Downsizing a Heavy Jig / Réduire un gabarit trop pesant

J’adore mon installation pour ce gabarit à vis cachées. Au début il n’y avait que la plaque de MDF sur laquelle le gabarit est fixé. Ensuite je l’ai amélioré en dessinant des règles à l’avant. Très pratique! Finalement j’ai ajouté les butées ajustables et rétractables lesquelles rendent les forages identiques faciles et rapides. Toutefois, compte tenu que je le range pendu sur le côté d’une solive du plafond, je le considère trop lourd. Pas drôle de vieillir !

I like my setup for this pocket hole jig. At the beginning there was only the MDF board on which the jig was secured. Then I improved it by drawing rules at the front end. Very handy ! Finally I added flipping and adjustable stops which make identical borings quick and easy. However, since I hang it on the side of a ceiling joist, I consider it too heavy. Getting old is not funny !

Downsizing a Heavy Jig / Réduire un gabarit trop pesant

Au banc de scie je coupe donc les parties excessives.

At the table saw I therefore cut the excessive parts.

Downsizing a Heavy Jig / Réduire un gabarit trop pesant

Downsizing a Heavy Jig / Réduire un gabarit trop pesant

Je vais maintenant adoucir les arêtes coupantes avec une ébarbeuse munie d’une fraise à chanfreiner.

Now I will smooth out the sharp edges using a trim router and a chamfering bit.

Downsizing a Heavy Jig / Réduire un gabarit trop pesant

Le gabarit sécurisé au bord de l’établi, je peux fraiser les arêtes avant et arrière, dessus et dessous, pour finir avec un ponçage des coins à la main.

The jig secured on the edge of the workbench, I can chamfer the front and back, upper and lower edges, and ending up by hand sanding the corners.

Downsizing a Heavy Jig / Réduire un gabarit trop pesant

Downsizing a Heavy Jig / Réduire un gabarit trop pesant

Ainsi j’ai pu réduire considérablement le poids en enlevant 4″ (10 cm) sur la longueur de la base.

En fait, rien n’est éternel ou coulé dans le ciment !

Doing so I considerably reduced the weight by removing 4″ (10 cm) lengthwise from the base.

In fact, nothing is everlasting or cast in concrete !

Downsizing a Heavy Jig / Réduire un gabarit trop pesant

Et je termine avec deux pièces pour un prochain gabarit !

And I end up with two cleats for a future jig !

Downsizing a Heavy Jig / Réduire un gabarit trop pesant

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10 Responses to Downsizing a Heavy Jig / Réduire un gabarit trop pesant

  1. wim31415 says:

    Hallo Serge,

    Concerning that last photo, how do you keep track of all those offcuts and keep them organised? I’ve just got a drawer with various offcuts, but I wonder how you, being organized as you appear to be, keep track of it all?
    And as allways, thanks for your inspiring projects.

    Regards, Wim

    • Hey Wim,

      Here’s a part of the answer.

      Besides that, I also have SonoTube behind a door of a floor cabinet (as per the above link). I also use a small pail for small wedges, and another one for small offcuts. I keep long stick in a 5 gal. bucket and longer wedges in a coffee can. As you can see on this photo, I removed the dish pans and lined up hardwood offcuts sideways.

      I hope those ideas could help.

      Best, Serge

  2. It looks like this jig is typically used while supported on a workbench that provides flatness and rigidity. If so, it may be possible to remove substantial additional weight from the jig base without sacrificing strength or rigidity by plunge-routing recesses on the back side within the two areas near the hanging holes, where none of the front-side parts are anchored.

    Here’s an example (table saw top) in metal; for wood you may want to have thicker ribs (?).

    It appears that casting designers are taught to stagger the ribs; I don’t know whether the reasons apply in wood:

    • That is a good idea John. At the beginning I thought about using a router but to cut through large holes (idea that I put aside), but your idea of milling recesses with the router is great. For now I’m thinking about two large rectangular 1/2″ deep recesses. I’ll see for the final ‘design’. I’ll probably make a post out of your idea. Thank you for this great input.


  3. Morgan says:

    I think you should get personal trainer and get stronger…..haha!
    No messing with Father Time though…

  4. Serge, pardon me, but I think that I would find it easier, quieter, quicker and less dusty to use a block plane to chamfer the arrises

    • Philip, I do pardon you ! 🙂 You know what, the idea of using a block plane didn’t cross my mind, perhaps because this is MDF. In my book, plane edges and MDF don’t have a good relationship ! 🙂