Simple Rotary Jig Modification

[bergerud]

Seems to me that if the rotary jig were to have rails on the bottom board for the dowel to roll on, a few problems would be solved. There would be clearance for dowels which are not perfectly round as well as clearance for dust between the dowel and the bottom board. (One would have to flip the bottom board over onto the rails or use a different board for the measurement process and the jig would sit a little higher.)

It would be an easy experiment to add two sand paper rails to the bottom board. Then make a rough 2 inch diameter hexagonal or octagonal cross section dowel on a table or band saw. The ends of the dowel that roll on the rails can be made circular with a 2 inch I.D.hole saw. Now either carve it circular or just carve it.

Further, if one made a set of precise 2 inch diameter "driver" wheels for each end to be part of the jig, more problems would be solved. The circumference of all projects would be consistent reducing the trial and error involved in pattern length. The need for precise dowels would be eliminated. The only requirement would be that the ends which attach to the driving wheels be cut square.

(Maybe different height rail sets would be a way to design a jig for variable diameter dowels.)