2012 Resolution Complete!

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Project by Aaron McCain posted 12-03-2012 05:16 AM 5448 views 17 times favorited 6 comments Add to Favorites Watch

At the beginning of 2012 my family and I sat down to make a few goals for the year. I prefer to make “goals” instead of “resolutions” so that they are something I can work towards during the year. My educational goal for 2012 was to learn how to make a box joint. I knew that I wanted to make a jig, so I looked at a few examples of jigs and alternated back and forth between a router based jig vs. a dado blade jig. In the end I settled on the jig for the table saw and dado blade because of the flexibility of making joints with different widths and heights.

The jig is pretty basic, just a framework with a replaceable face plate. I recognize that I will need to make a pin and set the distance with each set-up, but it doesn’t seem like too much to cut a strip off the box material to have something the exact thickness. Back in the summer I picked up a pair of 4×4 “skids” made out of what I think is UHMW plastic from a job site for free and milled a pair of runners out of it. (I still have a considerable amount of the stuff) That was about as fancy as I got. The final picture is the first ever box joint that I have cut. I am pretty pleased that I was able to cross this off the list for the year. Maybe next year will be handcut dovetails.

6 comments so far

View a1Jim's profile


117328 posts in 3775 days

#1 posted 12-03-2012 05:18 AM

Great job ,this will come in handy.

-- wood crafting & woodworking classes

View Mike's profile


139 posts in 2239 days

#2 posted 12-03-2012 12:06 PM

nice looking box joints! I have been looking for a nice simple jig to learn to make these myself! nicely done

-- A person of integrity never speaks of it...he walks in it...

View ptofimpact's profile


378 posts in 2514 days

#3 posted 12-03-2012 01:05 PM

Aaron, looks great, I have been working towards making one, yours inspires me. If I may ask, why the adjustable face?

-- Pete in NC

View Aaron McCain's profile

Aaron McCain

125 posts in 3037 days

#4 posted 12-03-2012 08:59 PM

@ptofimpact: When you set up the jig to make miter joints, the first pass over the dado blade establishes the groove that will hold the reference pin. Then the entire jig needs to be moved to the side a distance equal to the width of the reference sled so that the new groove and the reference pin are precisely spaced. The sled’s lateral movement is fixed by the miter slots, so the adjustable face allows for this lateral movement and fine tuning.

View doordude's profile


1085 posts in 3181 days

#5 posted 12-03-2012 11:37 PM

great jig, now you can make a lot joints

View TopamaxSurvivor's profile


18388 posts in 3874 days

#6 posted 12-04-2012 07:30 AM

Just in the nick of time for a new “goal” ;-)) Nice job. Hand cut dovetails are easier than hand cut box joints! Trust me ;-)

-- Bob in WW ~ "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence

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