While building a TV wall unit, I had to find a way to accurately machine flutes in long columns. The fluting jig shown here is my answer. What I like about the jig is that it makes it easy to rout straight, smooth flutes along the length of the workpiece. It’s worked so well in my shop, I also use it to rout grooves, dadoes, and mortises. The jig is made from 1/2" Baltic birch plywood and consists of a base and two sliding fences. These fences butt against the edges of the workpiece, which keeps the cuts nice and straight.
Building the jig starts by cutting an extra-long workpiece to width. Next, I cut the grooves for the hardboard runners, then cut the two fences free from the blank. You can use your router’s baseplate to mark and drill the mounting holes and bit opening in the base. I used the router table to rout the two slots for adjusting the fences. A centerline drawn across the top face and two edges helps position the jig during use. Next come the two fences. First, the hardboard runners are glued into grooves. A bolt, washer, and knob are used to tighten down the fences. The three counterbored holes allow the fences to be adjusted to fit a wide range of workpiece widths. A little paste wax helps them slide smoothly along the base.
