Twosided Jig For Routing Back Legs

Each leg is secured in the jig by screwing into the areas to be mortised, so mark out mortise locations on both faces.

End blocks, IV2 in. thick

Clamp the jig to a bench to rout the leg shape. A long bearing-guided bit can do the job in one pass; a shorter bit requires you to flip the jig and make two passes.

Screw jig to leg at mortise locations.

Cut leg to rough shape, then place it in the jig.

Router box simplifies mortising_

comfort. I use jigs to duplicate curved and angled parts, and to create accurate angled joineiy. These jigs will come in handy if you decide to build a set of chairs.

Shape the back legs using a template

First, trace the back legs on the stock using a full-size template made from Vi-in.-thick Masonite. Rough-cut the legs to shape using a jigsaw or bandsaw, being careful to leave the line. The only cuts that should be exactly to the line at this point are the top and bottom cross-grain cuts.

For final shaping, mount the back legs in a template-routing jig (see photos and drawing, p. 55) that works with both legs. Use a large-diameter, bearing-guided straight bit (V2 in. or more). Amana makes a lVs-in.-dia. by lV2-in.-long bit with a top-mounted ball-bearing guide (part No. 45468) that allows you to shape the leg in one pass.

Once you have both rear legs shaped, cut the front legs to length. Now you're ready to lay out and cut the mortises.

Aluminum bar stock to fit router baseplate

Wood screw

This jig allows you to cut angled and straight mortises in the legs with a plunge router. It also allows for mortising for the loose tenons in the ends of the side rails.

Fence, 8 in. long, rides along box sides to ensure straight cuts.

Notch for end-mortising, IV* in. wide by 4 in. long

Wedge leg in box for mortising. Adhesive-backed sandpaper prevents the wedges from slipping.

Plywood sides, 3A in. thick by 47/i6 in. wide by 26V* in. long

Straight mortise

Loose tenon

Side rail

Mortise is angled.

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Wood Working for Amateur Craftsman

Wood Working for Amateur Craftsman

THIS book is one of the series of Handbooks on industrial subjects being published by the Popular Mechanics Company. Like Popular Mechanics Magazine, and like the other books in this series, it is written so you can understand it. The purpose of Popular Mechanics Handbooks is to supply a growing demand for high-class, up-to-date and accurate text-books, suitable for home study as well as for class use, on all mechanical subjects. The textand illustrations, in each instance, have been prepared expressly for this series by well known experts, and revised by the editor of Popular Mechanics.

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