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That time I tried to make a 'quick' plywood jig for a weird angle
I had to cut a 22-degree bevel on a bunch of short pieces for a built-in. Thought I'd save time by making a simple plywood guide block for my circular saw. I spent an hour getting the angle perfect, but when I clamped it to the first board, the whole thing flexed and the cut came out wavy. The lesson was clear: a jig made from a single layer of 1/2 inch plywood is just too flimsy for a precise cut. I should have used MDF or doubled up the plywood from the start. Has anyone else had a jig fail in a silly way because the material wasn't stiff enough?
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eva_garcia566mo ago
That whole "right tool" idea applies to clamps too. A jig can be perfect, but if you use those little spring clamps on a long piece, the pressure isn't even. It'll bow the jig just enough to ruin the cut. Seen it happen with a router guide. You need the heavy bar clamps to spread the force out, or it's all for nothing.
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laurabennett6mo ago
Ugh, that's the worst. It's like a rule of the universe. The faster you try to do something, the longer it takes. You see it everywhere. People use a flimsy tool to save two minutes and wreck the whole project. My dad always said, "The right tool for the job isn't just a suggestion." He was talking about wrenches, but it applies to jigs too. That thin plywood was never gonna hold up.
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