Built Case For Leigh Jig...

[Derek Arita]

I've been asking questions in order to get a case built for my Leigh Dovetail Jig. I finally got around to finishing it, so I just thought I'd post it here. I originally made one out of 1/2" ply, but it weighed a ton, so I was trying to find a lighter material to make another. After asking for advice here, I decided to use some cheap HD 1/4" birch ply, that is actually 3/16" and very light. I used the jig to box joint to corners for added strength. The ply had a tendency to chip while cutting the box joints, so I had to use an spiral bit to help reduce that.
My fear was that the 1/4" was going to be too thin to take the weight, however now that it's done, I see that it's plenty strong to take the weight of the jig. It's not fancy, but it works. Take a look...
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[Ken Fitzgerald]

Practical and well executed! Nicely done Sir!

[lowell holmes]

Refresh my memory. I have a Leigh jig. How do you make box joints with it?
I'm guessing you just use straight bits in the router.

[David Eisenhauer]

I read somewhere, 40 years ago or more, that - pound for pound, plywood is stronger than steel. 1/4" ply is plenty strong enough, but effective joinery without introducing heavier frame components has always been the stymie for the average amateur builder types.

[Mike Cutler]

I read somewhere, 40 years ago or more, that - pound for pound, plywood is stronger than steel. 1/4" ply is plenty strong enough, but effective joinery without introducing heavier frame components has always been the stymie for the average amateur builder types.

A long time ago, in a life far, far, away, I used to install the nose cones on an obsolete ICBM. The nose cones were made of laminated sitka spruce, 7 layers to be exact.
I think Derek will be fine.;)

[Derek Arita]

Refresh my memory. I have a Leigh jig. How do you make box joints with it?
I'm guessing you just use straight bits in the router.

Lowell, you use a straight bit and a special setup, but it works. You are limited to a few sizes if you don't add more templates. Someday...