Right Angle Clamping Jig
While making my assembly table I was quickly reminded that when joining 2 large panels at a 90 degree angle, It's a pain in the butt! To make this an easier task for future projects, I knocked out a few of these right angle clamping jigs. Using scrap 3/4" plywood/MDF, I was able to batch out 8 of the jigs in under an hour.
Dimensions: 12" x 12" x 3/4"
To begin, I start by cutting some scrap 3/4" MDF to 12" wide at the table saw. The scrap piece I used is 48" long which was enough for me to make 8 jigs.
Using the crosscut sled I first crosscut the board in half since it was a little to long to safely cut in to 12" pieces.
Next I insert my stop block and set it to 12"
Referencing the stop block, I batch out the four 12" by 12" boards.
The next step is to cut the boards from corner to corner to make the 2 jigs.
To do this, I used the cross-cut sled and placed one corner in the kerf in the fence and lined up the other corner in the kerf near the blade and slowly cut the boards in half.
The clamping jigs have a 2" hold in them to assist in clamping the jig to the board.
To mark for the hole, I made a center line 1 1/2" from the edge and bottom of the jig.
Using a 2" forstner bit, I drilled the hole all the way through the jig. Since this is a larger forstner bit, I slowed my drill press down to make this a safer operation.
Next I focus on marking for the waste I need to remove for the clamping areas. When making the marks, I mark both sides of the board which you will see why shortly.
To begin, I scribe a line at 2" from the 90 degree edge.
Using a measuring tape I make another mark 7 1/2" from the bottom edge to mark the bottom of the clamping area
Using a combination square I strike the line.
I flip the jig over and make the same markings on the other side.
To begin removing the waste I set my band saw fence to 2".
And begin removing the waste.
This is why I marked both sides of the board. If I only marked one face, I wouldn't know where to stop when cutting the other side at the band saw.
To make the other cut i'm using my miter gauge. I line up the markings with the blade and setup a stop block so that I can once again batch out these cuts.
Finally, I made a notch on the corner of the jig to make sure that it doesn't interfere with anything when I'm using them.