Panel Jig

Panel Jig

Over the years I've heard from quite a few DIYers regarding tools, most asking how they can build top quality projects without spending thousands of dollars. One inquiry in particular wanted to know how to build a DR Horn in the absence of a eight hundred dollar table saw, perhaps by having a lumber yard pre-cut the parts. The problem with that scenario is that my projects involve a lot of 'trim-to-fit' steps, making pre-cut parts not a viable option. The good news is that I do not own an eight hundred dollar table saw either, and that you can build just about any cabinetry with a two to three hundred dollar table saw, or even better, buy a used one for a hundred bucks or so. This will understandably be a shock to those of you who regularly peruse tool catalogs, knowing that you can easily spend five hundred on a rip fence alone, let alone a saw to mount it upon. But the truth of the matter is that even a mediocre saw can turn out perfectly square and true panels of just about any size so long as you have a panel-cutting jig. My old trusty jig, after some fifteen years use and hundreds of projects, needed replacing recently, so I took pictures of the process to show you how you can make what I consider to be the most important piece of equipment in my shop.
Also include are plans for the cutting and assembly jigs for melded tweeter arrays, and cutting jigs for melded array mounts.
Plans are $1.95, delivered within 24 hours as email attachment in MS Word format. PDF available on request.