Christmas (Palm) boxes & single blade (kinda) box jig

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Project by rweitz posted 02-07-2016 05:12 AM 1342 views 5 times favorited 7 comments Add to Favorites Watch

Ok these were from LAST Christmas, and yes I’m WAY BEHIND in my postings and I actually used TWO blades in my single blade jig, and yes these are more PALLET wood projects.

Anyway, shout out to Bearpaw and SASmith for their info and advice on making palm boxes and all the other LumberJock posters who’s work I reviewed on boxes as well as all the folks who’ve posted stuff on their single blade box jigs. Without all of your fine help these gifts never would have been made! THANKS!

So I got a bunch more pallet wood milled down at my bro-in-law’s house with his planer and used my TS and my jointer jig to finish it off then got to work on making a single blade jig.
I did not want to use my TS blade, I do have a dado blade set so I set up this jig to use the two 1/8” blades from that set as my “single” blade. It gives me a clean bottom cut and only takes two passes per joint, speeding up the construction.

Since I used a std 1/4” “blade” had to make some spacers slightly larger, but was able to use an old 1/4” drill bit for the guide pin. Although I did find that of the 4 old twist drill bits I had they all were just SLIGHTLY different sizes and only one was perfect to my “blade”. The jig I built has several mod to it from all the builds I saw, the handle in the back. the clamp in the front, I think I added the cross bar in the front myself to hold the pcs together since mine is more like a mini-sled than most of the designs I saw. My TS has nasty groves so little things don’t slide that well on it.

One problem i have with my old Crapsman saw is that I only have about 2” cut height so with a 6” dado set I only barely can to 1/2” stock with this jig. I’ll have to get an 8” dado set to box cut thicker stock, or just do rabbets on the edges so I’m only left with 1/2” joints to box cut

On the boxes I used a slightly new twist for the pins as well. I drilled my holes with the lids clamped to the boxes (see ugly makeshift table I made to drill in these longer than my table top drill press would do) and then cut the brass pins to length, and used pliers to crimp ridges in one end, see pics. I used a drill bit and hand twisted a bit of extra material out of the lid, then pressed in the pin part way with the lid in place.

Next I put some CA glue with a longer set time on the ridged end of the pin and drove it home. It seemed to glue the pin in place so I could sand it smooth and flush, but leaving the lid freely swinging on the pin due to the enlarged hole in the lid.

My lids are chamfered on the inner edge to slide into a centered position when closed, leaving an even gap all around. for the most part. in theory. Wood is wood. and I am me—> :(

Still working on drilling the pin holes in the perfect spot to get a built in stop. Some of these had to be “adjusted” to work properly before the gift giving, others worked fine.

Anyway a lot to cover in this post, made 12 boxes for the loved ones and everyone loved them.
If you have any questions shoot me a msg. Thanks for looking.

-- You cannot build a reputation on what you are going to do. - Henry Ford

7 comments so far

View majuvla's profile


13633 posts in 3108 days

#1 posted 02-07-2016 05:23 AM

Nice jig, very efficient as I can see.Boxes just multiplaying.

-- Ivan, Croatia, Wooddicted

View robscastle's profile


5633 posts in 2445 days

#2 posted 02-07-2016 11:53 AM

OK considering they are all made from pallet wood and you drilled at least twelve pin holes with some sort of Jig?
Its got to be a Well Done!!

It that a brass or a gold pin I see as a hinge?

-- Regards Rob

View ptofimpact's profile


381 posts in 2557 days

#3 posted 02-07-2016 02:18 PM

They look wonderful, curious, are there plans you bought for the ‘sled/jig’ ?

-- Pete in NC

View Roger's profile


20965 posts in 3045 days

#4 posted 02-07-2016 04:04 PM

A very nice stack of very nice boxes

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

View Diggerjacks's profile


2291 posts in 3380 days

#5 posted 02-07-2016 05:38 PM

Hello rweitz

Very effective jig

I will make one for me in the future

The boxes are really nice

Thanks for sharing

-- Diggerjack-France ---The only limit is the limit of the mind and the mind has no limit

View Bearpaw's profile


257 posts in 3961 days

#6 posted 02-08-2016 02:56 PM

They look great. Thanks for the opportunity to help. That is what this site and all of the wonderful craftsmen are about on Lumberjocks.

-- "When we build, let us think we build forever." John Ruskin

View rweitz's profile


116 posts in 3319 days

#7 posted 02-10-2016 02:40 AM

Thanks for the comments folks! DiggerJacks and ptofimpact there are plans you can download from the woodfather to get you started.
I did find several mods in my research people had done that improve on that basic design:

the pins are brass rods from the big blue store I cut down with a dremel to length. I made a jig by drilling a slot in a scrap of wood to make them all the same size and hold them while I cut them.
The Jig i used to drill the holes is pictured – its just a bunch of clamps and stops and a temp drill press table on my table top style drill press. I have it mounted to hang over my bench so I just swung the normal table behind and clamped in place a bunch of scraps to hold the boxes in the position I needed. Pretty ugly. :)

-- You cannot build a reputation on what you are going to do. - Henry Ford

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