Two jigs, one with a problem

So, for cutting cubes I have a couple of new jigs – partially because it’s not only cubes I’ll be cutting.

One of the jigs is causing me a problem that I’d like to get some advice on.

First off, here’s the basic jig for cutting sticks.

(click on any image for a larger view)
One clamp is missing because it was incomplete when it was shipped to me and I’m waiting for the replacement.

Before I get to using this jig I rough cut the sticks to about 7/8 inch.

Closeup of one of the clamps

End view, showing runner and channel

The channel is 3/4″ plus a spacer wide (you’ll see the spacer later on.) The jig is used by putting the rough cut blank in the groove, clamping down and running the jig along side the blade for a skim cut. Then rotate once and repeat.

Spacer in place

Now put the spacer in, rotate the block one more time, clamp it down, skim cut. Repeat one last time with the spacer in place.

In theory this gives us a fast, repeatable way of skim cutting sticks without endangering our fingers.

There is one small problem. For the first cut the clamps are [i][b]extremely[/b][/i] tight. Tight enough, in fact, that when I was testing this on pine I was leaving indentations in the wood. By the time i get to the last cut though, the clamps aren’t even touching the wood.

Thoughts on modifications?

So, if we presume the first jig does the right thing, here’s the second jig for cutting blocks and/or shorter sticks.

Block Jig

The permanent block is set for length 4 (4 times as long as it is square) and then the other spacers are so I can make cubes, 2x, and 3x blocks. I need one more clamp (like is on the first jig) to hold down the spacer block. The thin strip across the top is to prevent cut blocks from coming up after they’re cut.

Examples of cut blocks.