End bar routing jig

[delber]

I promised in a thread that I'd post pictures of the jig that I was going to make when I did it next, but I can't find the post. So I'm hoping that anyone that may be interested could see it here.

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The router bit has a bearing on the bottom that rides the jig
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Here you can see the detail that the bit rides on.
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Starting end bar
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Completed end bar

I have to flip the frame over to rout both sides, but the de-sta-co clamps hold the bars down well so my hands are far enough away that it's totally safe to use. I also have a block that's cut one size for where it contacts the top bar and another piece that holds it where it attaches to the bottom bar. These 2 blocks keep it snug and hinders the frame from exploding. I did about 100 frames worth of end bars in about a half hour.

[ralittlefield]

Thanks for sharing! Looks like a good set up for frame production.

I do not make my frames any more, but if I did, I might give this a try.

I used to rip end bars from 2X6 stock. Before ripping I would plane it to 1 3/8", cut the 2X6 to length, route the grooves for top and bottom bars, the cut the profile on the block with a jointer. Then I would rip 10 or 11 completed end bars from each block.

[westernbeekeeper]

Wow, thanks for the pics! It gives me some more good ideas.

[psfred]

I just set my jointer to cut 1/8" and zip them through using a stop block or just a mark on the fence for where to stop.

You could just as easily set up a fence with a 1/8" offset past the bit and a stop block and zip them along -- much faster than mounting them on a jig.

Peter

[monrovi]

You could just as easily set up a fence with a 1/8" offset past the bit and a stop block and zip them along -- much faster than mounting them on a jig.
Peter

I have been using this method for end bars after I have trimmed them down to 1 1/4". It works pretty good for me and fairly quick.

[delber]

This is another way of doing it. I can see how it would work well, but now that I have the jig made I think I may be able to do it faster still. It seems what you're talking about is a 2 step process right? (cut the 1-1/4" part then cut the rest) What I've done is I'm able to get the whole edge of the frame done in one pass, then flip it over and I have now 2 end bars done. I assume that you push them into the cutter right? Do you have any isues with them splitting out or do you do it before the bottom bar joint is cut? I'm not making new frames, but rather modifying frames. I can't make them currenty cheaper than what I can buy them for sure. Perhaps when / if I ever get a good woodshop together then I may do it. I would be interested in seeing your setup. In thinking about it it seems that modifying the frames would be difficult to get them started into the cutter w/o the cutter wanting to take the end bar into itself or splitting. Do you have this issue?

[delber]

Ben, Thanks for sharing!!! Those are some great ideas / thought processes!!