|Project by KevinH||posted 02-05-2012 12:51 AM||7844 views||41 times favorited||23 comments|
I have been struggling with getting the mitered corners for a keepsake box dialed in just right, especially since I was having to adjust my saw to a 45-degree bevel cut with each attempt. I’d like to make several of the same box, so I figured a jig would save some aggravation.
All of the miter jigs I’ve seen cut the 45 with the angle measured horizontally from the plane of the blade. The sides of my boxes will be 3 1/2 inches high, or so. My 10-inch TS blade doesn’t have enough depth of cut for that, so I designed a jig with the angle set 45 degrees measured off the vertically from plane of the blade. I plan to use this jig for boxes that have sides between 6 and 15 inches long, maybe a little longer, and perhaps up to an inch wide. The jig as built will handle box sides that will be up to 10 inches deep when completed – far deeper than I plan to use right now. I added a stop in the form of a board with a 45 bevel on the left side of the bed of the jig as seen in the 2nd photo.
To use the sled, I crosscut the box side to length, plus about 3/32”. Then I slide it into the jig, bottoming out against the stop. Before I make the cut, I hold the piece in place with a speed clamp. My hands are then free to push the jig at the ends of the jig, well away from the blade.
The jig is made from materials I had on hand: 1/2” baltic birch plywood, scrap 4/4 red oak, glue and screws.
The angle is not yet exactly 45-degrees from verticle. It’s just a bit wide of that measurement, so the corners have a gap on the outside. I will experiement with several thicknesses of index cards at the top of the jig to get it dialed in just right.
Any comments, suggestions or cautions are appreciated.
-- Timing has a lot to do with the outcome of a rain dance. --Kevin in Happy Valley