View Full Version : Jig for doing popper mouths

10-13-2004, 06:24 PM
I mentioned this jig in another thread. A gent on the site asked if I would post a photo, so here it is. Basically, I took a short section of scrap wood and attached two sides to it to form a corner. This is placed in a vice on the drill press. I use a clamp to keep the blank verticle in the jig. In addition, I'll keep a hand near the top of the plug to secure it. To do the actual mouth, I'm using a full round rotar bit. Center the bit over the front of the plug and slowly lower the bit into the wood and drill to the depth you want. Instant popper mouth :) I used to use the same jig to keep my blanks verticle when thru-drilling on the drill press.


10-13-2004, 06:26 PM
Oh yeah, once it is done, I'll take a piece of sandpaper, place it over the mouth of the popper, and use my thumb to clean it out and round the sides at the top.


10-13-2004, 06:30 PM
thanks andrew.

10-13-2004, 06:42 PM
Hey Jigs

Where did you get that vise that bolts to the table of the drill press?. That is cool. I've never seen that in any tool catalog.

- - - SK

10-13-2004, 07:07 PM
Cool Jigman,thanks for showing.Thats why you are The Jigman and have all your fingers:D

10-13-2004, 09:40 PM
anyone got a 11/8 half round router bit:( nice jig jigs.

10-13-2004, 10:06 PM
You are welcome guys. Hope that helps you to keep your fingers too :)

SK, Home Depot I believe is where I got the vise. I've seen them a few places around town.

Umm, I guess thats a half round bit not full round :rolleyes:

Salty, dear, if you had squealed like a pig for me :eek: you would have had one in bandito colors too :D I check out the cave next year. I gots some special pink filtered glasses coming just for that trip :laughs:


10-14-2004, 08:17 AM
Originally posted by Jigman
I check out the cave next year.


Piece of wisdom for ya, Jigsy: never postpone happiness.

10-14-2004, 03:52 PM
Thanks Jigman. :)

Bob Thomas
10-14-2004, 04:14 PM

Biggest I could find was 1" at Spags in Shrewsbury. I made a jig like jigman but with the larger bit, I got a TON of "Chatter" Became dangerous when the bit holder thing-a-mabob came flying off. :smash:

10-14-2004, 04:56 PM
TXS...been looking for some time now...ran across a man that told me he had the jig that blue streak used for doing popper mouths..I gotta get back to see if he got a chance to dig it out......wouldn't that be nice.

10-14-2004, 06:15 PM
Originally posted by capesams
TXS...been looking for some time now...ran across a man that told me he had the jig that blue streak used for doing popper mouths..I gotta get back to see if he got a chance to dig it out......wouldn't that be nice.


10-14-2004, 06:21 PM
The router bit Jigman is using is called a round nose or core box bit. Do google search for that and you will find plenty of sources.

Jigman's jig looks like a good idea, but I would not rely on a spring clamp to hold the plug. The spring clamp is just not strong enough to hold the wood steady, and if that thing moves with a drill press spinning you might get a very unpleasant surprise. Might explain the chatter that Bob Thomas had problems with.

10-14-2004, 07:11 PM
Any suggestions on what might work better than the spring clamp? I also have a hand on the plug while I'll doing the mouth too to keep it steady. You are right, the clamp alone would not be enough.

Pa, know what you mean. Sooooo much to do up there and not enough time to do it all. Was meeting up with Winch and Timber that night for our last Cape surf trip. I'm sure the salty cave visit would have been great too. May be I need to retire early so I have more time to fish :laughs: :happy:


green meanie
10-14-2004, 08:11 PM
thanks for the tip.
a visual helps alot.

10-14-2004, 08:15 PM
Originally posted by Jigman
Any suggestions on what might work better than the spring clamp?


Jigster,would making a jig to the form of the plug with a square back on it and held with 2 screw clamps top and bottom work?

10-15-2004, 05:59 AM
try two quick-grips,,they have yellow rubber pads on the arms so it won't a leave a mark. they come in many sizes....

10-15-2004, 07:44 AM
Ya got the right idea Jigman. Try roughing out the opening w/ a big drill before you use that router bit - save wear and tear on the tool and I know its another step/operation as well.

Some De-Sta-Co clamps (toggle style)would be ideal if you have a lot to do. :D They make several different kinds - not cheap, but once you have it set up you flick the lever or two and pop in the next piece of stock.

Most drill presses have too much slop in the spindle - a manual milling machine is better way to go. ;) Lots more $ as well.

I'm not a plug builder, but I have lots of experience fixturing. :)

Jigman - pm me a mailing address and I'll send ya out a couple of clamps to try out. I have some used ones in a box.

10-15-2004, 09:12 AM
Jigman, sorry to criticize without offering an alternative. I have not done popper mouths that way so I will have to think about it. What about placing a vertical pin in a board the same diameter as the through hole. Place the plug on the pin, then keep the plug from spinning with a handscrew clamp. The pin could be a long machine screw. You could add some blocks to elevate the clamp closer to the action. Some handscrew clamps have groves for grabbing round stuff. Some of the other posts look promising as well

10-15-2004, 09:24 AM
Lots of good ideas. Thanks guys! Will give some of these a shot next time I'm doing poppers. I'm thinking a nail through the bottom of the jig that would fit into the blank combined with the suggested clamps might do the trick.

Backcast, not a problem. Anything that concerns a safety issue should be pointed out.


Pete F.
10-15-2004, 03:19 PM
If you have a router and router table you can put a piece of 1/4" laun over the table plunge the bit thru it, then fasten a piece of 3/4" ply with a hole in it bigger than the plug. Size of hole would be 2 x plug diameter minus bit radius minus whatever flat you want at the edge of the recess. Clamp the plug with a wooden handscrew for safety and hold it against the side of the 3/4" ply to start.

02-15-2005, 12:29 PM