A perfect union between an improved router fixture and a Moxon-style vise.
By Kenneth Speed
This fixture, which I’ve christened “Gizmozilla,” grew out of my general dissatisfaction with the methods available to small shops to cut mortises. At one time I used a small hollow-chisel mortiser but I never found the results satisfactory. I tried an open-sided box jig for router mortising, but by the time I had everything in position and clamped I was completely out of patience with the whole procedure. Finally, I resorted to drilling out mortises on my drill press and doing the final chopping out by hand. While I was generally happy with the resulting mortises, the process was far too slow.
Then I happened on an article in an old woodworking magazine that described a basic router mortising fixture. It was a wooden beam with an attached channel for the router edge guide; it used Jorgensen hold-down clamps to secure the workpiece. The author nailed stops to the beam to limit router travel. While the basic idea was sound, it seemed less than fully developed. Nailing stops to something I’d just worked hard to make smooth and square seemed a little crazy, so I added T-track and moveable stops.
I also added wooden clamping cauls of various lengths outfitted with steel bars and rare earth magnets to hold them to the clamps while allowing for some adjustment. The cauls and Gizmozilla’s 4′ length adds to its flexibility.
Video: Find out where the glue goes inside a mortise-and-tenon joint.
To Buy: “Getting Started with Routers” DVD.
Plan: Download a SketchUp model of Gizmozilla.
In Our Store: “55 Best Shop-Made Jigs” CD. Read more