THE ROUTING SAFETY JIG ROUTING IS THE MOST DANGEROUS ACTIVITY IN FLUTEMAKING. I BELIEVE THAT A SAFETY JIG IN DEFINITELY IN ORDER. THIS IS THE ONE I DESIGNED AND USE. FEEL FREE TO COPY OR MODIFY THIS VERSION.
***HAVING A SAFETY DEVICE DOES NOT ENTITLE YOU TO "PUSH IT". STAY WITH LIGHT CUTS AND DELIBERATE FEED RATES.
I BEGIN WITH A BOARD THAT IS 8.5" X 1.5"X THE LENGTH OF THE JIG YOU WANT TO MAKE. THEN RIP IT TO THE SIZES INDICATED.
I USE THE 5.5" HEIGHT BECAUSE IT GIVES ME SOMETHING TO GRAB WHILE FEEDING THE JIG OVER THE ROUTER BIT. IT CAN BE SHORTER OR TALLER.
THE 28" IS DETERMINED BY THE LENGTH OF THE FLUTES TO BE MADE. A JIG OF THIS LENGTH CAN MAKE MANY SIZES BY SIMPLY ADDING AN ADDITIONAL TOGGEL CLAMP FOR THE SHORTER FLUTES. BELOW I AM SHOWING THE LOCATING HOLES FOR THE TOGGLE CLAMPS. THREE CLAMPS IS THE MINIMUM.
THE CLAMPS OFTEN NEED TO BE CUT SHORTER AS SEEN BELOW.
THE CLAMPING PAD OF THE TOGGLE CLAMP SHOULD JUST BARELY CLEAR THE MOUNTING BOARD AND ALSO NOT DRAG ON THE ROUTER TABLE WHEN IN USE.
HERE ARE ALL THREE CLAMPS MOUNTED ON THE FRONT BOARD.
NEXT WE DECIDE WHERE WE WANT THE SPIN-ON KNOBS AND BOLTS TO BE AND DRILL A HOLE AND A LOCATING CENTER LINE TO GUIDE US IN ROUTING THE DADOS ON THE BACK BOARD.
CENTER THE DADO USING THE GUIDE LINE ABOVE AND ROUT A 3/4" WIDE BY 1/2" DEEP SLOT FOR EACH PIECE OF TRACK.
INSTALL THE TRACK IN EACH DADO. 3 SCREWS IS MINIMUM.
I LIKE THE BOLTS WITH THE THIN FLAT HEADS, BUT ORDINARY BOLTS WILL WORK JUST FINE. SOMETIMES A LITTLE FILING IS NEEDED TO GET THE FIT YOU WANT.
I MOUNTED THE TRACK JUST INBOARD OF THE CLAMP.
THE ALIGNMENT IS IMPORTANT FOR SMOOTH OPERATION.
HERE IS THE COMPLETED JIG. IT IS JUST THAT SIMPLE. LOOSEN THE KNOBS IN ORDER TO MAKE HEIGHT ADJUSTMENTS AND THEN RETIGHTEN.
BE SURE TO ADJUST THE CLAMPS SO THAT THEY CLAMP FIRMLY IN EVERY CASE. THE HEIGHT IS ADJUSTED TO THAT THE BOTTOM OF THE BLANK IS EVERN WITH THE BOTTOM OF THE JIG.
****IF THE ABOVE IS NOT CLEAR ENOUGH PLEASE EMAIL ME AND I WILL CONTINUE TO WORK ON IT. | 
