Jacobsstyle Chuck

7. Place a 1-1/16-in. bit in the Jacobs-style chuck and drill about three-quarters of the way through the body (Photo 4). Work slowly and back the bit out frequently to remove chips or the bit may overheat. Excessive heat can ruin your bit and possibly crack the wood.

Alternate method: The 1-1/16-in. hole is required only for the first 1-in. above the 1-5/8-in. hole. You can drill the body using a more common 1-in. bit and then widen the hole for that lower 1-in. section with a round nose scraper.

8. Clean up the bottom of the mill body using a skew chisel held flat on the rest to lightly scrape the end grain (Photo 5). The base should be flat.

9. Mount the waste block into the scroll chuck. Create a tenon for a jam fit with the large hole on the mill body (Photo 6). The length of the tenon is slightly less than the hole's depth. The fit is critical. It must be tight enough to hold the mill secure for turning, but loose enough to remove the body without undo force. Approach the diameter sizing carefully—as every cut is double. In other words, if you push in 1/32-in. you remove 1/16-in. of diameter. The shoulder of the waste block tenon should be flat or slightly concave.

10. Mount the mill body on the waste block and finish drilling the 1-1/16-in. hole from the top (Photo 7).

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