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Tjig1here are probably thousands of ways to scarf two boards together, this is what I put together to use the materials and equipment I had at hand.  Everything, except the Plexiglas was from the scrap pile.  I started with the router that had a maximum extension of about 1¼”, so the baseplate needed to be as thin as possible so I could scarf together the chine logs which were 1″ thick.  For this I used a piece of Plexiglas 24″x 10″.  A version of the jig on YouTube used aluminum angle, but with only 3 holes for mounting, this posed a bit of a problem.  I used the baseplate from the router to position the mounting holes and locate the center.  A ¾” mortising bit with a guide bearing was my initial thought to produce a flat surface.  A ⅞” hole was drilled through the Plexiglas.jig2  Make sure the mounting screws for the baseplate are countersunk below the surface of the Plexiglas.  It was also noted that there was too much flex in the baseplate, so a stiffner was added as close to the back of the router as possible.

The tapered sides were from a single 2″ x 4″ x 24″, softwood, spruce or pine, no knots.  A diagonal line was drawn, ½” from the left at the start of the cut on the right side and finishing at ⅝” from the right side at the end of the cut to allow for the thickness of the sawblade and end up with 2 pieces with the same slope of 12:1.

jig3A means was needed to hold the work piece, and keep the two sides the same position with each other, and not obstruct the wood shavings from discharging out the back so the work piece would be clear all the time.  To hold the work piece, a short pipe clamp is used, to keep both sides in the correct position, an interlocking index was used with a spacer in the center for the pipe clamp.  The clamp should be toward the front half of the jig to keep the work piece in position near the area being scarfed.  There should be enough room at the front of the jig to put a 3″ to 4″  sacrificial board the same thickness as the guides at the end of the scarf so the guides don’t get scarfed.  Make sure everything is nice and square before screwing and gluing the guides to the tapered boards

When doing the chine or sheer logs, two pieces can be put in the jig at the same time, don’t over tighten the clamp or the pieces will buckle up in the middle.  Make multiple passes taking ¼” at a time.  On the last pass, leave enough on the front edge, so a bit of sanding with a belt sander will bring the edge to a fine feathered edge.

Put a pencil mark at the top of the scarf so you can see where to align the pieces without going too far when gluing.

 

Happy scarfing

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