I am just a tinkerer in the workshop. Recently I was working on a project that required a groove in the end of a one inch round dowell. As luck would have it the groove needed to be within a few thousands of the cut of one of my stiff backed saws and about five inches down the length of the dowell. I tried several different way of doing this cut but I couldn't keep the saw blade from wandering. Finally I made up my own jig and it works great. There are probably many solutions to this problem but this is what I came up with.
I had a piece of scrap 1'x 4"x4" soft pine. I used my T-Square to mark perpendicular lines on all four sides of the 4"x4" and a parallel line to the sides right down the middle. Where the lines crossed I drilled a hole using a one inch Forstner bit chucked up in my Mini- Mill ( a lot more powerful than my drill press). I drilled the one inch hole through the top of the 4"x4" and then I sawed across the
4"x4" two inches deep, following my marked lines exactly. This gave me a perfect groove to place my saw exactly in the middle of my 1" dowell. I then drilled a hole on each of the sides of the 4"x4" that allowed me to tap a 3/8" diameter hole with 1/2" wood threads. I then used my 1/'2" wood dies to thread two six inch dowells. This allows me to stick a one inch dowell into the 4"x4" and screw the two dowells on the sides in from the sides to hold the one inch dowell firmly in place. An 8 inch C-Clamp lets me clamp the jig to my workbench solidly. I can then place the saw in the groove I had previously cut across the top with the one inch dowell down in the hole about an inch from the top of the 4"x4". This allows me to start a perfectly centered cut across the top of the one inch dowell. After the initial cut I just loosen the dowells on the sides and push the one inch dowell up the hole and continue my cuts until I have reached the depth I need. I have used this homemade jig on several Oak, pine and Maple dowells and it worked great on all of them so far.There may be better ways to do this and I would love to know how others have solved this problem.
Dennis