



While working on a cabinetry project I needed to rout dados on 7' long panels. This means I needed to bring the tool to the piece. I can use a straight edge of some type and a clamp to get this job done but on every cut, I would have to measure for the offset of the base which introduces the possibility for human error. I decided to make a zero clearance jig to help make this task not only repeatable but fast. I measure on the panel for the top or bottom of the dad and slide my jig into place and it's ready for the cut.

The jig is super simple to make. The fence portion is 12" long and the perpendicular rail is 18" long. Both pieces are 3" wide and are made out of MDF. To attach the rail to the fence I first used CA glue and activator to create an instant, but temporary bond so that I can install 1 1/4" screws. Next, I needed to create the zero clearance cut and this part is important because it's going to make this jig unique to whatever setup I'm using. I used a 23/32 router bit for 3/4" plywood because oftentimes 3/4" plywood is actually a little thinner. This router bit is specifically made for 3/4" plywood that I picked up years ago.

Parts used in this build(affiliate links below):

23/32 Router bit: https://amzn.to/2EOoBlP

Bosch Plunge router kit: https://amzn.to/2EOsPdk

CA Glue: https://amzn.to/2Hr1Ffe

CA Activator: https://amzn.to/2C9bESX

Wood Glue: https://amzn.to/2EU1ZAB

Clamps: https://amzn.to/2EOVhMc