Flat Jig - FJ.35 (.350" Deck Height)

Flat Jig - FJ.35 (.350" Deck Height)
Brand: WEBFoot Custom Calls
Product Code: FJ.35
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Quantity Available: 6
Price: $80.00
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These are the last 4 until a new batch of blanks gets processed which will be a while.  They were made from some extra FJ blanks, and have the ".35" hand engraved next to the "FJ".  The first place we will update when we have a better idea of when there will be more available is the "availability" field right here.   So as soon as we know something, it will be posted here in the availability line.

Tall Deck Flat Jig (FJ.35) - Hardened and cut on a Wire EDM from quality tool steelIf you are looking for a standard deck height flat jig, we have the original standard Flat Jig with a 0.335" deck height - Part #: FJ1

All of our jigs ae made from high quality tool steel and THROUGH hardened to  ≈61-64Rc to resist most files and band saw blades.  These jigs CAN NOT be altered with standard tools.  We dont skimp on material or hardening processes, quality is our #1 focus!  

Cork Notch Height: .165"  Suggested cork/wedge:  316DCC, 177SW, or use 162SW for double reed applications.  Sand thickness for desired fit.
Suggested Reed: Any Duck Reed - You are the pilot - take her where you want to go!
Board Length: Back of cork notch to end of jig:  2.025" +/- .030"
Bore Size: .6245 - .626" (for 5/8 tenons)
Deck Height: .350  +/-.005"

This jig has a 5/8 bore and is a handy tool for designing your own town board.  Much like a public jig, which acts as a guide to get you to a starting point, the flat jig backs up one step.  The flat jig has only a cork notch and a flat tone board.  This allows you to have repeatable cork notches and soundboard height while trying to design your own tone board. 

You can also use this jig to create the flat tone board you would need for building a curved reed call.  One of the older and more historic ways of making a call was to have a flat tone board and "curl" the reed to create the reed to board clearance for air flow.  This is an excellent way to get that perfectly flat tone board. 

The standard overall length of the jig is ≈2.3" with a ≈2.1 toneboard (from back of cork notch to tip) and the cork notch is .165" tall and the deck height (height from bottom of jig bore to top of soundboard is ≈.350").  There are 2 tapped holes on the bottom of the jig along the bore.  These holes are 1/4"-20tpi and allow you to thread a bolt or set screw through the bottom, and to gently push up on the insert in different spots, to adjust where your base line is - for example if you were making an upslope reed design. (The two threaded holes in-line with the bore are standard, the two on the outside edges have been removed from the current versions)

Another useful feature of the Flat Jig, is one can use it as the starting point for designing goose guts that fit a 5/8" bore.  The tone board is appx .350" tall - so one can cut a wedge and sound board off of the jig and have room to fit them to the bore (ie taper the wedge bottom and angle the sound board top).

Flat jigs come with one steel socket head cap screw, one nylon socket head cap screw (less holding power but does not mar the material as badly)

Remember, do not sand, grind, or use carbide tools on the jig unless you are purposefully trying to alter the shape.  Our Jigs are designed to withstand normal steel cutting tools with a Rockwell hardness of 60Rc or less - less being better for the jig (typical Nicholson files are approximately 55Rc) but the jigs can NOT stand up to carbide, diamond, grinding or abbrasives (like sand paper).   Our jigs are through hardened A2 tool steel and are 61-64Rc hardness.  We suggest avoiding tools made of material that is harder than 60Rc.  Some import files have been found to be harder than the industry standard of 55-58Rc - use at your own risk.  Some HSS or Cobalt tools (such as RotoZip bits etc) can possibly be harder than 60Rc and may prematurely wear on your jig.  We suggest you test any tool you use on the bottom or corner of the jig to be sure its not removing jig material prior to use on the toneboard portion of your jig.

Do not use a hammer on any hardened part or tool as it may fracture and cause injury.

Interested in having your own "Public Jig"?  We offer manufacturing services as well as products.  If you have a design or idea you would like to discuss - feel free to email us.

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