shooting boards and clamping cauls

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Project by Mcnervy posted 05-17-2013 12:43 AM 2579 views 1 time favorited 4 comments Add to Favorites Watch

I am in the process of making 3 boxes, one for my sisters graduation, one for my mom for mothers day and one for my wife. Last time I did a mitered box I had a difficult time in glueup and fitup. So i decided to make 2 jigs and set of cauls. Standard shooting board for ensureing flat edges. A modified donkeys ear shooting board for fine tuning the miters, and the cauls for clamping the miters.

The construction of the donkeys ear board started by using a bit that cuts a 90 deg angle grove (split 45 each side) this groove serves and one rail for the plane to run on the top board with a 45 deg bevel serves as the other. the Tilt box magnetic angle gauge was so helpful in getting the 45 deg cuts. I also found that when I lock my table saw angle it slightly changes it, so be sure that you check the angle after locking the position, this goes for the miter saw also, I had to disable the detents as they were not accurate enough.

The standard shooting board was pretty easy to assemble a perfect 90.
The 45 degree board was very difficult it took about 4 passes to get the plane to ride at 45 deg angle
Box building really shows off how precise your setups have to be. Box project to follow.
The shooting boards work well, but the plane must be freshly sharpened and I had to take very small cuts, but the result was very good

The cauls really allowed me to close up the miters, i did find it necessary to use a couple of bar clamps to slide the one of the sides into position, the other 2 glue ups did not require it, but it is helpful to be ready for any adjustment during a glue up. Thanks for looking.

-- Bennett; If it can't be fixed with a hammer its an electical problem

4 comments so far

View Dallas's profile


3599 posts in 3000 days

#1 posted 05-17-2013 12:57 AM

I think I spend more time cutting perfect miters than I do anything else at times.

If the miter isn’t perfect it really throws things off.

-- Improvise.... Adapt...... Overcome!

View Joe Lyddon's profile

Joe Lyddon

10739 posts in 4565 days

#2 posted 05-17-2013 01:26 AM

COOL stuff!

Thank you.

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: ... My Small Gallery:

View Ben Simms's profile

Ben Simms

191 posts in 2804 days

#3 posted 05-17-2013 07:11 PM


-- I played with Legos as a kid and I never had the part I thought I needed, so I learned to improvise. Now I'm an engineer with a woodworking hobby.

View NormG's profile


6480 posts in 3516 days

#4 posted 05-19-2013 05:20 AM

Great idea

-- Norman - I never never make a mistake, I just change the design.

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