|Project by Douger||posted 03-26-2011 05:30 PM||2998 views||10 times favorited||9 comments|
This is a box-joint jig I made and used to cut the joints on the tool box I posted a few days ago. It is set up for 1/8” joints (the width of my saw blade kerf, because I don’t currently own a dado set), but by replacing the plate that holds the 1/8” registration key, I can use it to cut box joints of any width (once I get that dado set). I based this on a jig that was featured in Woodsmith magazine some years ago (maybe 20 years ago, now that I think of it). I made one back then for my dad’s saw. The little vertical backing plate with the hole in it slides in and out in a kind of dovetail groove—it’s replaceable, too. The idea is that it reduces tear-out on the back side of the cut, so having different plates for different widths is a good idea.
It was sort of a quick-and-dirty job (as you may be able to tell, I only countersunk one of the adjustment bolt heads, partly because I didn’t anticipate cutting a joint that wide), but it gets the job done. I also didn’t have a drill press when I made this, so the slot for the width adjustment bolts is pretty sloppy. I will probably make another one at some point—there’s not much to it.
This one is made of maple and 3/16” tempered hardboard.
-- Doug, Kansas, http://newwoodshop.wordpress.com