Jig Blog #2: Jig for the Ute Box Lid

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Blog entry by robscastle posted 09-04-2015 09:20 AM 779 reads 0 times favorited 4 comments Add to Favorites Watch
« Part 1: a 67.5 degree Jig Part 2 of Jig Blog series Part 3: Another Shaper Dough Nut or is it Donut? »

I wanted to make a curved lid for my “Ute Box” so I spent most of the day perfecting a “Curved Vice/Clamp” jig to do the job,

Backgound: The staved part of the lid has five sections joined by a loose tongue and groove at a joint angle of 10 degrees.

Some years ago I made some stave projects and had a steep learning curve trying to glue them all together, in that case I used a plastic cable drum and ratchet straps.

This time I wanted to use a curved vice or clamp so I set to work with some sophisticated plans drawn in chalk on the garage floor.

I made a prototype with some small identical stave pieces to get a concept of what I needed, they are the items sitting at the front.

The frame held the center stave at zero degrees the the next two were at 10 degrees then 20 degrees at the final pieces

There are three frames duplicated with exactly the same dimensions to hold the lid staves in this case.

I used my drop saw at 10, and 20 deg and cut each block on either end of the timber then moved to the table saw set at 90 deg and a stop block set at the required heights.
I cut up the blocks to the required lengths from the measurenents taken directly from the physical setup.

I used a slot cutter set up in my shaper and a temporary 5 deg table to achieve the T&G alignment

The odd looking staggered ends are for a end piece which will be cut into the top after the glue has set.

Have a look at the small lid to the right I made some years ago this may explain the concept of the odd looking ends.

It all fitted together well and I was pleased with it. Issy Swan would be proud of me!!

Tomorrow it will be tested when I do the glue up, possibly all a bit over the top for a box (no pun intended) but it was enjoyable getting the jig perfected

-- Regards Robert

4 comments so far

View SPalm's profile


5249 posts in 3301 days

#1 posted 09-04-2015 11:53 AM

Good work, looks like fun.


-- -- I'm no rocket surgeon

View JoeinGa's profile


7366 posts in 1426 days

#2 posted 09-04-2015 02:25 PM

Hmmmm… sophisticated plans, 5 degrees, 10 degrees, 20 degrees … I sure hope this works, because I was told

-- Perform A Random Act Of Kindness Today ... Pay It Forward

View Joe Lyddon's profile

Joe Lyddon

9325 posts in 3472 days

#3 posted 09-04-2015 05:24 PM

Very interesting… COOL…

Looks like it should work very nicely!

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: ... My Small Gallery:"

View Boxguy's profile


2122 posts in 1687 days

#4 posted 09-04-2015 07:00 PM

Rob, you are a busy critter. I like the ingenuity of the jig and clamp. I see the problem and like the solution. I’ll be interested in the next step.

My project this week has been a stool for my four-year-old grandson. It uses dadoed slots and plywood. This is pretty much the prototype.

Looking forward to the glue up phase of your project.

-- Big Al in IN

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