Router Jigs for Futures SUP Handle
Here are the two jigs that I use to install Futures SUP handles. If you make your own jigs make sure to test them on a piece of scrap before you use them on your board. The jigs are really easy to make and can be easily tuned for a perfect fit. I will write a full tutorial on making homemade router jigs with pictures but I was asked how I size my jigs so here is as a teaser. The fin box jigs are made in the exact same way.
Here is how you can make perfect router jigs without a tape measure:
- Make a right angle with two pieces of material (first fence) by fixing them to a narrow base that is slightly larger than you will need. (Pictured in the top jig.)
- Place your router base tightly against the right angle.
- Place the fixture that you are routing for next to the router base.
- Place the material for the second fence next to the fixture.
- Then clamp an extra fence tightly against the second fence with a couple of spring clamps.
first fence (fixed)
fixture (desired distance to rout)
material for second fence (loose)
extra material temporarily held in place with spring clamps.
- Now remove everything except the fixed fence and the temporary fence.
- Use the router bit to measure how far the second fence needs to be moved inward to achieve the perfect cut. You should be left with a perfectly spaced jig for your fixture.
- If any adjustments are needed you can easily measure with feeler gauges (business cards) how much you want to the fence to move. If you want you jig looser you simply add the feeler gauge to the outside of the second fence, clamp the temporary fence back in place and then move the second fence.
- For a tighter fit: butt the temporary fence against the second fence. loosen the second fence. Add the feeler gauge between the fences and retighten the second fence.
You should have a perfect fit the first time but you will have it the second time for sure! Notice on my jigs that bottom left corner was the perfect 90 degrees with full length pieces and the second fences are not full length. This allows you to set the width separately from the length. I usually remove the excess base material by running the jig through the table saw but the top jig was never finished.