Don Stephan
Posts: 825
Joined: 2003-07-18
Location: Cincinnati, Ohio
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I made one of 3/4" plywood using the video as a reference. The two cauls were about 36" x 10". Down the centerline of each I screwed a perpenidicular piece about 6" wide, as if adding the base of a "T". For the upper caul, the adjoining edge of the second piece was tapered from the midpoint to each end at I think 1/16" per foot, so that when the two cauls are brought together they touch at the middle. Finally, I added 9.5" x 9.5" square ends to the lower caul so that it will sit upright on the work table, and bored 1" holes near the bottom of each so that a Jorgensen clamp will pull the two cauls together. Joint the long edges of the lower caul so that they are very straight, and can serve as edge guides with a bottom-bearing straight router bit. Because of the slight curve in the upper caul, when the two clamps are clamped together pressure is applied all along the veneer. If the top caul were perfectly flat, and the veneer being clamped 12" long, if excessive clamp pressure were applied the upper caul would flex and only apply pressure to the ends of the veneer.
This jig has been extremely useful, but lately I have been working with veneer up to 60" long. Has anyone tried making and using a longer version of this? Thanks.
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