This is a router table jig that easily produces square and rectangular wooden saucers. It is easy to make and use on any router table.
This frame consists of 4 clamps and 4 arms. Dimensions of elements are on figures, except arms length, which is optional, and depends of your needs. In my case, arm length is 550 mm.
Required elements for building this frame are:
1. Playwood 18 mm thick - dimensions is about 730 mm x 220 mm
2. Bolt M8 x 30 mm - 4 pcs.
3. Wood Deck Screws 4 mm x 35 mm - 8 pcs.
4. Insert nut screw M8 - 4 pcs.
5. Wooden rod 12 mm diameter - about 130 mm length
6. Measuring tape, which length is equal to leg length - 4 pcs.
Step 2: Cutting the Elements
Cutting of elements is done according to the dimensions on pictures. For these operations, a table saw, a band saw or a manual saw is used.
Step 3: Making Arms
After cutting, it is only necessary to drill a hole of 12 mm in diameter and hollow out a channel for the measuring strip. The channel width depends on the measuring tape you have, and the depth of the channel should be equal to or slightly higher than the thickness of the measuring tape.
Step 4: Making Clamps
After cutting and drilling the holes on the basis of the dimensions given on images, the nuts are first inserted and part of clamp is connected to the base of the clamp. Adhesive and nails are used for this. The movable part of the clamp is fastened with screws that are twisted up to half of their length and thus serve as a guide for the movable part of the clamp. Screw M8 is used to moves and fastens the movable part.
Step 5: Connecting Arms and Clamps
Marking and drilling the body of the clamp, so that the clamp becomes an extension of the arm.
Step 6: Assembling
When all four clamps are connected to the arms, the frame is formed by the interconnection shown in the pictures. After checking the right angle, screws must be tightened.
Step 7: Set on the Table Router
Two lines at an angle of 90 ° are drawn through the center of the table router. Frame arms are adjusted based on the size of the saucer we want to make, using the formula shown. The screws is tightened and the arms are set so that the lines that we have previously painted on the table, pass through the points of crossing the arms. When we have set this up, we attach the frame to the table with carpentry clamps. Now we're ready to start making a saucer.
Step 8: Work With the Frame
Paste the double sided tape on a piece of wood that will serve us as a handle. Paste handle on a workpiece.
Turn on the table router and move the workpiece inside the frame. The final depth of the saucer is achieved by lifting the router bit and repeating the procedure.
This frame I used to make a saucers for Dropping Proof Wooden Serving Tray (see the video here).
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