Introduction: How to Make Dowels: Dowel Making Jig ( With Table Saw )
Have you ever needed a dowel but weren't sure how to make one and ended up buying one instead? You can actually make dowels yourself without using a lathe! In this guide, I'll show you how to create a jig for making dowels using a table saw.
Supplies
Material:
- Plywood
- Lag screw
Tools:
- Clamp
- Compressor (optional)
- Braid Nailer (optional)
- Orbital sander (optional)
- Belt Sander (optional)
- Hand Planer (optional)
Step 1: Design Concept
The idea is to create a jig with a circular channel that allows the lumber to pass through. There are three simultaneous motions involved:
- The table saw spins and cuts right at the edge of the circle.
- The drill rotates the lumber while simultaneously pushing it through the circular channel.
I'm also sharing the 3D CAD model in Fusion 360 format.
Attachments
Step 2: Jig Making in Action
Here are some screenshots of the making of the jig, but make sure you watch this section of the video to get concrete ideas.
Step 3: Using the Jig the First Time
To begin, align the center of the jig with the saw blade and cut the bottom part of the jig. When you're ready to use the jig, raise the saw blade to the desired height and clamp the jig to the fence. Refer to the picture and video for more details.
Step 4: Prepare the Lumber
Use a table saw to rip the lumber slightly larger than the hole size of the jig. Avoid cutting the lumber to be the exact same thickness as the diameter of the jig's circle—I'll explain why in the discussion section of this guide.
Taper one end of the lumber so that it can easily fit through the jig's hole. For smaller dowels, you can use a knife or a belt sander; for larger sizes, I recommend using a hand planer.
For the other end of the lumber, use a socket to hold it if you're making smaller dowels. For larger dowels, drill a lag screw into the end. Then, attach the socket or the lag screw to the drill.
Step 5: Making the Dowels
Ensure the table saw blade is raised to the desired height so that the blade edge just touches the boundary of the circle. Place the tapered end of the lumber into the hole, turn on the table saw, and use the drill to rotate the lumber while pushing it through the hole simultaneously.
Be sure to keep the direction of the push aligned with the hole.
See this section video in action.
Step 6: Sand the Dowels
Sand the dowels further to make them perfectly round and smooth.
Step 7: Discussion
There are several important things to keep in mind when using this method:
- Blade Height:
The height of the blade must be precise. You may need to fine-tune it to get the perfect cut.
- Alignment of Holes in the Jig:
When making the jig, ensure the holes on the front and back panels are perfectly aligned. If they aren't, the dowels will not come out perfectly round.
- Lumber Thickness:
When preparing the lumber, make sure its thickness is slightly greater than the diameter of the hole. This is because the rotation center may not be exactly at the center of the lumber. If the lumber is the same thickness as the hole's diameter and the rotation is off-center, some parts may not be cut and remain flat. As shown in the animation, the two sides of the lumber didn’t get cut and stayed flat.
- Directions for Feeding the Lumber:
When feeding the lumber into the jig, ensure the direction is properly aligned with the hole. Misalignment can result in dowels with uneven thickness.
Step 8: Summary
To summarize,this method is straightforward because the jig is simple to make and only requires a table saw. However, as discussed earlier, there are a few critical details that must be precise to achieve a perfect dowel. I still find it quite challenging to get everything right. In the future, I might share a different jig design with fewer moving parts that can produce even better results.