Maker Mind Router Texture Jig

Tools

• Tape Measure
• Speed Square
• Pencil
• Awl or Center Punch
• Drill or Drill Press
• Miter Saw
• Jigsaw or Hand Saw
• 2-5/8 in Hole Saw or Forstner Bit
• 3/32 in Drill Bit
• Brad Nailer
• Clamps
• Router

Cut list

• Left and right frame sides — 2 × 7 in L x 4 in H x 1/2 in thick 1/2 in plywood
• Bottom frame panel — 1 × 7 in L x 3-3/4 in W x 1/2 in thick 1/2 in plywood
• Front and back pieces — 2 × 4-1/2 in W x 3 in H x 1/2 in thick 1/2 in plywood
• Router block — 1 × 3-3/4 in x 3-3/4 in x 1-1/2 in thick 2x6 lumber
• Fence — 1 × 2 in H x 3/4 in thick x user-determined length 3/4 in plywood

Build steps

1. Confirm the Router Fit and Lay Out the Jig

   • Measure the router motor body where the block will grip it and confirm whether a 2-5/8 in opening will provide a snug fit. • If your router body has a different diameter, adjust the hole size before cutting the router block. • Lay out both 1/2 in plywood side panels together as a matched pair so their pivot locations will align. • Mark a pivot center on each side panel 3/4 in down from the top and 3-1/2 in from one end. • Mark the center of the 3-3/4 in x 3-3/4 in router block by drawing diagonal lines between opposite corners. • Confirm that the plywood edges are straight and square before beginning assembly.

2. Cut the Plywood and Router Block Parts

   • Cut the two side panels, bottom panel, and front and back pieces from 1/2 in plywood. • Cut the router block to 3-3/4 in x 3-3/4 in from the 2x6 lumber. • Keep the router block faces flat and parallel so it sits evenly between the side panels. • Cut the fence from 3/4 in plywood to a user-determined length suitable for the workpieces you plan to texture. • Keep one long edge of the fence clean and straight because the jig will reference against it. • Stack the two side panels and confirm that they match exactly. • On the bottom panel, mark a centered 5/8 in x 2-1/2 in rectangle with its length following the router swing direction. • Drill an access hole in one corner and cut out the opening with a jigsaw.

3. Make the Clamping Router Block

   • Use an awl or center punch to mark the center of the router block. • Drill the 2-5/8 in center hole using a hole saw or Forstner bit with a drill or drill press. • Cut a straight relief slit from one end-grain edge into the center opening using a hand saw or jigsaw. • Drill a clearance hole across the relief slit for the 3 in construction screw. • Countersink the screw hole so the screw head does not interfere with the router block swing. • Test-fit the router and confirm that tightening the screw closes the relief slit and clamps the router securely. • Clamp the small block firmly while drilling and cutting. Do not hold it by hand.

4. Drill the Pivot Holes

   • Clamp the two side panels together and drill through both pivot locations at the same time so the holes remain aligned. • Mark matching pivot locations on opposite faces of the router block so the swing axis passes evenly through the block. • Drill 3/32 in pilot holes in both sides of the router block for the 1 in Kreg pocket-hole screws. • Keep the pilot holes square to the router block faces. • Dry-fit the side panels and router block with the two pivot screws. • Confirm that the router block sits centered and rotates without rubbing against the frame. • Lightly ease the router block corners with sandpaper if additional swing clearance is required.

5. Assemble the Plywood Frame

   • Apply wood glue to both ends of the bottom panel. • Clamp the side panels in place, making sure they are flush with the ends of the bottom panel. • Check that the frame is square before securing it. • Fasten the side panels to the bottom panel using 1-1/4 in brad nails. • Apply glue to the mating edges of the front and back pieces. • Position the front and back pieces with their bottom edges aligned with the bottom panel. • Secure both pieces using 1-1/4 in brad nails while keeping the frame square.

6. Install the Router Block

   • Place the router block between the two side panels and center it within the frame. • Clamp the block in position if needed. • Confirm that the pivot locations are 3-1/2 in from one end and 3/4 in down from the top on both sides. • Drive one 1 in Kreg pocket-hole screw through each side panel and into the pilot holes in the router block. • Tighten both pivot screws evenly until side-to-side play is removed but the block still swings freely under hand pressure. • Insert the router into the 2-5/8 in opening. • Tighten the 3 in construction screw only enough to hold the router securely. • If the swing feels tight, loosen both pivot screws slightly and evenly.

7. Mark the Fence and Jig

   • Mark reference lines every 1-1/2 in across the full length of the fence. • Use a speed square and a permanent pen or pencil so each line is straight and easy to see. • The 1-1/2 in spacing is based on the swing distance of this jig when using a 1/2 in cove bit at the example cutting depth. • If the router bit size or cutting depth changes, test the actual swing distance and adjust the fence spacing accordingly. • On both sides of the jig, mark a reference line 3-1/2 in from one end. • Transfer this reference line across the bottom and both side panels. • During operation, align the jig reference line with each marked line on the fence.

8. Test and Establish the Texture Pattern

   • Clamp or screw the fence securely beside a scrap workpiece with the marked edge parallel to the workpiece. • Install a 1/2 in cove bit in the router and set a shallow initial cutting depth. • Place the jig against the fence and make one smooth test swing cut. • Move the jig to the next 1-1/2 in fence mark and repeat until one full row of matching cuts is complete. • Move the workpiece forward 1/2 in to begin the next row, matching the width of the cove bit. • Offset the workpiece by 3/4 in to the left or right on every other row. • The 3/4 in offset is half of the 1-1/2 in swing distance and creates the repeating woven texture pattern. • Adjust the cutting depth or spacing on the scrap piece until the pattern is consistent.

9. Texture a Workpiece

   • Begin texturing the final workpiece only after the scrap pattern looks correct in depth, overlap, and spacing. • Secure the fence and workpiece firmly before routing. • Keep the same face of the jig against the fence throughout the process. • Align the jig reference line with each 1-1/2 in fence mark and move one line at a time without skipping. • After completing each row, move the workpiece forward 1/2 in. • Offset every other row by 3/4 in to maintain the woven pattern. • Allow the router to reach full speed before beginning each cut. • Lift the router bit clear of the workpiece before repositioning the jig. • Keep both hands on the jig and router assembly and keep the power cord clear of the swing path.

Safety notes

• Wear safety glasses, hearing protection, and appropriate respiratory protection when cutting, sanding, routing, or machining materials.
• Read the entire project plan and confirm all measurements, material sizes, and tool setups before beginning any cuts or assembly.
• Always follow manufacturer safety instructions and use proper safety equipment such as guards, clamps, and stable work supports.
• Clamp the small router block securely before drilling the center hole, relief slit, or screw hole.
• Confirm that the router is firmly clamped inside the block and that the pivot screws are secure before turning the router on.
• Keep both hands on the jig and router assembly during operation and keep the power cord clear of the swing path.
• Never operate tools while fatigued, distracted, or under the influence, and seek supervision or assistance when using unfamiliar tools or techniques.
• Maker Mind provides informational project guidance only; users are responsible for safe tool operation, verifying measurements, and maintaining a safe workshop environment.

Finishing suggestions

• Leave the jig unfinished, or apply a light coat of paste wax to the bottom of the jig and other rubbing surfaces to help it slide smoothly.
• Do not apply a thick film finish to the pivot points or mating surfaces because it may interfere with the swing.
• Inspect the jig regularly and retighten the clamping and pivot screws as needed.