Box Joint Jig

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Project by Maveric777 posted 04-11-2010 08:34 PM 5520 views 33 times favorited 17 comments Add to Favorites Watch

This is the newest addition to my collection of jigs. I seen a few videos and looked at tons of designs and came up with this. I wanted something that is adjustable so no matter what size I set my dado blade I can set the jig to accommodate it.

The key (what I call the piece that fits into the dado cut to align the next cut) was made out of an old small square my employer was going to throw away (the handle broke… making it not a square anymore…lol). I cut, ground, filed, drilled, and cursed both pieces until I got it where I wanted it. The inside (closest to the blade) part of the key is adjustable to match the thickness of the dado cut. You can see in picture #4 the adjustment for it.

I used a small section of T-Track I picked up on sale from Rockler to make the right side of the base movable then tighten down when the desired distance from the blade is achieved. What I found works is I measure the cut of the dado. I then multiply by two, then measure from the edge of the inside key to the edge of my cut line on the left base. Seems to work pretty good so far.

I used hard board on the face of the fence to make it easier to replace the middle section when it gets wore out. You can see on the first pic how the fence has 3 pieces on the fence. Two are there to stay… The middle is replaceable.

I did have to make a few changes… First I used my miter slide that came with my table saw as I have seen on many other similar jigs. It didn’t work out to well for me. It tend to move around making it hard to make perfect cuts. So I made a miter slide out of red oak scraps I had around the shop and that fixed that. No movement at all in the jig now.

The only other thing I think I will do is figure out a way to make the left side of the base easier to adjust. It isn’t hard now, but I have to bump and tap it to get minute movement. I have something in mind, but ran out of time to give it a try… Maybe later….lol

Thanks for checking out my jig.

-- Dan ~ Texarkana, Tx.

17 comments so far

View bigike's profile


4048 posts in 2560 days

#1 posted 04-11-2010 08:36 PM

cool looken jig i might have to make one like this, if it’s ok with you? ;)

-- Ike, Big Daddies Woodshop,

View a1Jim's profile


114791 posts in 2849 days

#2 posted 04-11-2010 08:52 PM

I made this jig from” shop notes” it works very well.

-- Custom furniture

View Routerisstillmyname's profile


728 posts in 2781 days

#3 posted 04-11-2010 08:57 PM


-- Router รจ ancora il mio nome.

View degoose's profile


7177 posts in 2626 days

#4 posted 04-11-2010 10:12 PM

Very well constucted …. and variable too.

-- Drink twice... and don't bother to cut... @ For lovers of all things timber...

View woodwkjohn's profile


14 posts in 2325 days

#5 posted 04-12-2010 12:06 AM

Hey Dan. I just looked at my e-mail and found your blog on your jig. Looks great, you can send me the blue prints. lol We are still on the road, in Chattanooga will be home in San Diego on 17th. Take care keep up the good work. Uncle John

-- woodwkjohn

View ChuckM's profile


561 posts in 2938 days

#6 posted 04-12-2010 01:02 AM

Those who want to learn about the Shopnotes’ jig as mentioned by a1Jim can find out more details here:

-- The time I enjoy wasting is not time wasted

View Bricofleur's profile


1343 posts in 2465 days

#7 posted 04-12-2010 02:04 AM

Adjustable! This is clever (read indispendable). Thanks for sharing.



-- Learn from yesterday, work today and enjoy success tomorrow. --

View donjoe's profile


1360 posts in 2303 days

#8 posted 04-12-2010 02:34 AM

Nice jig. Well designed and built. I made one fashioned after this. It works great. Well done on your project.

-- Donnie-- listen to the wood.

View NormG's profile


5248 posts in 2276 days

#9 posted 04-12-2010 04:12 AM

Looks great, meets your needs and you appear to have learned some skills from building it. I like the recycled SQ. into the new jig.

-- Norman

View WistysWoodWorkingWonders's profile


12390 posts in 2429 days

#10 posted 04-12-2010 05:25 AM

This is a great looking jig…. hope it works as good as it looks… finger joints enhance a lot of projects so a worthwhile jig to have around…

-- New Project = New Tool... it's just the way it is, don't fight it... :)

View RexMcKinnon's profile


2593 posts in 2467 days

#11 posted 04-12-2010 03:41 PM

Lots of nice features. Cool.

-- If all you have is a hammer, everything looks like a nail!

View Kristoffer's profile


674 posts in 2488 days

#12 posted 04-12-2010 04:35 PM

Nice job. I keep meaning to make one of these, the, I forget, then I remember, then I forget and so on. I don’t think that I’m going to make it adjustable, but that is a great idea.

-- Cheers and God Bless

View Triumph1's profile


856 posts in 2351 days

#13 posted 04-13-2010 02:32 AM

The fixture looks great…I have yet to build one of these. Can’t wait to see the hinges and the box they are attached to! Great job Dan.

-- Jeff , Wisconsin Please...can I stay in the basement a little longer, please!

View Maveric777's profile


2692 posts in 2348 days

#14 posted 05-09-2010 04:05 PM

Are you talking about the fingers I cut out of an old square that adjust Notottoman? If so I can tell you first step is to start cursing and get that out of the way….lol

-- Dan ~ Texarkana, Tx.

View Ken90712's profile


16578 posts in 2461 days

#15 posted 05-20-2010 11:52 AM

Cool jig and web page post!

-- Ken, "Everyday above ground is a good day!"

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