George’s 3 Favorite Woodworking Jigs for Cabinetmaking

3 Favorite Cabinet Jigs

I’m always looking for ways to streamline my woodworking. Thrifty (read cheap) woodworker that I am my preference is to problem solve with shop-made woodworking jigs rather than commercially produced jigs.

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Here are my three favorite shop-made woodworking jigs for cabinetmaking:

3 Favorite Cabinet Jigs

Dado Sizer

For years I used the T and E method (Trial and Error) for sizing dadoes. That is until I came up with the Dado Sizer.

Here’s the deal. Using a piece of Baltic Birch plywood I cut a series of increasingly wider dadoes, starting at 23/32″. After cutting the 23/32″ dado I added a .005″ shim and cut another dado. Added another .005″ and cut another…on and on until I had a dado that was .010″ over 3/4″ wide. I labeled each dado with its size.

3 Favorite Cabinet Jigs

When I’m ready to make a dado I simply slip the shelf into the dadoes until I find which dado it fits in. That’s the dado head/dado shim set up I use on the table saw.

I still make test cuts, but this jig cuts a lot of time off my dado head set up.

3 Favorite Cabinet Jigs

Adjustable Shelf Hole Jig

There are lots of ways to make holes in case sides for adjustable shelves, including drill presses, hand-held drills, high falutin’ specialized tools and more, but this is my favorite.

It’s made from a piece of 1/4″ Baltic Birch plywood. The holes are 5/8” diameter on 3” centers. Use a drill press to make the holes so you can use a fence and ensure the holes are all equidistant from the edge.

The holes are 1” on center from one edge and 2″ on center from the other edge. Use the 1” set back on cases with face frames and the 2″ set back on frameless cases with inset doors.

Since you may not always use every hole in the jig it’s helpful to number the holes so you can track which ones you do use.

3 Favorite Cabinet Jigs

Clamp the jig to your case side making the end and edge of the jig even with the end and edge of the case. If you consistently position the jig (you’ll need to flip it over as you go from one edge to the other) you holes will be consistently spaced and your shelves won’t rock and roll.

Make the holes using a 5/8″ guide bushing in a plunge router and allowing the guide bushing to seat in each hole. With a 1/4″ or 5 mm router bit in the router and depth correctly set you can quickly and easily plunge shelf holes. With the high rpm of the router bit you’ll never chip a veneer.

jig1

Routed Dadoes

On big cases, it’s easier to bring the tools to the work than the work to the tools. If you need to cut dadoes in a big case side, like an entertainment center, it’s almost impossible to do that on a table saw. This jig will handle it for you, no sweat.

It’s made of Baltic Birch plywood with one long side fixed to the cross pieces and the other side adjustable. I made mine long enough to straddle a 24″ wide case side. The narrow fixed side is 4″ wide. The wider movable side is 6″ wide. When you fasten the fixed side to the end cross pieces be sure they’re perfectly square.

jig2

The movable side gets its adjustability by virtue of 1/4″ carriage bolts going through 1″ holes. A fender washer straddles the hole and a wing nut locks it down.

jig3

Set up the jig by squeezing a piece of shelf material between the fixed and movable sides. Lock the movable side in place using the wing nut.
jig4

Set up a pattern bit in your router and you’re ready to rout. The bearing on the bit rides on the edges of the fixed and movable sides creating a dado that is perfectly sized to your shelf material. Be sure the pattern bit is smaller in diameter than the thickness of your shelf material. I use a 5/8″ bit for 3/4″ shelves.
Discussion
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13 Responses to “George’s 3 Favorite Woodworking Jigs for Cabinetmaking”
  1. BobE

    I guess I’m thick but I don’t understand this. What / where are you routing? I’m supposing this is to route dados for shelves.

    Thanks,
    BobE

    Reply
    • WWGOA Team

      This can be used anywhere a dado is required. Yes, a cabinet shelf or carcase construction is a perfect application for a dado joint.

      Reply
  2. ddcoleman

    I love this type of jig for making dadoes because you can get a perfect fit every time with very little setup. But with a standard pattern bit the jig has to be thicker than the cutting length of the bit. I therefore prefer to use a dado-cleanout bit which is essentially a short pattern bit.

    Reply
  3. bobforsthoffer

    With the bearing riding between the guides and the bottom of the cutter 1″ below the bearing, how do you adjust the depth of cut? I need a 1/4″ deep dado.

    Reply
    • WWGOA Team

      In your case you might need to either find a router bit with a shorter cutter, or alternatively extend the height of your plywood to enable the appropriate depth dado to be created with the bit that you currently have.

      Reply
  4. g5flyr

    WWGOA made a video re the routed dado jig. I can’t find it any more. Did it get removed? If it is still available can you point me in the right direction?

    Reply
  5. Fred

    George made a video years ago and showed how to make and use the adjustable dado jig. What happened to it?? I still have some of the printed article covering this jig but the video seems to sink in better. Sure could use his measurements so I could build it again. His details were great and I had perfect results but that was years ago and the jig was misplaced. Help would be nice even if it is on a video I would have to buy. Thanks Fred

    Reply
    • Customer Service

      Hi Walter. These images have now been fixed. We are sorry for any inconvenience.
      Thanks
      Jean-WWGOA Video Membership

      Reply
  6. PAUL

    It wouldn’t hurt to add a little more content to these brief instructions. I know you can’t run a business ugiving it all away, but it might help to give enough so when the reader is done he feels like learned something. I find you sometimes assume too much or not enough. Tough place to be, I get it. Maybe if you offered a choice of instructional Levels to select from before each mini-instruction.

    Reply
    • Customer Service

      Hi Paul. Thank you for your feedback. I will forward your comments on to the proper department. Your comments are important to us and help with the development of our online video streaming community.
      Thanks
      Jean-WWGOA Video Membership

      Reply