Double Duty Box Joint Jig

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Project by ChrisJ posted 01-10-2012 09:32 PM 3751 views 16 times favorited 11 comments Add to Favorites Watch

I wanted to try out some box joints on my router table so spent a little time designing a jig. It struck me that I might want to do more than one size of box joints but I didn’t really want to build 2 jigs. I noticed that the router bit is not centered in the table and so I could combine both a 1/4” and 1/2” jig in one. It took a few test pieces to figure out the pin system but both sides work great. The 1/4” side works best on wood that’s 1/2” thick or less, though I’ve tried it with 3/4” with some success—just takes a lot of cleaning up afterwards.

Pics 1-3 are the jig itself
Pic 4 & 5 are PO Box door “safes” (not banks) made using the jig’s 1/2” side (3/4” lumber)
Pic 6 is a frame for a bulletin board made using the 1/4” side (about 1/4” thick lumber)

11 comments so far

View Michael Wilson's profile

Michael Wilson

587 posts in 1577 days

#1 posted 01-10-2012 11:33 PM

Nicely done. I’ve got to get around to building myself one of these.

View Tokolosi's profile


674 posts in 1442 days

#2 posted 01-11-2012 01:48 AM

There goes my saturday morning. Guess the lawn will have to wait. Have to build one of these now!!

Great looking jig

-- “There is nothing like looking, if you want to find something. You certainly usually find something, if you look, but it is not always quite the something you were after.” ~ JRR Tolkien

View a1Jim's profile


113818 posts in 2664 days

#3 posted 01-11-2012 04:07 AM

Good idea well done.

-- Custom furniture

View TDSpade's profile


85 posts in 1503 days

#4 posted 01-11-2012 05:07 AM

I like this design as well. Are you using the miter slot at all?

-- For every expert, there is an equal and opposite expert.

View Ben's profile


302 posts in 1417 days

#5 posted 01-11-2012 05:44 AM

TDSpade, it looks to me like he has a guide that runs the edge of the table. If it had a miter bar, it would need to be switched to use the different sides

-- Welcome to downtown Coolsville, Population: US! --Hogarth Hughes

View JohnMeeley's profile


254 posts in 1420 days

#6 posted 01-11-2012 02:23 PM

I like the idea a lot. I’ll be working on my own edition soon. I’ve been messing around with a TS jig, that I’ve scrapped because of the inconvenience of blade changes midstream. Now if I’ll just get down to it, I’ll have fodder for my first post.

-- "The greatest pleasure in life is doing what others say you cannot do."-Walter Bagehot

View BinghamtonEd's profile


2047 posts in 1456 days

#7 posted 01-11-2012 03:10 PM

Very nice, I might have to make one of these this weekend!

-- - The mightiest oak in the forest is just a little nut that held its ground.

View PaBull's profile


930 posts in 2752 days

#8 posted 01-11-2012 05:40 PM

I like that two sided aspect of your jig, very clever!

-- rhykenologist and plant grower

View ChrisJ's profile


55 posts in 1906 days

#9 posted 01-11-2012 06:04 PM

TDSpade, Ben is right. It doesn’t use the miter slot, it has a guide on each side that runs along the side of the table.

View Backwood's profile


35 posts in 1420 days

#10 posted 01-11-2012 07:55 PM

Great idea!! (slapping forehead)Why didn’t I think of that? Since I left off the miter slot on my router table, I now see how I can build a box joint sled. Thanks a million!!

View TDSpade's profile


85 posts in 1503 days

#11 posted 01-12-2012 05:18 AM

Thanks Chris, I didn’t see the guide on the other side. This is timely for me as I have been looking at different designs of box joint jigs on the web. I think this one will work for me.

-- For every expert, there is an equal and opposite expert.

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