Corner Radius Jig II: Now Adjustable

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Project by NiteWalker posted 05-11-2013 02:53 AM 5211 views 45 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


1402 posts in 1895 days

#1 posted 05-11-2013 02:58 AM

I like !

View Dutchy's profile


1262 posts in 1254 days

#2 posted 05-11-2013 05:43 AM

Thank you for sharing. Nice jig.

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

View DIYaholic's profile


18001 posts in 1761 days

#3 posted 05-11-2013 02:34 PM

Need I say more!!!

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

View sras's profile


4264 posts in 2215 days

#4 posted 05-11-2013 03:57 PM

Same for me Randy! Great idea!!

-- Steve - Impatience is Expensive

View oldnovice's profile


4641 posts in 2454 days

#5 posted 05-11-2013 05:07 PM

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


10691 posts in 2841 days

#6 posted 05-11-2013 05:20 PM


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

View NiteWalker's profile


2728 posts in 1663 days

#7 posted 05-11-2013 07:28 PM

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


640 posts in 2465 days

#8 posted 05-12-2013 11:15 AM

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


5749 posts in 1953 days

#9 posted 05-12-2013 04:26 PM

Simple and brilliant

-- Ivan, Croatia, Wooddicted

View NiteWalker's profile


2728 posts in 1663 days

#10 posted 05-12-2013 10:53 PM

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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