days


posted 610 days ago

That is pretty slick. I like it….

-- Max "Desperado", Salt Lake City, UT

View ChrisBabayco's profile

ChrisBabayco

64 posts in 678 days


posted 609 days ago

That is a great jig! Definitely something to remember.

View Thos. Angle's profile

Thos. Angle

3949 posts in 713 days


posted 609 days ago

Great Idea, Peter, I’ve been meaning to build one of these and didn’t know quite how I wanted it. This looks like a good solution. Thanks. It makes getting those arch top doors done easier and quicker than the tape. Not to mention easier to register each time.

-- Thos. Angle

View CharlieM1958's profile

CharlieM1958

6674 posts in 969 days


posted 609 days ago

Nice jig. I may have to steal that one.

-- Charlie M. "Woodworking - patience = firewood"

View mot's profile

mot

4892 posts in 787 days


posted 609 days ago

Yup…gonna have to add this one to my list! Nice

-- You can discover more about a person in an hour of play than in a year of conversation. (Plato)

View dennis mitchell's profile (online now)

dennis mitchell

3703 posts in 1065 days


posted 609 days ago

Thanks for the edit…nice jig!

-- http://www.woodsongsfurniture.com

View Mark Mazzo's profile

Mark Mazzo

329 posts in 663 days


posted 609 days ago

Peter,

Great idea for this jig. I remember seeing an older video of Frank Klaus doing tenons with a jig on the table saw where he had cams as clamping mechanisms on the jig. Great solution to the pricey double-stick tape.

-- Mark, Webster New York, Visit my website at http://thecraftsmanspath.com

View cckeele's profile

cckeele

76 posts in 623 days


posted 609 days ago

Very well executed. Definately looks like it will give you very good control over the workpiece and still remain safe. Job well done sir.

-- All donations should be made out to me and in the form of wood or tools ~Chris

View USCJeff's profile

USCJeff

864 posts in 819 days


posted 609 days ago

Love it, I use a similar jig for bandsawing with a template. I always have to clean it up with a router, so maybe your jig will do both at the same time. Worth a shot. Nicely done.

-- Jeff, South Carolina

View Todd A. Clippinger's profile

Todd A. Clippinger

4942 posts in 850 days


posted 609 days ago

That looks like a great jig. Nice looking and added safety, another sign you are an “American Craftsman.”

-- Todd A. Clippinger, Montana, http://amcraftsman.com

View Andy's profile

Andy

443 posts in 659 days


posted 608 days ago

Great idea,will need to make one for a project I will be doing soon.

-- " If I can make it,so can you" ANDY

View cajunpen's profile

cajunpen

5952 posts in 816 days


posted 598 days ago

Great idea – thanks for sharing it.

-- Bill - "Suit yourself and let the rest be pleased." http://www.cajunpen.com/

View jerryw's profile

jerryw

74 posts in 667 days


posted 597 days ago

Thanks for adding the plans. I had already made one of the jigs to use on my router tables. it worked great first time and every time. Thanks again for sharing with us.

-- jerryw-wva.

View Dick, & Barb Cain's profile

Dick, & Barb Cain

6380 posts in 1050 days


posted 597 days ago

Thanks for sharing a great jig!!

-- -** You are never to old to set another goal or to dream a new dream ****************** Dick, & Barb Cain, Hibbing, MN. http://www.woodcarvingillustrated.com/gallery/member.php?uid=3627&protype=1

View Douglas Bordner's profile

Douglas Bordner

3314 posts in 814 days


posted 597 days ago

Very conscientious of you to add the plan and notify of the update, Peter. Thanks for posting this, now I have no excuse not to gin one up. ;^D

-- "Bordnerizing" perfectly good lumber for over a decade.

View bryano's profile

bryano

544 posts in 684 days


posted 597 days ago

Im with Douglas. will build one this weekend.

-- bryano

View porrapai's profile

porrapai

10 posts in 633 days


posted 590 days ago

Peter

Great Idea.
Some of us aren’t selfish. Thanks for sharing.
I like the clear way you have made your statement.
Carlos Castanheira
porrapai
porrapai@gmail.com
South Africa

-- carlos castanheira, South Africa

View shaun's profile

shaun

361 posts in 656 days


posted 590 days ago

Oh ya, this is getting added to the “to do” list. Thanks for sharing Peter.

-- I've cut that board three times and it's still too short!

View Bob #2's profile

Bob #2

2663 posts in 772 days


posted 590 days ago

Good one Peter.
One jig for several tasks is really getting important around here.
I’ll make one up shortly.
Thanks

Bob

-- A mind, like a home, is furnished by its owner

View MsDebbieP's profile

MsDebbieP

13433 posts in 911 days


posted 590 days ago

There has been lot of talk about jigs lately and, not ever having seen one or used one, I’m sure there are tips and tricks to process behind the finished product and to using them.
This would be a great blog discussion as a resource for people like me with limited skills/experience.

-- "Functional WoodArt" by Debbie, Canada (http://www.execulink.com/~yohan)

View LJ's profile

LJ

92 posts in 818 days


posted 575 days ago

Peter, A nicely designed jig. I’m not bashful… I’ll make it and put it to plenty good use. Thanks for sharing!

-- Peace, LJ http://beam.to/4goldens.org

View Karson's profile

Karson

21154 posts in 1151 days


posted 575 days ago

Great Jig Peter. Nice design and thanks for posting this.

-- Karson Southern Delaware karson_morrison@bigfoot.com †

View Hawgnutz's profile

Hawgnutz

518 posts in 827 days


posted 575 days ago

Very nice jig, Peter! I will have to make one for my pattern routing. I get tired of peeling (sometimes) the double-sided tape and fionding it left a sticky residue behind.

Another jig on my to-do-list!

God Bless,
Hawg

-- Saving barnwood from the scrapyards

View gbvinc's profile

gbvinc

493 posts in 697 days


posted 575 days ago

Nice Peter. Thanks!

View Jiri Parkman's profile

Jiri Parkman

599 posts in 563 days


posted 541 days ago

Very nice jig. Enjoy it.

-- Jiri

View Dusty56's profile

Dusty56

2769 posts in 439 days


posted 347 days ago

Any more tune ups to the jig since you posted it last ? Looks like a great idea : ) thank you very much !

-- You know you're getting old when you know the difference between you're (you are) and your (belongs to you) AND how to use them in a sentence .

View jeanmarc's profile

jeanmarc

1750 posts in 467 days


posted 335 days ago

Great Idea..Nice jig.

-- jeanmarc manosque france

View Peter O's profile

Peter O

982 posts in 625 days


posted 300 days ago

Hey, Dusty – one change I would recommend: make the diameter of the cams larger. Leave the pivot hole about ½” off-center, but make the radius of the cam more like 2”. My cams tended to loosen up at the 1” radius, but no problem at the larger radius.

-- http://www.north40custom.com -- http://north40studios.etsy.com --

View mleedix's profile

mleedix

54 posts in 301 days


posted 290 days ago

Very nice Jig. Thanks for sharing.

-- - Michael [..for God's glory." 2 Cor. 10:31] Over 300000 species of trees, yet we take the credit for their beauty...

View tooldad's profile

tooldad

355 posts in 466 days


posted 157 days ago

Thanks for the plans. This jig is not only functional but safer. We build adirondack chairs as a mass production unit in our general shop class. we use the router to make the legs and arms from a pattern. This will increase the safety aspect of that operation. Thanks again.

View John Gray's profile

John Gray

1424 posts in 636 days


posted 157 days ago

THANKS, I favorited it.

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

View cabinetmaster's profile

cabinetmaster

4474 posts in 309 days


posted 139 days ago

Thanks for the plans. I needed of these.

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

View Chris's profile

Chris

292 posts in 108 days


posted 101 days ago

I just tripped over this because of your post on the ‘jigs’ thread. I absolutely need this jig and didn’t even know it. I’ve been doing the double sided tape thing and grumbling. The benefit of that post is that I’ve found this jig, need it, but never would have been looking for it (maybe not never, but I can grumble for a long time!).

-- Chris

View PurpLev's profile

PurpLev

1775 posts in 399 days


posted 101 days ago

Splendid Jig indeed! thanks for the post. one thing that is possible to do, is maybe set some tracks on the base of the jig to allow for the fence to move back/forth? which will accomodate different depths of patterns? (or one could make a couple of those with common depth fences I guess) – just an idea. something similar to the holes you setup for the holddown clamps – but on the base for the fence to be attached with.

-- When in doubt - There is no doubt - Go the safer route.

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