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PM2000 Box Joint Jig

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Project by smitty22 posted 1339 days ago 5150 views 18 times favorited 12 comments Add to Favorites Watch

One of my woodworking goals was to learn more advanced joinery and the box or finger joint looked like a fairly simple one to tackle. (Boy was that a bad guess.) Had seen several commercial box joint jigs and a couple of shop made versions here on LJS, so after some study of these, decided to modify my PM2000 miter gauge to convert it to a box joint jig. This project is the result…

The miter gauge provided with the Pomatic PM2000 is a good one, having a positionable extruded fence fastened to the miter face with T’bolts. The fence can be slid horizontally to adjust the box joint notch width, but I wanted a more precise method of adjusting the jig position than the ‘bump and pray’ method. This solution was to add a 10-32 threaded rod adjustment and seems to work pretty weill. The left white block is threaded, and when the fence T-bolts are loosened, the screw is used to move the fence either left or right with respect to the miter gauge body. Turning 1/6 turn – one flat on the hex acorn nut – produces a pretty consistent .005” change. I’m sure there are better ways to do this, but was a fairly simple mod and pretty cheap, relying mosting on stuff out of the junk box.

A few features of this mod are: a. The added box joint hardware can be installed on either side of the miter guage, allowing either left or right miter slot application. b. The added hardware can be quickly removed returning the MG to it’s original configuration. c. The added hardware can be reinstalled without disturbing the basic box joint settings. d. Did I mention Cheap?

Picture 1 – The completed modified miter gauge (MG).
Picture 2 – The Stock PM2000 miter gauge.
Picture 3 – The components added to the MG. White material is Corian, it works very nicely for jigs.
Picture 4 – Face of the box joint jig and first attempt at a box (screwed up, but later fixed).
Picture 5 – Completed test box, most happy with the results! Needs a lid.
Picutre 6 – Took all this stuff! to make a silly little box!

Anyway, hoping this mod might be of some use to others, and was a fun project.

-- Smitty





12 comments so far

View Tim Dahn's profile

Tim Dahn

1462 posts in 2166 days


#1 posted 1338 days ago

Very cool build Dale, I have tried the Woodcraft box joint attachment and promptly returned it. This looks pretty precise and a nice addition to the miter gauge.

-- Good judgement comes from experience and experience comes from poor judgement.

View Ken90712's profile

Ken90712

14821 posts in 1790 days


#2 posted 1338 days ago

Great post, I just finished a quick jig for box joints but need to make a real one that has adjustments like yours.

Well done on yours, good tight joints.

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

View patron's profile

patron

12961 posts in 1942 days


#3 posted 1338 days ago

sweet build

i thought it was a commercial one
sure looks it
the adjustment feature sure would come in handy

bet you can make different width fingers

nice

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View smitty22's profile

smitty22

590 posts in 1548 days


#4 posted 1338 days ago

Thanks all, glad this might be of use.

Patron, on this version, finger width is fixed and depends on the index key. I saw another recent LJ post where the key was adjustable, but my version didn’t get that fancy (yet).

Barry, Yep that’s right, sometihing I copied from another LJ post! Didn’t show in the pics, but I’ve marked one of the flats on the hex acorn nut… Turning just 1/6 (one flat) gives a pretty consistent .005” change.

Cheers!

-- Smitty

View NormG's profile

NormG

3998 posts in 1605 days


#5 posted 1337 days ago

Wonderful idea, Glad to see your PM is working out for you

-- Norman

View Routerisstillmyname's profile

Routerisstillmyname

679 posts in 2110 days


#6 posted 1337 days ago

I guess I don’t get it, the front box joint fence seems to have the usual pre-cut slot and a space and guide (all equal size I presume). And then it’s crewed to your miter gauge. So how can the jig move the distance between the cut and guide for adjustment?
What am I missing looking at the pics? THX

-- Router è ancora il mio nome.

View smitty22's profile

smitty22

590 posts in 1548 days


#7 posted 1337 days ago

Router… I’ll try to explain, but may need to add a sketch or more pics later.

The key to this is that there are actually 3 fences involved, the wooden face fence which holds the index block, the extruded middle fence with T-slots on both front and back, and the face/fence of the miter gauge itself. The wooden fence and the extruded fence are secured together with T-bolts and remain together for all box joint operations. They move laterally on the face of the miter gauge to adjust the position of the index block with respect to the blade and thus the position of the initial ‘slot’ that is cut. That’s what the adjustment mechanism does.

The slot width and depth are of course determined by the dado/blade stack width and height. Spacing of the second and subsequent slots is determined by the width of the index block (hopefully identical to the first cut).

Sure hope this helps!

-- Smitty

View Routerisstillmyname's profile

Routerisstillmyname

679 posts in 2110 days


#8 posted 1336 days ago

Thank you, I knew there had to be more to it than what we see in the pics.

-- Router è ancora il mio nome.

View bigike's profile

bigike

4031 posts in 1889 days


#9 posted 1304 days ago

saweeeeet jig, i want to get parts for this saw. If you can look in your manuals an see if there are #’s i can call or a website i can go to an get parts for this same saw (pm2000)? I want to get the miter guage and the fence system, this is the reason why i ask. I want to put them on a delta saw too.

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

View smitty22's profile

smitty22

590 posts in 1548 days


#10 posted 1304 days ago

Ike, The Miter Gauge Assembly p/n is 1791789.

The Accu-Fence Assembly p/n is 2195079Z.

Might want to check in with WMH Tech support (800-274-6848 to start) to see if there are any updates to these.

Best of luck with the upgrade. I’m about 99% happy with both of the PM2000 items, no complaints, but I’m a bit short on experience with very many other table saws to make an A-B type test comparison. I do use the Incra V2700 for light work and also happy with it, but revert to the PM gauge for serious stuff including box joints.
Happy New Year!

-- Smitty

View smitty22's profile

smitty22

590 posts in 1548 days


#11 posted 1297 days ago

Kind of a footnote to this project – Although the adjustment mod to the miter gauge (MG) was cobbled together as a box joint jig, it actually has turned out to be a really good microadjuster to precisely position the MG front fence. I’ve used it a lot in cutting 45deg miter joints and rabbet joints.
Cheers!

-- Smitty

View joeland45's profile

joeland45

1 post in 6 days


#12 posted 6 days ago

Hello, Great page, Im in Chile and I was searching for buy a GRR Ripped, a Micro Jig, but now I found this page.
We have a Carpentry Shp and built our own beehives and parts.
Lately we have an accident-no heavy but just for a miracle- and I decided get information.
¿Would you give more about jigs o holders for working on tablesaw or circular saw within risks for fingers?
Thanks, rally, a lot. And Excuseme my english. I speak preferently spanish, but I undestand some of english too.

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