This page describes a jig I made for a plunge router. This jig worked well for me and helped me create many 3/4 and 1 inch bore NAFs. In reading forum posts, many people are looking for inexpensive ways make their NAF. Not all people have access to expensive wood working tools. I hope someone finds this method useful.
The particular plunge router I used came with a collar, as many routers do. These collars are made to allow the user to accurately follow specific patterns or jigs. In the case of my router it was an 1 1/2 outside collar. Another aspect of most plunge routers is that they come with adjustable steps on the depth gauge. this works well for NAFs because of the large bit typically used. This requires multiple passes, successively deeper to accomplish the full bore. I generally attempt no more than 1/8 inch per pass, even on my router table.
Please keep in mind, I will describe the measurement in generalities and they will need to be adapted to your particular situation.
This jig is made of scrap 3/4 plywood, 1/4 plywood and 1 inch pine.
My jig frame measures 5 inches wide by 32 inches long by 5/8 tall, on the inside. The width is not so important, other than helping make it more rigid. The length needs to be longer than the length of any NAF you want to build. The height needs to be just higher than the thickness of any blank. It is made from 3/4 plywood with 5/8 x 3/4 pine on each side. The picture shows the jig with a blank in it. The blank is clamped to one side with a 1 x 2 of the same length and height as the jig frame.
The SAC guide, shown in this picture, is aligned over the blank and clamped in place. The router collar will then follow this guide, creating an accurate SAC. The SAC guide is made from 1/4 plywood with 3/4 x 1 pine board on one side to use as a fence.
The Bore guide is a longer version of the SAC guide. I created mine about 16 inches long. For longer flutes, I would have to make part of the bore and then move it and finish the remaining part of the bore.
If you would like more details or clarification, feel free to contact me.
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