Revised Wheel Kerfing Jig Indexer.

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Project by LittleBlackDuck posted 11-05-2018 03:09 PM 3121 views 6 times favorited 36 comments Add to Favorites Watch

Boys and Girls, What can I say… WHAT CAN I SAY!

Well a bloody lot but little relating to this topic. This is my second project that has surpassed all my expectations.

The indexer on my original kerfing jig worked well, however, it was a pain to fabricate and had to be exact. Muck up one measurement, even slightly and after the assembly, if it played up, I would have had to start again.

I was inspired by J’1974 with his perforated exhaust heat shield and over a few casks, decided that this could be the excuse for another jig… I should have been an Irishman!

My primary thought behind the jig was the need for a simple indexer, however, my main apprehension was driven by the desire not to use the kerfing jig’s indexer.

Hit SketchUp and came up with a concept that I thought would befit my kerfing jig.

As I had an order for the jig, I decided to supply it with the new indexer which was better than what previously was just instructions for the recipient to make hisr (like the gender neutral?) own indexing pin out of dowels. With this new design I could supply the indexer with the jig.

Anyway got it into the kerfing model and redesigned the body with the new indexer and removing all the holes required for the old one,

The main challenge I thought I’d have to face is to find the right type of spring. Well lo and behold we just had a recent sale on at our local Mitre 10… bloody Churchill has no shops but a bleeding KFC (my least favourite junk food) and a Mitre 10… and there was a box of springs for a couple of dollars on offering that I bought just in case.

Foraged through the box, stretched a few, for exercise, and found one that I thought would fit the bill.

I made the full range of indexers (18, 20, 24, 30 and 36 which are the ones that have been used in the T&J models I’ve been exposed to).

Now the old indexer was out of 3mm MDF and this new one was 6mm, so I had to provide a few packers to make up the extra 3mm. The appropriate 6mm will be in any new jig.

Slapped it together and not having used the jig for a while, had to read the manual of how to assemble it for tablesaw use.

Before making any cuts, I decided to try the new jig body in my Foredom configuration. unfortunately the movement of the indexing lever was limited and I had to do some ad-hoc surgery to permit desired operation.

Jigged it up to my mitre guage and made a test cut. Advanced the lever and made another cut. While pushing on the rotating gear at the top, I found that the indexer advanced one notch without manual indexer lever manipulation. Holy-shit I screamed… neighbors complained and told me to shut up! I was a bit apprehensive using this new innovation and finished the kerfing with some manual intervention.

Then I decided to try my 36 indexer. This time I tried a dry run of the “auto advance” and when it seemed to operate I proceeded to do a wheel using this feature.

One step up from holy and I screamed perforated-shit…. Yeah, neighbors again… it took about 70 seconds to do the 36 kerfs. Here is a realtime extract of my “full” video to demonstrate the 36 kerf timing.

Now to put a new spin on this (or any other indexer). It is my belief that the indexer’s wheel cannot be larger than the wheel you are kerfing… that is why I come up with the geared design (and because I could). If you make the indexing wheel too small, the indexes (holes, slits or whatever) would be too close. That is why mine are near the perimeter. Now with this design the indeces are on the perimeter which is about as efficient as one can get. I will add that this is an issue as I wanted to cater for a max of 36 kerfs knowing that the average is between 18 to 24.

I made a generic indexer that could be bolted to another jig or shared between many jigs using removable bolts,

witn the assortment of the various indices,

Now if the wheel to be kerfed is placed in the middle of a boxed construction with the saw blade being raised in the middle, much like this,

I could see this indexer being used inline without the need for use of offsetting gears.

Again for all those hard of hearing, I have made this video so you don’t have to read the above… just turn your hearing aid up to appreciate the full harmony of my table saw and dust extractor.

-- If your first cut is too short... Take the second cut from the longer end... LBD

36 comments so far

View NY_Rocking_Chairs's profile


528 posts in 4239 days

#1 posted 11-05-2018 03:34 PM

Holy freaking macaroni! That is awesome, I must admit I have been a little intimidated at the prospect of how to cut those kerfs on the T&J wheels. Are the plans available somewhere?

Happy kerfing.

-- Rich, anybody want a peanut?

View stefang's profile


17039 posts in 3976 days

#2 posted 11-05-2018 03:57 PM

Looks like a well thought out and well made jig, but It isn’t clear to me what the product will be used for. Will the teeth be shaped further to make it into a gear which can mesh with other gears or is it just to make wheels for toys?

-- Mike, an American living in Norway.

View Jason1974's profile


251 posts in 964 days

#3 posted 11-05-2018 06:05 PM

Alex, I think I just started a whole new revolution!!! lol

-- Jason, Camden, NC -- I didn't do it, Stupid Did!

View pottz's profile


7989 posts in 1626 days

#4 posted 11-05-2018 06:11 PM

dang duckie what kind of rube goldberg contraption have you come up with how much vino did it take to complete this always amaze me buddy.congrats on top 3.

-- sawdust the bigger the pile the bigger my smile-larry,so cal.

View GR8HUNTER's profile (online now)


6974 posts in 1354 days

#5 posted 11-05-2018 06:21 PM

I love the idea of a separate indexer GREAT JOB :<)) GRATZ TOP 3 ….OH loved the video also you da DUCK

-- Tony---- Reinholds,Pa.------ REMEMBER TO ALWAYS HAVE FUN

View bushmaster's profile


3800 posts in 2925 days

#6 posted 11-05-2018 06:22 PM

Wow wow, will have to take a day and tey to figure this one out. Who needs cnc.

-- Brian - Hazelton, British Columbia

View crowie's profile


3443 posts in 2593 days

#7 posted 11-05-2018 08:06 PM

Yes well done again Alex.
Love the new simpler indexing.
Will it retrofit the old units please?

-- Lifes good, Enjoy each new day...... Cheers from "On Top DownUnder" Crowie

View hunter71's profile


3491 posts in 3829 days

#8 posted 11-05-2018 08:55 PM

WOW, I am truly impressed. My simple indexer I made so many years ago is JUNK compaired to this.

-- A childs smile is payment enough.

View Dutchy's profile


3556 posts in 2810 days

#9 posted 11-05-2018 09:16 PM

I found your first jig complex, but this time maybe I will make a dutch copy.



View robscastle's profile


6736 posts in 2846 days

#10 posted 11-05-2018 10:01 PM

Its actually a machine to accurately pick a winner for the Melbourne Cup!

A spring in a piece of KFC sure beats a needle in a strawberry.
A least you may be eating something nourishing as an iron supplement!!

-- Regards Rob

View robscastle's profile


6736 posts in 2846 days

#11 posted 11-05-2018 10:07 PM

OK now that I have got that off my chest …Absolutley bloody amazing mate!

How do you think up these gizmos let alone make them and then importantly actuallly get them to work so easly!

I have been meaning to ask some time ago, as I had seen it before, what is that yellow plug/circle just in front of the saw blade? at first I thought it was a for a router but the realised it was too close to the blade mech to be for that, so I just hadda ask!

-- Regards Rob

View robscastle's profile


6736 posts in 2846 days

#12 posted 11-05-2018 10:32 PM

Keep your eyes open at Aldi too!
There is sometimes some interesting “stuff” there

The step drills were actually in two separate boxes, but as I was short on space and put then into just one.

Springs were about $6 and the drills $12 each box of three.

-- Regards Rob

View Pjonesy's profile


337 posts in 1468 days

#13 posted 11-05-2018 10:36 PM

I am impressed, what a brilliant job you have done with that. Are you going to sell them? Maybe I need to pay you a visit when I’m over in Aussie next time.

-- Don't tell me it can't be done.

View robscastle's profile


6736 posts in 2846 days

#14 posted 11-05-2018 10:43 PM

Alex do you think you could squeeze a 50 indexer in?

I think there are 50 bar tread indents, what say you?

-- Regards Rob

View pottz's profile


7989 posts in 1626 days

#15 posted 11-05-2018 11:02 PM

Alex do you think you could squeeze a 50 indexer in?

I think there are 50 bar tread indents, what say you?

- robscastle

hey why not,go big or go home right-lol.

-- sawdust the bigger the pile the bigger my smile-larry,so cal.

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