Corner Radius Jig II: Now Adjustable

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Project by NiteWalker posted 467 days ago 3316 views 38 times favorited 10 comments Add to Favorites Watch

Back when woodpecker made their one-time tool quick radius jigs, I knew this was something that would get a lot of use in my shop, so I made my own. There were two limitations I wanted to overcome with that design though; only two radii per jig could be used, and because of the required positioning of the stops, the jig wasn’t really suitable for pattern (top bearing) routing unless the two unused stops were removed.

So back to the drawing board for designing a more versatile radius jig. On my old jig (which did get used a TON), I liked the size, finger hole and stops, so I repeated those, only using 3/4” baltic birch plywood this time instead of 1/2” and 3/8” polycarbonate for the stops instead of 1/4”. I also lengthened the stops by 1/2”.

The big change, though, is how the stops attach. Instead of just screwing the stops to the jig body with screws, I drilled and tapped 1/4-20 threads in two holes on each side of the jig body and through holes in the stops. Small thumb screws are used to attach the stops in the proper locations to use the desired radius. I chose the 4 most used in my shop, but could easily make another if needed.

Using the jig is identical to the old one; with the jig placed on top of the workpiece whose corners need to be rounded, I set up a flush trim bit at the router table so the bearing rides along the jig body. The finger hole in the jig is for holding the jig in place while routing.

Based on how much use my old non-adjustable jig got, I can already tell this one will be used even more.

-- He who dies with the most tools... dies with the emptiest wallet.

10 comments so far

View cabmaker's profile


1305 posts in 1434 days

#1 posted 467 days ago

I like !

View Dutchy's profile


456 posts in 794 days

#2 posted 467 days ago

Thank you for sharing. Nice jig.

-- My englisch is bad but how is your dutch?

View DIYaholic's profile


13259 posts in 1300 days

#3 posted 467 days ago

Need I say more!!!

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procratination a bad thing?

View sras's profile


3813 posts in 1754 days

#4 posted 467 days ago

Same for me Randy! Great idea!!

-- Steve - Impatience is Expensive

View oldnovice's profile


3684 posts in 1993 days

#5 posted 467 days ago

Makes a lot more sense which just proves that the mind is a very powerful tool.

I thought about buying that Rocker version but now I’m glad I didn’t as this one is better and more versitile. Thank you for your insight and sharing this project!

-- "I never met a board I didn't like!"

View lew's profile


9991 posts in 2380 days

#6 posted 467 days ago


-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View NiteWalker's profile


2709 posts in 1202 days

#7 posted 466 days ago

Thanks guys. It only took a couple of hours to make, most of which was spent on layout.
It’s getting plenty of use.

-- He who dies with the most tools... dies with the emptiest wallet.

View thelt's profile


618 posts in 2005 days

#8 posted 466 days ago

You better patent your idea. if not it won’t be long before Rockler and Woodpecker start mass producing them for retail sale. It is a wonderful idea and I’m going to build oone for my shop. The only good thing is we can make our own for a lot less money than what they will sell them for.

-- When asked what I did to make life worthwhile in my lifetime....I can respond with a great deal of pride and satisfaction, "I served a career in the United States Navy."

View majuvla's profile


3305 posts in 1493 days

#9 posted 466 days ago

Simple and brilliant

-- Ivan, Croatia, Wooddicted

View NiteWalker's profile


2709 posts in 1202 days

#10 posted 465 days ago

thelt, I’d love to, but don’t have much experience in doing so. So far searches have led to a “non-provisional” application?

-- He who dies with the most tools... dies with the emptiest wallet.

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