Jensen-style Z-Chair #3: A Jig Interlude

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Blog entry by Ross Leidy posted 05-18-2019 03:16 PM 311 reads 1 time favorited 4 comments Add to Favorites Watch
« Part 2: Planning and Prototyping Part 3 of Jensen-style Z-Chair series Part 4: Slats »

Since I was switching gears to use butt joints with floating tenons instead of the puzzle joints, I started looking at various router jigs for cutting the mortises. I found a lot of helpful videos on homemade jigs, and eventually I modeled mine largely on the Morely Mortising Jig However, for mine I wanted to use interchangeable templates for repeatability and ease-of-use, rather than use the siding side stops that Morely uses. Other than that, the structure of mine is like the Morely jig.

It’s all 3/4” baltic birch ply, cut out on the CNC, with some cocobolo runners on the subtop.

The Microjig dovetail clamps work very well. I like that they can be positioned in the vertical dovetails loose and they don’t slide out.

The top slides on the runners and adjusts to set the distance away from the side of the material for the mortise. The recessed area accommodates the sight insert and the plexi templates (cut on the CNC). I added some magnets to hold the templates securely.

The cross-hair sight insert allows me to precisely position the material in the center of the opening.

I just used some nuts for the magnet strikers in the templates. They’re recessed into the template and super-glued in place.

The first trial run:

4 comments so far

View mafe's profile


12042 posts in 3477 days

#1 posted 05-18-2019 11:01 PM

That is one cool jig!
Really fine work on that one.
Love your sense of detail, really impressed, look forward to see what you are up to.
First time I see you here, so a hi also.
Best of my thoughts,

-- MAD F, the fanatical rhykenologist and vintage architect. Democraticwoodworking.

View Ross Leidy's profile

Ross Leidy

51 posts in 2329 days

#2 posted 05-19-2019 01:04 AM

Thanks for the kind words. I’ve benefited from this site over the years, so it’s high time I try to contribute back. I’m having a blast with this project, and am happy to share the experience.

View mafe's profile


12042 posts in 3477 days

#3 posted 05-19-2019 09:51 AM

;-) Look forward to follow as you go on.

-- MAD F, the fanatical rhykenologist and vintage architect. Democraticwoodworking.

View 489tad's profile


3602 posts in 3399 days

#4 posted 05-20-2019 09:21 PM

That is a nice jig. Very clean looking.

-- Dan, Naperville IL, I.G.N.

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