Jig-a-Long

[Crooked Stic]

I come up with an accent idea a few years back that has a few curves in it and worked on getting the patterns perfect from time to time. It turned out to be a real b---- to get perfect. So i set it back. There is a regular on another site that has a CNC machine that was kind enough to cut my patterns out for me.
I use plexiglass on the bottom of the jigs that rubs on the guide wheel.
I laminate (glue and screw)two pieces of 3/4 MDF together for the jig base. That hiegth gets me on the flat part of the sanding drum.
 
Here are the pattern pieces on the base. Dril several holes and countersink so the screw head are past flush. Center them up and put in the screws. When drilling the plex go slow. it catches bad when breaking thru. Do not over tighten onto the plexi.My drill has different settins. It was on 7 slip clutch setting.
 
Ready for screws.
 
Now bandsaw within about 1/8 of the plexi.
 
Now run it on a table router or hand router with a pattern bit.
 

MORE TO COME

[tenbrook]

Keep it comin'

Thanks!

[T Folts]

Mike, Looks good. I have a question. When you have the pattern made do you take in account for the width of accent you are going to use. Im thinking if they are a perfect match then if you add 1/4 of a inch in accents it would be off a bit. This is where I am have a difficult time wrapping my mind around making my jigs.

[Crooked Stic]

Well T I had a 1/4 in. taken out on this project thinking I could put back in a 1/4 in. and be good. Not so on this radical of curves. Too many. I am thinking maybe if you cut the actual riser block it may work. Could be a stack of tolerances between the actual cut and my work that threw it off    
Anyhow it is gonna take some major tweaking to get this to fit up good. I probably needed to stay with more gradual curves here.
Anyhow I will post pics of the rest of the jig build. I would say stay with some circles and save yourself headaches.
 Cant get Photobucket to resize. Back later.

[Buemaker]

Best of luck, this kind of stuff can drive a poor soul nuts. Bue--.

[Crooked Stic]

Ok I will go thru the rest of the jig build.I was so sure this was going to work that I used the riser block right off. I should have started with a 2x4 first.    Ok figure out where you want your accent to be in the riser block. Then place the back stops accordingly.
 
You will want them to be shorter than the riser block to prevent hold down interferance. I put two hold down spacers behind the backstops about the same hiegth as the block I use potty hold down studs 1/4. with wingnuts. 1/2 plywood hold downs. You can put sticky back 80 grit on the riser block end for extra holding.
 
 
Now mount each jig part on center and mark and bandsaw between the lines.
 
Remount to jig and run on profile sander untill piecs are down to even with jig. You dont have to take it all in one pass. I make a few quick passes at the end to smooth it out.
 
 There you have it. Use a less radical design than mine cause this one aint fitting good at all. This is the first time for me to get this crazy. Keep it simple    :rolleyes:

[tenbrook]

Good deal Mike.  Thanks for the info!