A quick jig can make the difference in a woodshop. This height gauge helps measure and set cutting tool heights and thicknesses for rabbets, dadoes, chamfers, etc. Since it incorporates a digital caliper, the dial is easy to read, precise and accurate.

diy-height-gauge

This tool came in handy building the light box project – I hit the rabbet depth and thickness dead-on each time.

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Step 1: Tools & Materials

DIY Height Gauge

Materials:

Small Clamp, either F- or C-style will work, but the clamp must clamp well. I find spring clamps don’t work.
2 #8 1-1/4” Wood Screws
MDF, roughly 6”x10”, either 1/2” or 3/4” thick
Calipers with a depth bar

Tools:

Scroll saw or band saw
Miter Saw
Drill Press with 1-1/2” Forestner Bit
Drill with Countersink & #2 Phillips Bit

Step 2: Assembly:

Assembly:

Lay out the gauge on a piece of MDF. I have linked to a SVG & DXF for those readers with access to a CNC or laser cutter. You can also use this PDF to print out a template.
Use a drill press to drill out the top of the cut out.
Use a miter saw to cut the gauge into two halves.
Use the scroll saw to trim the waste and complete the cut out.
Drill two pilot holes, countersink and attach the halves with wood screws.

Step 3: To Use:

Use:

To use, clamp the fractional dial caliper to the upright. Set the gauge on the tool table. Then, drop the depth gauge so it touches the table surface. Zero out the reading. Reposition the height gauge over the tool itself. Raise the tool itself until the dial reads the negative of your needed height.