Variable Box Joint Jig w/o Dado Stack

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Project by DarbinOrvar posted 08-25-2015 07:19 AM 3818 views 23 times favorited 7 comments Add to Favorites Watch

I built this box joint jig because I wanted to cut different sized box joints without a dado stack. It works really well and I have already cut over 60 boxes using it, making boxes ranging from 1/8 inch to 1/2 inch sized joints. I made this jig to fit on my cross cut sled which I built a few weeks ago (and which I made a detailed how-to video on, so anyone can build it if they want to).

For the addition, I used baltic birch for most parts, and some mahogany I had around for a wheel, handle and other small parts.

This jig works really well, you do have to count in order to get different sized joints, however it is not very difficult once you get used to it. I really like that you don’t need many parts to create this jig, it’s not a complicated build, it’s pretty easy, and it’s very useful.

I also made a very detailed video of this build including measurements and process. Please check it out if you’re interested in building one too:

View on YouTube


7 comments so far

View Tugboater78's profile


2432 posts in 1615 days

#1 posted 08-25-2015 11:34 AM

Awesome, was looking forward to the boxjoint part of your sled build.

-- "....put that handsaw to work and make it earn its keep. - summerfi" <==< JuStiN >==>=->

View Oldtool's profile


2365 posts in 1614 days

#2 posted 08-25-2015 12:51 PM

Nice design on this jig, easy repeatable accuracy. Thanks for sharing the details.

-- "I am a firm believer in the people. If given the truth, they can be depended upon to meet any national crisis. The point is to bring them the real facts." - Abraham Lincoln

View  woodshaver (Tony)  's profile

woodshaver (Tony)

3939 posts in 2776 days

#3 posted 08-25-2015 02:04 PM

Excellent way to make box joints! I also count when I make box joints on my Horizontal Mortise Machine (A Matthias Wandel’s plan build). Set up is different but the results are very accurate.
Nice work you your build!

-- Tony C UAW, St Augustine FL, My high school shop teacher said "You can do it"... Now I can't stop!

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14 posts in 429 days

#4 posted 08-25-2015 02:13 PM

Very nice, thanks for the video.

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7383 posts in 1430 days

#5 posted 08-25-2015 06:52 PM

Cool beans. Thanks for sharing !

-- Perform A Random Act Of Kindness Today ... Pay It Forward

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3814 posts in 1316 days

#6 posted 08-26-2015 02:42 AM


-- The Old Rednek Workshop

View Jim Jakosh's profile

Jim Jakosh

16816 posts in 2529 days

#7 posted 08-28-2015 04:09 PM

That is a top shelf jig. I love it!!

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

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