If you don't have a jointer, this easy-to-use jig lets you joint boards with a router. The method depends on a simple aluminum-angle-edged guide board and a commercial-grade flush-trimming bit. I use the Bosch #85602M bottom-bearing, flush-trimming bit, which features three cutting flutes, a replaceable bearing and a 1-1/2-in. cutting length.

To construct the jig, rabbet the guide board to receive the aluminum angle. Attach the angle to the guide board with countersunk screws every 6 in. or so. Now clamp the workpiece over the guide board so that it overhangs the aluminum bearing surface by 1/8 in. or less. I like to use deep-throat Vise-Grip clamps to clamp the workpiece to the guide board, but C-clamps will work fine. If the workpiece is badly bowed, take two cuts, or rip the board on the tablesaw first. This concept has worked so well I made a smaller version for jointing the ends of crosscut boards. For this operation, it's important to double-check your depth setting to make sure the bit clears the angle. Also, take light cuts (less than 1/16 in.) to avoid burning the workpiece.

Andrew A .Westerhaus, Burnsville, Minn.

Fine Woodworking Magazine, June 1994 No. 106 , ,
October 25, 2005