Small handle profile jig

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Forum topic by Mike Morris posted 02-23-2009 08:09 AM 1267 views 0 times favorited 2 replies Add to Favorites Watch
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Mike Morris

27 posts in 3386 days

02-23-2009 08:09 AM

Topic tags/keywords: jig router milling question

I’m currently working on a project that calls for some small ebony handles to be made. I’m attempting to come up with the safest & easiest jig to make the 1/4” cove profiles on the router table.

Here’s what I have so far…basically a 1” MDF sandwich made of 2 – 1/2” sheets screwed together with 3/4” #8 woodscrews along with 2 ‘mortises’ to receive the handle blanks. Would use a sacraficial fence on the router table and use my rubber push block to run the jig through the cut.

Would like your opinion on if this is the safest way to route the profiles, or if there’s an easier way of getting the profiles routed without sacraficing safety.

Would also like your opinion if you think I’m 100% off my rocker :)





2 replies so far

View kiwi1969's profile


608 posts in 3436 days

#1 posted 02-23-2009 11:54 AM

looks like it should work but it will need to be a firm fit to stop it rattling inside the jig. If it were me I would just rout it on both sides of a long length of stock and then split it off on the saw, then cut to length before routing the ends using a sled or something as support.

-- if the hand is not working it is not a pure hand

View Mike Morris's profile

Mike Morris

27 posts in 3386 days

#2 posted 02-23-2009 07:01 PM

Kiwi & Dave,

Thanks for the response guys.

I didn’t put the slot dimensions on the drawing, but they’re the same as the 4” x 1” x 1/2” blanks. The intent is for the blanks to fit like a glove in the jig…if not even have the blanks a hair above 1/2” thick to allow the 2 MDF pieces to clamp them in tight once screwed down.

I do like the idea of the toggle clamps, would allow quicker release and prevent the need for jig assembly/dis-assembly for each cut.

Unfortunately my current setup doesn’t allow me to safely route a longer piece of 1” x 1/2” stock. This is my first time working with ebony, so not sure how well it behaves being routed and also want to minimize waste as much as possible.

Dave, to tell you the truth, I can’t remember how I built that handle…it was a while ago, so it doesn’t suprise me that it’s all jacked up…was defintely before going through your Sketchup how-to’s…worked for quite a while via trial and error to get the routed profiles to meshed successfully at their meeting points.

Thanks again for the great advice guys!

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