Thorsen Side by Side LJ / PW Challenge Karson #4: A jig I made for use in the Thorsen table

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Blog entry by Karson posted 05-09-2007 03:30 AM 2719 reads 0 times favorited 6 comments Add to Favorites Watch
« Part 3: My Holly Thorsen Greene and Greene Table. Part 4 of Thorsen Side by Side LJ / PW Challenge Karson series Part 5: The second of the twins. The Popular table. »

I wanted to show the jig that I used for making the Thorsen Greene & Greene table Aprons.

The plans in Popular Woodworking had a cutout on each of the aprons. Different patterns on the sides and the front and back.

I took the plans and printed them on my printer but each of the boxes were suppose to be 1” square and they were small. So I took the printout to Staples and had them copy them at 125% increase. I ended up with 1” squares. I then glued the paper on some ½” particle board and then went back and drew new lines 1/16” outside all of the original lines.

I then used a scroll saw and cut to my new drawn lines. I then sanded and filed smooth .
I glued some brass sheets on the jig using carpet tape. My plan was then to use carpet tape to hold the aprons in place. That was the theory, but the brass plate stuck to the apron tighter than to the jig. So i then glued some end blocks at the end of the apron length and screwed down hold-down clamps.

The jig was then supported upside down on two sawhorses so that the router bit would not hit anything as it exited the apron.

You might notice the cloud lifts on both edges of the jig. The cloud lift on the edge of the apron was cut as the cutouts were routed.

The other cloud lift was used as a pattern for the stretches for the shelf support. One jig for the lower cloud lift and the other jig for the upper cloud lift.

I used a 5/16” router bushing with a ¼” spiral carbide router bit. This was used in a plunge router and I probably plunged about ¼” deeper each time. Each cutout was done is its entirety before I went to the next cutout. The reason was when I tried to move the router I kept hitting the jig with the router bit that was spinning and I mared up the edge of the jig cutouts. So I finished each one before moving on.

The cloud lift portion for the stretchers were not cut with a router but on a bandsaw. But I used the jig for the pattern to draw the pencil lines.

I was able to mount 1 apron in each of the jigs and cut out the pattern. So two passes through were required to complete one table.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

6 comments so far

View Don's profile


2603 posts in 4629 days

#1 posted 05-09-2007 04:08 AM

Thanks for a very instructional blog, Frank.

-- CanuckDon "I just love small wooden boxes!"

View oscorner's profile


4563 posts in 4763 days

#2 posted 05-09-2007 09:43 AM

Nice jig, Karson. Thanks for sharing.

-- Jesus is Lord!

View Roger Strautman's profile

Roger Strautman

657 posts in 4586 days

#3 posted 05-09-2007 11:29 AM

That look like too much work making a jig so that’s why I didn’t make the cutouts. By the looks of your table maybe I should have spent some time and made that jig. LOL Thanks Karson!

-- " All Things At First Appear Difficult"

View Mark A. DeCou's profile

Mark A. DeCou

2009 posts in 4858 days

#4 posted 05-09-2007 03:59 PM

are you going to make it in time Karson? I’m afraid that I may not make it by the deadline. Just too many things ahead of it in the que.

thanks for the lessons,

-- Mark DeCou - American Contemporary Craft Artisan -

View fred's profile


256 posts in 4551 days

#5 posted 05-09-2007 06:37 PM

Thanks again for your information. You have really helped this beginning amateur woodworker. I love jigs.

-- Fred Childs, Pasadena, CA - - - Law of the Workshop: Any tool, when dropped, will roll to the least accessible corner.

View Karson's profile


35194 posts in 4853 days

#6 posted 05-09-2007 11:43 PM

Mark I hope to cut the shelf to side and then the tenons and start glueing up the table. The breadboards are all glued on so that part is done.

I hope that I can take one to the Woodworkers guild meeting that I’m making the presentation to in a week. So I’m OK. I believe!

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

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