You can produce exact duplicates from a master pattern using this overhanging jig on your table saw. To make the jig, glue the pieces of 1/2-in. plywood in an L, reinforcing the joint with braces and screws. Clamp the smaller side of the jig to the saw’s rip fence with two C-clamps. Allow 1/8-in. clearance between the underside of the jig and the stock to be cut. Now, by moving the rip fence, set the guide edge of the jig directly over the outside of the blade.

Cut a master pattern from 1/2-in. plywood to the exact size and shape of the part to be duplicated. Fasten the pattern to oversize precut blanks with tacks or double-sided tape. Now you are ready to cut the duplicate part. Press the master pattern against the guide edge of the jig and push through the blade. For safety’s sake remove scraps from under the jig as you cut and stand to one side of the line of cut. Otherwise you’ll be dodging projectiles of scrap that pile up under the jig and eventually get fired out by the blade.

The table-saw jig is limited to duplicating straight-edged parts in plywood and thin, solid stock. To reproduce thicker parts, and those with curved edges, set up a similar jig on the band saw.

Ed Stevenson, Hammonton, N.J.

Fine Woodworking Magazine, December 1980 No. 25

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