%!$ Easy Diy Woodworking Bench Plans For You #!@

keyhole-router-jig-yield Download PDF. Remove the spacer for the second pass. Measure the maximum width, length, and thickness of the slab. For more related content, subscribe to our newsletter! Become A Member.

Also, initially make the rails about 3" oversized in length. Mark the ends of the mortises on the edges of the rails.

Lay out the center mortise Sign Router Jig Yield for a tight fit, but provide extra space on both ends of the outermost mortises. Next, outfit your router with an upcut spiral bit and edge guide. I use a dial caliper to check the offset between the face of the stock and the mortise wall. Now, leaving the edge guide setting as is, adjust the depth of cut for the haunch groove, and rout it out between the mortises.

Mill four pieces of straight-grained stock to about 2" wide and a few inches longer than the width of your panel. Most importantly, joint the edges absolutely straight. Crosscut each excess section of rail into two, and tack each half between the ends of a pair of fences, as shown in Photo B. Afterward, use a square to Keyhole Router Jig Analysis check the fence edges for parallelism. Run the assembly over a jointer if needed to square the edges and bring them into perfect alignment.

This is important to ensure tight rail contact at the shoulders of the joint. Now mark the tenon shoulders fully across one face of the panel using a sharp pencil, and install a wide straight bit in your router. Make the cuts on a piece of scrap the same thickness as your panel, and test the fit in a mortise. Secure the panel to a couple of risers on your benchtop. Clamp the fences in place, offsetting them from the tenon shoulder line a distance equal to the offset between the edge of your router sub-base and the perimeter of your bit.

Make the cuts as shown in Photo C. The most efficient approach is to use spacers whose width equals the diameter of your router bit.

For longer tenons, use more spacers. After routing, lay the individual tenons out to width; then use a jigsaw to cut out the haunched area between them. Round the edges of the tenons to approximately match the ends of the mortises Photo D.

Now adjust the tenons to fit. For this I use a shoulder plane Photo E , but you can also use sandpaper wrapped around a hardwood block. Remember to remove the same amount from each face to keep Router Table Finger Joint Jig Yield the rail centered across the thickness of the panel. Mark out the dowel hole locations on the undersides of the rails, and clamp them in place.

To do this, I crosscut two stout clamping cauls of identical width to a length about 8" longer than my panel width. The cantilevered ends of the cauls keep the clamps from interfering with the edge guide when routing. Set up a router edge guide to align the bit with the dowel hole locations. Then set the plunge depth to bore through the rail and the tenon, stopping short of creating a through hole unless you want the look of exposed pegs on the top of the panel assembly.

Now plunge the holes into the underside of the panel, as shown in Photo F. Remove the rail, adjust your edge guide, and then widen the outermost holes into slots Photo G. Pare small chamfers at the ends of the joint, where shown in Figure 1. Assemble the parts, gluing only the centermost 6" or so of the joint, and glue short dowels into the holes. After the glue dries, saw and pare the dowels flush to the surface, and then plane or sand both faces of the panel assembly to flush up any discrepancies.

You must be logged in to write a comment. Log In. Find a Store. My Account. My Cart. Go to Home Page. Mobile Navigation. Same Day Shipping Find a Store. Search Go. Topics Cabinetry. Choosing Hardware. Dust Collection. Friends of Woodcraft. I also used a countersink bit so my screw heads would be flush. I again drilled countersunk pilot holes and applied some glue. This jig is truly so simple but makes keyholes so easy! Not only does it help guide your router, but more importantly it allows you to make multiple keyholes at the exact same distance from the top of your work piece, which means your frames will hang level every time.

Tip : You don't need a plunge router with this jig. Simply press the router base against the bottom edge of the jig and push the router straight down into the work piece until your base sits flush on the surface. Then slide the router all the way up and back down again before pulling out the bit. Perfect keyholes every time. Or head Keyhole Router Jig Code over to diymontreal.

Introduction: Keyhole Router Bit Jig. More by the author:. I post how-to videos on my YouTube channel, as well as step-by-step tutorials on my website www. Builds include mainly woodshop project… More About diymontreal ».

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