The Box Joint Machine (Another Stumpy Design) - Part 2

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Blog entry by William posted 04-10-2012 01:47 AM 8488 reads 1 time favorited 15 comments Add to Favorites Watch

If you read yesterday’s blog on this project, I will now demonstrate the difference between a real hardware store and Home Depot. I walked into Hayden’s Hardware this morning. I told them I needed three bronze bushings to fit a three eighth’s piece of all thread. The guy lazily reached into a box behind the counter, laid them on the counter, and asked if there’d be anything else.
So then I was off to the shop to get my lazy butt back to work.

With the proper bushings now in hand, the crank and lead screw assembly practically fell into position on it’s own.

I studied Stumpy’s design for the quick release. It is a great design. However, I forgot to pick up some epoxy when I bought the other items for the project and was not about to go back to town. While thinking of a way to make it work without epoxy, I remembered I hadn’t cranked up my welding machine in some time. It was the perfect solution for me.
If you have a welding machine and go this route when building this project, I recommend using a longer connection type coupling instead of a regular nut. It gives more area to weld to and will allow more threads to contact the lead screw.
For all of you who don’t have a welding machine, I assure you that Stumpy provides a great design that uses a nut and a small piece of hardwood. Just don’t forget the epoxy.

I also altered the mount for the quick release just a tiny bit. This is supposed to be a tab extended off of the carriage side. However, I used a soft wood for the carriage and wanted this block to be made out of hardwood to help assure against wear and wobble. So I screwed and glued a hardwood block to my carriage instead.

The quick release and whole crank assembly works great. It is a little tight. I have worked with wooden gears before though. I know from experience that a little tight is fine. The wood will wear down and it’ll work fine. If you make it too loose though and there’s slippage, no wood will ever grow back.

Then the fence.

I am ready to cut fingers.
Unfortunately, I’d had about all I could take for the day. It hasn’t been a good one friends. So we’ll just have to stop there, until next time.


15 comments so far

View Rob_n_Wood's profile


109 posts in 3370 days

#1 posted 04-10-2012 01:52 AM

Well did you at least lean back and have a cold one
Cause it looks like you deserve one my friend I think
Stumpy will be proud
Nice Job

-- "I predict future happiness for Americans if they can prevent the government from wasting the labors of the people under the pretense of taking care of them." Thomas Jefferson

View Dave's profile


11429 posts in 2861 days

#2 posted 04-10-2012 01:54 AM

Man William it is looking great. I love your ability to follow a good set of plans. great job.

-- Superdav "No matter where you go - there you are."

View boxcarmarty's profile


16298 posts in 2381 days

#3 posted 04-10-2012 02:03 AM

Ready to cut fingers??? Get the first aid kit and the ice bucket ready…..

-- My mind is like lighting, one brilliant flash, then its gone.....

View William's profile


9949 posts in 2864 days

#4 posted 04-10-2012 02:09 AM

Thanks guys. It’s coming along nicely.
The plans are easy to follow.
Everything works just like it’s supposed to.
Of the two machines of Stumpy’s I’ve built, they are brilliant in their simplicity. When you watch his videos, it looks like complicated machinery. After getting the plans and studying them though, it all makes perfect sense.


View DIYaholic's profile


19623 posts in 2696 days

#5 posted 04-10-2012 02:27 AM

That’s what I need; Plans that are simple (like me) and make sense. NOT those poorly translated into broken English plans, that come with most imported items!!!

Great job. Looks like you have it all “fingered” out!!!

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procrastination a bad thing?

View geoscann's profile


258 posts in 2302 days

#6 posted 04-10-2012 02:28 AM

William good job looks great i,am working on mine i think i to will weld the rod.

-- BIG geo ---Occam,s razor The simplist answer is often correct

View William's profile


9949 posts in 2864 days

#7 posted 04-10-2012 02:29 AM

Thanks DIY.
I think you underestimate yourself.
You’ve let the cat out of the bag when you showed us your work.
You’re more than capable of building anything you set your mind to.


View William's profile


9949 posts in 2864 days

#8 posted 04-10-2012 02:34 AM

Yea Geo.
I welded the rod only because I didn’t want to go back to town for epoxy. After doing it though, I like it better. While Stumpy’s design should work fine, I see less chance of play wth the welded rod over time.

A couple of words about welding it though.
The one you see in the photo is my third attempt.
As I already said, use the longer connecting nut. You can usually find them near the all thread in most hardware store. I melted the regular but on the first attempt.
The second attempt was my own fault. Use a square and make certain the connecting rod is straight. If it is even a tiny bit off, the threads will not mate up well with the lead screw and it won’t work properly.

By the way, I don’t know how others are cutting their nuts for the quick release. There are several ways of doing it. I cut mine by putting a metal cutting blade on my band saw.


View foneman's profile


112 posts in 4116 days

#9 posted 04-10-2012 12:57 PM

Sure is looking nice and glad to see things moving along.

View Roger's profile


20928 posts in 2825 days

#10 posted 04-10-2012 01:03 PM

comin along very nicely. plus, ya gotta luv them good-ole hardware stores.. they’re gettin hard to come by

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed.

View StumpyNubs's profile


7598 posts in 2822 days

#11 posted 04-10-2012 01:28 PM

Welding the nut is a great idea. I didn’t put that option in the plans because most woodworkers don’t weld. But anyone who has a welder will surely want to consider that option.

Using the longer nut (they are found in the hardware store next to the threaded rod and are usually used to couple two of them together) is also a good idea. I had originally planned to do that, but it is more work to cut in half and I didn’t want people to get frustrated.

The hardwood block for the rod to run through is a must! You want NO wobble, and it will quickly wear softwood. Another option would have been to unsert a bronze bushing into the hole for the rod to run through. But threaded rods will still wobble in a bronze bushing. So hardwood is a better idea. And your block is great because it can be replaced if it wears out in time!

The gears will feel tight at first. File any sharp edges off the teeth and put some bees wax on them. After the first couple of uses they free up and turn very nicely.

Looking good! Anyone who wants to make one can get the plans by following the link at the top of the page at! (Check out some of the episodes of Blue Collar Woodworking while you’re there!)

-- Subscribe to "Stumpy Nubs Woodworking Journal"- One of the crafts' most unique publications:

View gfadvm's profile


14940 posts in 2712 days

#12 posted 04-11-2012 01:14 AM

You are doing a great job on this jig. As soon as you finish it, you can start on mine! LOL

-- " I'll try to be nicer, if you'll try to be smarter" gfadvm

View William's profile


9949 posts in 2864 days

#13 posted 04-11-2012 01:49 AM

Thanks everyone.

That’s a great idea.
Maybe Stumpy and I need to open a business. He can design em, and I can build em. Our wives could handle shipping.

The last installment is coming in a few.


View gfadvm's profile


14940 posts in 2712 days

#14 posted 04-11-2012 02:26 AM

Let me know when mine’s ready to ship!

-- " I'll try to be nicer, if you'll try to be smarter" gfadvm

View William's profile


9949 posts in 2864 days

#15 posted 04-11-2012 02:30 AM

Thanks, I’ll take that as a compliment.
If you’d like, you can go here and see the finished machine now with the first cuts on it.


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