Was Wagner planer, now Jig for feeding keys

[JIMRPT@aol.com]

The "Wagner Power Planer" is a tremendously useful tool and though I have 
used it to do a few sets of keys I was never comfortable using it.....and I had a 
sliding jig to keep my hands away from the planer head.

 So in search of a 'safer' method, that furnished equally good results, I 
came up with the following:

1. I built a tray to hold two rails. The rails were installed about 4 inches 
apart.
2. The rails are capped with melamine counter top material and screwed to the 
tray.
3. Between the two rails, and attached to the tray, I installed a parallel 
jawed machinist type vise. I shimmed the vise base until the jars were 
absolutely suare with the top of the rails. The type vise I used has a quick release 
button for fast insertion and removal of 'stuff' :-) I have found that this 
'quick release' is overkill when doing keys but it helps doing other type 'stuff'
4. I made an oversized/rectangular plexiglass base for my router... 
....attached rails, on the underside of the base, so that sliding the router up the 
left side and down the right side will cover any key to be resurfaced.
5. I installed a keyfront stop in the tray so that each key sets in the same 
position every time....as well as stops for the router base at the back of the 
rails to stop the router in the same place on each key........these two stops 
give a uniform appearance to the back side cut line and PLUS keeps me from 
going too far!! :-)
6. To use........ I insert a key in the vise making sure the key bottoms out 
on the vise base and holding slight pressure I tighten the vise jaws 
firmly.... but not enough to crush any wood.
7. Since the jaws of the vise are parallel and the jaws are plumb/square with 
the two rails the key is held such that any resurfacing is automatically 
'square' with the key sides.
8. Depth of cut is adjusted by raising or lowering the carbide bit with the 
router's depth adjustments thingee.

 I find this method/jig works very well for me and have used it exclusively 
for many years now....might not be your cup of tea but I thought it was worth a 
mention....I am sure that there are others out there with something similar 
and/or better. :-)
Jim Bryant (FL)