Making a Jig for Shaping Curves with Tom McLaughlin

Summary

In this tutorial, Tom McClaflin demonstrates how to create a jig for shaping curved parts, such as the legs of a tall Craftsman-style rocking chair. Using a master pattern, a router table, and toggle clamps, Tom walks through each step to ensure a precise, smooth curve. The jig design involves strategic use of indexing blocks, spacer blocks, and stop blocks to maintain accuracy throughout the shaping process. This technique saves time, reduces cleanup, and ensures high-quality results, making it a valuable tool for woodworkers seeking precision and efficiency.

Takeaways

• 😀 Master patterns are essential for creating accurate jigs that can replicate complex shapes like curved chair legs.
• 😀 Use a solid support board (48" x 13" for this project) to anchor your jig and provide stability during the shaping process.
• 😀 Toggle clamps are used to secure the workpiece in place, ensuring consistent results during routing and shaping.
• 😀 Spacers (16th-inch thick) are important for ensuring accurate alignment and offset during the jig setup process.
• 😀 Start by marking the front and back edges of your master pattern with a pen for better visibility when cutting.
• 😀 Lightly tack the master pattern to the support board with brads or nails to prevent movement during routing.
• 😀 Use a router table to flush-route the edges, allowing the bearing to ride along the master pattern for precise shaping.
• 😀 Attach stop blocks to ensure the workpiece is indexed correctly and remains steady during each cut.
• 😀 Adjust the direction of the router bit to match the grain direction to avoid tear-out, particularly on steep curves.
• 😀 After routing, minimal cleanup should be required, saving time and ensuring high-quality results.
• 😀 The jig allows for repeatable and accurate shaping of curved parts, significantly improving project efficiency and precision.

Q & A

What is the main purpose of the jig described in the video?

The main purpose of the jig is to create a long, curved leg for a tall craftsman-style rocking chair efficiently and accurately, minimizing the amount of cleanup and enhancing the overall project quality.

What materials are needed to build the jig?

To build the jig, you will need a master pattern, a support board (48x13), toggle clamps, indexing blocks, veneer spacers, stop blocks, glue, screws, and an 18-gauge nail gun for quick assembly.

Why is it important to use a pen instead of a pencil for marking the pattern?

A pen is used because its lines are more visible than a pencil's, and it doesn't create a wide line, ensuring more precision when cutting on the bandsaw.

How is the pattern attached to the support board for routing?

The pattern is tacked to the support board with small brads, leaving a slight overhang (about 1/16th of an inch) on the curve. This ensures accurate routing without damaging the pattern.

What role do the spacer blocks play in the jig setup?

The spacer blocks are used to create a 1/16th-inch gap between the pattern and the workpiece, ensuring that when the first cut is made, there is enough material to trim during the second cut without affecting the final dimension.

How does the direction of the router bit affect the quality of the cut?

The router bit's direction is adjusted based on the grain direction of the wood. For instance, when the grain is steep, the router bit must spin counterclockwise to avoid tear-out and achieve a smooth cut.

What is the significance of the toggle clamps in the jig?

The toggle clamps are used to securely hold the workpiece in place against the stop block during routing. Proper adjustment of the clamps is crucial to prevent the workpiece from shifting, which could lead to an imperfect cut.

What should be done before making the second cut on the router table?

Before making the second cut, the jig setup needs to be adjusted to ensure the workpiece is flush with the pattern, and the new indexing blocks are positioned properly to maintain alignment and achieve an accurate cut.

Why is it important to mark the jig with 'first cut' and 'second cut' labels?

Marking the jig with 'first cut' and 'second cut' labels helps avoid confusion during the routing process, ensuring that the correct side of the workpiece is being routed at each stage for accurate duplication of the pattern.

What benefits does using this jig bring to woodworking projects?

Using this jig increases the efficiency and accuracy of shaping curved parts, reduces the amount of cleanup needed, and ensures consistency across all parts, leading to better quality in the finished woodworking project.