The Jig

As you can tell from the image above, I just grabbed material and made my jig. It works so it doesn't have to be pretty and hangs on the wall until needed again.

The measurements I'm giving for making the jig are not hard and fast and can be changed if you want, follow the basic design I have shown or change to suit your needs.

When cutting your basic stock material don't worry about it being perfectly square or strait as most wooden bumpers you see are old RR ties or ruff cut lumber.

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Making the Jig

Making your jig is simple. A piece of wood 12" X 8" should be big enough for a base. 6 pieces 1/2" X 1/2" X 2" long and 1 piece 1/2" X 1/2" X 7" long, 1 piece 1" X 3/8" X 7" long.
Lay out on the board the position of the 7" piece, then use a square to layout the position for the 6 vertical pieces.The spacing of the post on my jig was set to the distance between ties so that the bumper would fit down over a section of track. The lines drawn on the post spacers are use as a guide in placing the side pieces.
Note: You want to make the spacing between the vertical pieces a little over 1/2" to allow removing the finished sections from the jig.

The bottom line is determined by the thickness of your track ties. To make sure that the measurement remains the same for all vertical post I tacked the 1" X 3/8" X 7" long along the line. The post pieces are pushed under the 7" guide and till they are seated under the guide.

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Material needed to make a Bumper

It is easier to make more than one bumper at a time so you will need to make up some stock to work with. Make up some rough cut lumber to cut the pieces needed to make the bumper. Make up stock, 1/2" X 1/2", for the post. 1/2" X 3/16",for the side and top, 1/2" X 3/16" for end section bracing, and 1/2" X 3/8", for the bumper block. As I said before don't worry about making precise cuts.

To make one bumper you will need the following.

10 pc. 2-1/4" from 1/2" X 1/2" stock.
3 pc. 3-1/4" from 1/2" X 3/16" stock.
1 pc. 4" from 1/2" X 3/8" stock.
8 pc. 5" from 3/8" X 3/16" Stock.

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Making a Bumper

You can now use your bumper jig. Place your post in the jig, next add the two side pieces, using the lines on the jig as a guide, using glue and nails or brads. Using the Jig to make right and left side sections. After you remove the sections from the jig turn over and attach the wood strip on the back of each section.

Now trim off the extra length from the post and side pieces. Using the Hand saw, band saw or the table saw of your chose.

Using the pictures below you should be able to finish your bumper.

I use my hand power tool to finish add detail to my bumpers after they are put together. Then use a torch to burn off the fuzzy material left by using the tool. I leave the ash on the bumpers and paint right over it. I leaves a nice surface to work on.

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