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Router Table Box Joint Jig

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Project by bvdon posted 1117 days ago 6988 views 36 times favorited 7 comments Add to Favorites Watch

This project is loosely based on the Rockler Router Box Joint Jig. Just a glance, then came up with my own design. It cost less than $10 to build and was a good way to waste away a Sunday.

I will be using this for other projects, but to test things out I made a utility guitar speaker riser out of cherry. The joints came out nearly perfect first time, but the router bit was a 1/2 inch mortise bit so there was a little tear-out. Not that bad. Will try out an spiral up-cut bit next time.

Last photo is the result.

To make:
The Base: used 3/4 ply, sized to sit on the router table (arbitrary). Slides left to right (you want to center it relative to the router bit) with oak stock cut to fit in the router table miter slot. I used a combo-square to attach the oak perfectly on the base. On the top side I used a dado blade to cut slots for the sled to ride on.

The Sled: used 3/8 MDF with melamine on both sides – slides nice and easy. Cut to fit oak on the bottom of the sled (screwed from the top) to ride on the base, careful to keep things square.

Front of the sled has solid maple stock for support after the sled is cut by the bit.

Furthest most back is a fixed fence with a slot to hold an adjustable sacrificial fence. The ‘sacrificial’ part of the fence has the notch that is the same size as the bit…. if I want to use a different size bit I need to build that part of the sled—fairly easy.

Since glue would be useless on a melamine board, lot’s of screws were appropriately sized for the small pieces, pre-drilled and counter-sinked.

P.S. – I did some new up-spirial router bits (1/4 & 1/2 inch), not yet tried out. I did have some scrap cherry and figured out how to get no tear-out. Simply cut from the back (pulling the sled into the back of the piece) just a tad, but not all the way through the wood. Then bring the piece behind the bit and push the sled as normal. Should eliminate most tear-out problems.

-- http://woodwork.me





7 comments so far

View bigike's profile

bigike

4031 posts in 1885 days


#1 posted 1117 days ago

very nice, I like this one. Can you use smaller bits though?

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

View bvdon's profile

bvdon

456 posts in 1611 days


#2 posted 1117 days ago

Yes, you can use smaller or larger bits. To use a different size bit you create a new sacrificial board with a block-notch and two holes to adjust left to right. It only takes about ten minutes to create a new one—in fact, I screwed up the first one when drilling the holes and made another in no time.

-- http://woodwork.me

View bvdon's profile

bvdon

456 posts in 1611 days


#3 posted 1117 days ago

I need to build some shop drawers, and real curious if I can cut 4 boards at once ;) Will let you know how it works out.

-- http://woodwork.me

View scarpenter002's profile

scarpenter002

466 posts in 2501 days


#4 posted 1117 days ago

Very nice idea. I like it. Thanks for sharing.

-- Scott in Texas

View cranesgonewild's profile

cranesgonewild

344 posts in 1504 days


#5 posted 1117 days ago

This is a different twist on things.
I never thought of making a sled on a router table.
Thanks for sharing your ideas with us.

-- I'm a Fungi --

View James Frederick's profile

James Frederick

106 posts in 2317 days


#6 posted 1116 days ago

Very nice and simple, just the way I like it. Well Done.

-- Change begins somewhere may as well be with me.

View kimball's profile

kimball

317 posts in 1893 days


#7 posted 1111 days ago

Super sled! I have to make one. After thinking about it some, I decided to use my dado blade to make shallow dados to insure main runner is square to router table. I will also use it to cut through the melamine in order to glue and square the runners to the sled. The runner that holds the base square to the bit will have a full length runner to aid in the indexing of the base. Hope my thoughts work out and thank you.
Kimball

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