|Project by DeLayne Peck||posted 10-27-2012 11:05 PM||5400 views||22 times favorited||22 comments|
An Exact-Width Dado Router Jig is a great addition to any shop. The Wood Whisperer presents the jig in this video: Click Here. The variation on this jig that I like works without guide bushings. And, it worked beautifully when I recently dadoed T-Track into my new drill press table.
But, a jig that limits you to a one router and one bit combination strikes me as a problem. Why build a one trick pony? You use a mid-size router and a 1/2” bit for a 3/4” dado. OK, but later you want to use a compact router to mate a dado to thin stock using a smaller bit? Or for veining or other decorative cuts?
No can do.
The Solution: Make the fiber board insert easy to remove and replace with other widths. I simply cut a 1/4” deep, 1/2” wide rabbit into the interior edge of each of the two guide rails before final assembly.
The result: A slot or receiver for the replaceable fiber board inserts. A couple of small wood screws hold the insert on each side.
Want to the change router and bit combination? Lift four screw. Pull your old inserts. Cut new inserts, width: 1/2” (rabbit) + distance from the edge of the router base to the bit + 1/8” (trim off). Insert and secure your new inserts. Trim both sides with the bit of your choice. You are ready to bingo a dado!
Picture 1: Top View.
Picture 2: Underside.
-- DJ Peck, Lincoln Nebraska. Lord, keep your arm around my shoulder and your hand over my mouth.