This is another great attachment for the Ultimate Crosscut Sled with Dust collection. This jig gives plenty of accuracy and stability for oversized projects that require spline reinforcement. So lets get right down to the project. Plans can be found here: http://rhwoodshop.com/store/#!/Spline-Jig-Attachment-for-the-UCCS/p/84549028/category=23790301
Materials and Hardware that you will need:
Enough 1/2” and 3/4” plywood that will make what you see here.
Also, you will need to get you a 4 ft stick of T Track with T bolts and knobs to attach the jig to the sled later.
Begin by cutting the base, stabilizers, uprights and tops to the dimensions on my plan.
Now utilizing the sled with the miter attachment, cut the 45 degree angle on the upright pieces, not to mention the small knock off miter on the back top corner of the upright (take your time with this step. Very important to get the miter cuts exactly 45 degrees).
Utilizing the help of two speed squares, and a clamp for safety, make the miter on the bottom edge of both tops. (take your time with this cut, it is super critical)
Now the uprights must have a notch out of the back edge to accommodate the stabilizer. Find the exact thickness of the stabilizer by cutting into a piece raising the blade up into the piece until it clears away the thickness at the apex of the blade. Now using the sled and my half lap cutting technique that I developed, cut the notches out.
Using the dado stack in the table saw, cut the 3/8” deep dado for the T-Track.
Drill out 4 holes (if you prefer, but 2 is only needed) in the base of the sled for the T- Bolts. Hold downs can be used in the back to secure the sled.
Using some rapid fuse glue from DAP, a speed square and patience, align the uprights to the top and then glue the whole section to the base. Remember the center upright will act as a blade guard so it must be in the EXACT center of the top and base.
Now check for a perfect 90 degree angle, you should be right on if everything was cut properly.
Glue in the stabilizer inside the uprights and to the base.
Cut the T-Track to length using the Table Saw and glue it in using more DAP Rapid Fuse Glue.
Now attach the jig to the sled and make your first pass through cut. Now take your frame or box and make spline grooves to accommodate as many splines as you like.
Thank you for coming and I hope to see you again real soon!
Take care, be safe in your shops and I will talk to you on the next build. BOOM!!!