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Box Joint Cutting Jig on Router Table

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Project by woodworm posted 2102 days ago 10767 views 6 times favorited 12 comments Add to Favorites Watch

This is not my latest project acually.
When I posted my clamping square box, I did mention using box joint cutting jig on the router table. So Jockmike2’s commented why not show it here. I could not find the soft copy in my photo album, thus I shot a few for LJs to view.

I built this jig the very moment (frankly speaking, planned to build) I saw the featured Video & Slides in FW Magazine.com. presented by Guido Henn.

I made first test cut using 1/4” bit on 3/4”T X 3-5/8”W stock. By right I should have 7 nos full 1/4” fingers + 1 half finger (1/8”). But that was not the case. As can be seen in the third pic the last finger was only 1/16”. It took me about 1/2 hour to figure out the mistake. I double checked every part of the jig but not the slider. then I found out that the slider is not snugly fit the miter channel. So to overcome that problem, I constantly put pressure to the right while pushing the jig.

Thank you for viewing and any comment are welcomed.

-- masrol, kuala lumpur, MY.





12 comments so far

View hairy's profile

hairy

1988 posts in 2137 days


#1 posted 2102 days ago

Thanks for the post. I need to do that,yours looks like a real good one. The big pictures are a big help.

-- the last of Barret's Privateers...

View Woodwrecker's profile

Woodwrecker

3567 posts in 2180 days


#2 posted 2102 days ago

Good Job Woodworm.
It was smart of you to solve that thickness problem.
Thanks for sharing your experience.

-- Having fun...Eric

View John Gray's profile

John Gray

2370 posts in 2490 days


#3 posted 2102 days ago

I really like your idea but could you tell us about the “attachment” in picture 2?

-- Only the Shadow knows....................

View Timber4fun's profile

Timber4fun

215 posts in 2205 days


#4 posted 2102 days ago

Nice setup. On my list of things I would like to try. Tim

-- Tim from Iowa City, IA

View woodworm's profile

woodworm

14124 posts in 2195 days


#5 posted 2102 days ago

Thanks Hairy, Woodwrecker, John Gray and Tim for viewing and comment.

To answer John Gray : The attachment with threaded bar is actually the “indexing pin” carrier.
There are 2 independent indexing pins (made from L bracket trimmed into approx. 3/16” wide). These pins are attached to two separate adjustable carriers, and they are overlap.
If I want to cut 1/4” finger/box joint for example, I move the carrier of the second indexing pin away from the first pin to make up both combined size : 1/4” wide. Then I lock both carriers using the 2 knobs. By loosing the wing nut at the centre, now I am able to move both carriers simultenously using the welded wing nut on the threaded bar to achive the desired distance (in this instance 1/4” from the edge of the router bit). Tighten the wing nut at the centre so both carriers are locked to the fence. Place the workpiece until it’s edge touchs the indexing pin and made the first cut. Place the first cut slot on top of the indexing pin, and make second cut.

To make the cut on mating workpiece, place the first finger of the first workpiece in between the indexing pin and the router bit. Place the 2nd workpiece to be cut where it edge touchs the edge of the first workpiece iand make first cut. Take out the first workpiece, make the second & subsequent cut follow as we do on the first workpiece.

I can use this jig to cut box joint of any size from 1/4” , 3/8” or 1/2” without changing the indexing pin (just adjust it to make desired size).

Thanks.

-- masrol, kuala lumpur, MY.

View clieb91's profile

clieb91

3254 posts in 2539 days


#6 posted 2102 days ago

Woodworm, Thanks for the post I too have been contemplating making something for my routertable as I have no dado blade for the saw. May have to look real close at yours.

Looks like it does a fine job.

CtL

-- Chris L. "Don't Dream it, Be it."- PortablePastimes.com (Purveyors of Portable Fun and Fidgets)

View woodworm's profile

woodworm

14124 posts in 2195 days


#7 posted 2102 days ago

Thanks for viewing Chsis. For a clean cut and less noise, I use solid carbide bit – spiral down cut.

-- masrol, kuala lumpur, MY.

View John Gray's profile

John Gray

2370 posts in 2490 days


#8 posted 2101 days ago

Thanks for the update on the attachment!!!

-- Only the Shadow knows....................

View Douglas Krueger's profile

Douglas Krueger

396 posts in 2328 days


#9 posted 2059 days ago

A well designed and constructed jig Woodworm, it’s always nice to have a repertoire of jointing methods to choose.

-- I can so I wood but why are my learning curves always circles

View woodworm's profile

woodworm

14124 posts in 2195 days


#10 posted 2059 days ago

This jig was built based on plan presented by Guido Henn in FW featured video and slides.
I’m still not happy with the jig I made because the 1/4” ply base is not very flat (not the furniture grade ply).

-- masrol, kuala lumpur, MY.

View POPSHOP's profile

POPSHOP

125 posts in 1856 days


#11 posted 1855 days ago

i love it !

-- POPSHOP ,

View bigike's profile

bigike

4031 posts in 1893 days


#12 posted 1712 days ago

nice job

-- Ike, Big Daddies Woodshop, http://www.icombadaniels@yahoo.com

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