Making jigs and templates for repeat cuts

First of all — what is a jig, and what is it used for?

A jig is essentially a guide or template that helps you make the same cut multiple times with accuracy. They’re especially useful when you need parts to be as close to identical as possible — for example, the legs of a table.

Jigs and templates are often made from MDF, plywood, or even acrylic. These materials are relatively stable, meaning they don’t expand or contract as much as natural timber in response to humidity or temperature changes.

I’ll often use a jig on the table saw or mitre saw, while templates come in handy with a router and a flush-trim bit. A flush-trim bit has a bearing that sits in line with the blade — this allows the router to copy the shape of the template directly onto the piece being worked on.

In most projects, I’ll make several jigs and templates for different components — for example, table legs, corner details, or recesses for fittings. This makes it possible to cut slots, holes, and shapes in the same location across multiple pieces.

While making jigs and templates does add some extra time at the start of a project, it pays off in the long run. They allow for precise, repeatable cuts and save a lot of frustration when it comes time to assemble everything — because things actually line up the way they should.

Blanks ready to be made into there final shape using the router and flush trim bit. In this situation, the template is fixed to the plywood and the piece being worked on is on the top.