Pergola #5: After a long delay, back on the job...

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Blog entry by Bermuda_Les posted 04-20-2015 12:13 PM 1478 reads 0 times favorited 2 comments Add to Favorites Watch
« Part 4: An Easy Day Cutting Angles Part 5 of Pergola series Part 6: The best laid plans... »

After many weeks away from the pergola project, which included an unexpected trip trip to Johns Hopkins in Maryland, I am back on track I hope. Finally got around to making the jig I need to cut the notches in the pergola slats.

First I needed to make a template at the correct angle (105°) for the notch…

which went smoothly, and gives me the necessary shape to align the jig.

Next I made the spacers, each angled at 105°, for the inside of the jig. Initially they were both the same, but they will get cut down to size when in place.

Then to make and position the first side. I used the template and router bit for the optimal placement.

I then marked the side panel and trimmed the spacer blocks to size.

Here’s the side without the template in the way…

Having screwed the spacers in place, I then put on the second side. Not trying for a work of art, just need it to be sturdy enough to do the job.

Lastly came the top. Cut out an opening slightly oversized so the router bit can follow the inside, and nailed it on.

OK, we’re done. Let’s sit this fella on a correct slat width and see how it fits…

Yup! Fits like a glove. And just for giggles, lets set the board at the correct angle, and sit a router on the jig. I’ll clamp the jig in place when routing the notches…

Well that completes the jig build, so hopefully next week we can get back to working of this project again.

-- Making sawdust in Bermuda. It's a dirty job, but someone has to do it!

2 comments so far

View ButchCassidy's profile


26 posts in 1869 days

#1 posted 04-20-2015 12:26 PM

Now aren’t you the “Smart One” very ingenious. Glad everything well at clinic and you are back on the pergola. Keep us up to date.

-- " If you want your PRAYERS to be answered" get off your knees and go to work

View Bermuda_Les's profile


162 posts in 1840 days

#2 posted 04-20-2015 01:57 PM

Thanks Butch… trying to cut the notches with a jigsaw was insane. Hopefully this will make short work of them.

-- Making sawdust in Bermuda. It's a dirty job, but someone has to do it!

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