Router Levelling & Cutting Jig-01#

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Project by Grumpy posted 04-10-2017 01:35 AM 4570 views 10 times favorited 21 comments Add to Favorites Watch

I had a need for a router jig to surface & mill burls. We all know how brittle burls can be because of the crazy grain problem. I didn’t like the idea of putting the burl through the thicknesser because I didn’t know if it would come out the other end in pieces.
Routing seemed the solution but not on the router table as I needed to mill out for a clock mechanism as well as get the burl faces even & flat.
I have a good quality portable work stand that gets little use.

I saw a few examples on LJ’s & liked the simplicity of one done by Scott Rieman
All I needed to do was attach removable runners to the work stand. Some aluminium door frames that were waiting for about 25 years to be put to use came in handy;

The adjustable clamps on the work stand were good for holding the workpiece, sacraficial slides in between saves damage to the clamps.

The Jig for the router is fairly simple. 2 recessed pieces for the X axis with threaded rod for use as stops & an end piece either end for the Y axis.

Both units together formed the jig.

For those of you concerned about the height of the router above the workpiece you could use smaller guides. That’s not a problem in this case because I have a long spiral upcutter bit.
The end result on the workpiece was satisfactory for the back of the clock, parallel, even & recessed for the mechanism.

Thanks for watching.

-- Grumpy - "Always look on the bright side of life"- Monty Python

21 comments so far

View pottz's profile (online now)


16100 posts in 2035 days

#1 posted 04-10-2017 01:47 AM

nice job solving a problem many here have.gonna be copied by many I’m sure.nice work grumpy.

-- working with my hands is a joy,it gives me a sense of fulfillment,somthing so many seek and so few find.-SAM MALOOF.

View Woodwrecker's profile


4240 posts in 4626 days

#2 posted 04-10-2017 01:47 AM

That is a really cool idea Grumpy.
And a mighty crazy burl.
(hope to see that clock when you are done with it.)
Nice work brother.
Always like seeing your ideas.

View a1Jim's profile


118161 posts in 4627 days

#3 posted 04-10-2017 01:52 AM

Nice work a super jig Grumpy


View ZAGREB's profile


1276 posts in 2700 days

#4 posted 04-10-2017 02:48 AM

very useful jig,Grumpy
my favorite for a while

-- bambi

View papadan's profile


3584 posts in 4419 days

#5 posted 04-10-2017 02:57 AM

Nice jig Grumpy, but why didn’t you show us the clock? ;-)

View Gene Howe's profile

Gene Howe

12314 posts in 4479 days

#6 posted 04-10-2017 02:59 AM

Thanks Grumpy. Now to find something long and straight as your door frame.

-- Gene 'The true soldier fights not because he hates what is in front of him, but because he loves what is behind him.' G. K. Chesterton

View doubleDD's profile


10260 posts in 3093 days

#7 posted 04-10-2017 03:15 AM

I like the simplicity of this Tony. I have to get off my rump and make one to do some of these cool projects. I’ll be waiting to see the clock too.

-- Dave, Downers Grove, Il. -------- When you run out of ideas, start building your dreams.

View Grumpy's profile


26811 posts in 4901 days

#8 posted 04-10-2017 03:31 AM

Thanks Pottz
Thanks Eric, the clock is coming soon.
Thanks Jim &Bambi
Be patient Papadan & Dave. All good things come to those who wait. LOL
Thanks Gene. Any hardware store would have this sort of frame.

-- Grumpy - "Always look on the bright side of life"- Monty Python

View Grumpy's profile


26811 posts in 4901 days

#9 posted 04-10-2017 03:32 AM

I have another simpler jig in the melt. Will post when I get the bits I need.

-- Grumpy - "Always look on the bright side of life"- Monty Python

View CFrye's profile


11211 posts in 2890 days

#10 posted 04-10-2017 04:52 AM

Handy jig, Tony! Did you tell your wife “See, I knew I’d need that door frame, someday!”? I’d of told hubby that! Looking forward to seeing the finished clock!

-- God bless, Candy

View Grumpy's profile


26811 posts in 4901 days

#11 posted 04-10-2017 05:44 AM

Candy, the wife knows. I bought a CNC type laser burner & I did the clock face with it.
She does card making so she’s after me to do projects for that. No rest for the wicked they say Candy. LOL
The frame is from an office renovation where I worked. I got some of the wooden panels as well.

-- Grumpy - "Always look on the bright side of life"- Monty Python

View Mark Wilson's profile

Mark Wilson

2923 posts in 2113 days

#12 posted 04-10-2017 07:52 AM

You’re a freaking genius, Tony. I’ve seen many a “router-leveling-jig” (see, for instance: CharlieK), but they always seem so big, clunky, and cumbersome as to be off-putting. You did something here that, when I have need of one, I will return to.

-- Mark

View Jim Jakosh's profile

Jim Jakosh

26056 posts in 4156 days

#13 posted 04-10-2017 09:45 AM

I love it , Tony!! We need one of them for our shop in Az.!!


-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View ChrisK's profile


2053 posts in 4132 days

#14 posted 04-10-2017 10:41 AM


-- Chris K

View helluvawreck's profile


32122 posts in 3917 days

#15 posted 04-10-2017 12:07 PM

Grumpy, this is a well thought out fixture and you have done a fine job on it. It’s a great addition to your shop.

helluvawreck aka Charles

-- helluvawreck aka Charles,

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