|Project by peterbb||posted 05-07-2012 10:53 PM||3512 views||9 times favorited||11 comments|
I recently made the Advanced Box Joint Jig from Woodgears.ca. I found the documentation easy to follow, and the completed jig works well. Matthias now has a series of videos showing the construction of the jig.
I used 1/2” (12mm) plywood rather than the 9mm (3/8”)Matthias suggests, and had one minor problem as a result: the thicker plywood lifted the main gear so it wouldn’t mesh properly with the driven gear. I had to reduce the thickness of the plywood piece under the main gear by 1/8” to make it work. (I was also a bit sloppy in cutting the gears, which didn’t help.) I also foudn that the 5/16” knob that I first used to hold the main gear hit the gear, so I replaced it with a wing nut.
I used a Forrest Woodworker II blade to make the joints shown in the last picture. It makes a kerf just over 1/8” – just right to make a 1/8” joint with a single cut. For a 1/4” joint, I have to turn the 48 tooth main gear exactly 1/2 turn for a second cut on the first notch, then a turn and a half to start the second notch. For a 3/8” joint, I need cuts at 0, 180 and 0 degrees, then 2 turns to the next notch. Unfortunately this blade leaves a bump in the middle of the kerf, so the bottoms of the notches are a bit rough.