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Router Sled For Cutting Box Joints...

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Project by BusterB posted 300 days ago 2192 views 13 times favorited 22 comments Add to Favorites Watch

I really like the look of the box joint so after several less than successful attempts at cutting them by hand, I decided to break down and machine some. The standard approach to this seems to be using a dado blade on the table saw. Until recently my old Craftsman did not have a arbor long enough to accept a stacked dado set so I never bought one (do have a adjustable wobble dado but I am not a big fan…lol) . I have seen various projects posted where fellow LJ’s had used a router to make the joints so a while back I started experimenting on a jig to use. After a few failed attempts, I laid the sled aside and moved on. Went down today to work on a cutting block for my daughter and noticed the sled laying there gathering dust and decided to give it another go. After a wee bit of tweaking I grabbed up some pieces of poplar and tried again. Results would have been a tad better if I had ran the poplar through the planer and actually squared the ends but it still worked out ok. Still gonna make a jig for the new tablesaw but was pleased to finally get the sled to work.

-- Buster, Ocoee TN (Critics are men who watch a battle from a high place then come down and shoot the survivors - Hemingway)





22 comments so far

View AngieO's profile

AngieO

1135 posts in 772 days


#1 posted 300 days ago

Cool. I haven’t tried box joints yet And since I am not very good doing most things by hand… maybe on the router would work. I’ll have to try one of these some day.

Nice jig

View BusterB's profile

BusterB

1372 posts in 633 days


#2 posted 300 days ago

Thanks Angie… Look forward to seeing what you come up with.

-- Buster, Ocoee TN (Critics are men who watch a battle from a high place then come down and shoot the survivors - Hemingway)

View Jamie Speirs's profile

Jamie Speirs

4109 posts in 1481 days


#3 posted 300 days ago

Buster super cool my buddy
It is also my favourite joint and I cant stand dovetails
I’m as of 5 minutes ago finished making a box jig doing
some Greene & Greene box joints. There joints are the
best you get, sexy even.
I’ve two more box jigs to makes as each size has a different
finger arrangement if that makes sense?

Boxes Boxers

Jamie

-- Who is the happiest of men? He who values the merits of others, and in their pleasure takes joy, even as though 'twere his own. --Johann Wolfgang von Goethe

View MarkTheFiddler's profile

MarkTheFiddler

1766 posts in 813 days


#4 posted 300 days ago

Outstanding Buster! Simple and great joints! Consider it SO stolen.

I made something very similar for the table saw sled. No I can see that I didn’t take it far enough.

-- Thanks for all the lessons!

View BusterB's profile

BusterB

1372 posts in 633 days


#5 posted 300 days ago

Thanks Jamie….makes perfect sense. This one will only do 1/2”. I think instead of making another sled to do 3/4”, would probably be simplier to just make a new face plate for this one. Good looking bunch of younguns you posted my friend. Stay safe and take good care of those guys.

Thanks Mark, need to have a look at yours for tablesaw. I plan on doing one for a dado set very soon.

-- Buster, Ocoee TN (Critics are men who watch a battle from a high place then come down and shoot the survivors - Hemingway)

View Monte Pittman's profile

Monte Pittman

13726 posts in 962 days


#6 posted 300 days ago

I bought the Incra Ibox jig. Love it. Good job on your jig.

-- Mother Nature created it, I just assemble it. - It's not ability that we often lack, but the patience to use our ability

View Jim Jakosh's profile

Jim Jakosh

11277 posts in 1730 days


#7 posted 299 days ago

Nice handy jig, Buster. You sure got a nice fit on those 2 boxes with the router!!.
I have been thinking about a box joint jig, too. I was going to put my wobble dado on the table saw and try it like that. The last box joints I did were done on my Craftsman Radial Arm Saw. I tilted the blade to the horizontal position and made a fine adjustment wheel for the vertical adjustment and they fit like a glove. I used a regular saw blade and took 2 cuts for each joint. They were 1/4” wide notches.

..............Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View Mean_Dean's profile

Mean_Dean

1345 posts in 1772 days


#8 posted 299 days ago

Hadn’t thought of doing box joints on the router table, but your jig makes it look easy! Nice work!

-- Dean

View luv2learn's profile

luv2learn

1673 posts in 927 days


#9 posted 299 days ago

Simple is almost always the best solution and your sled is certainly a model of simplicity. Great job on the sled Buster the box joints look nice and tight.

-- Lee - Northern idaho~"If the women don't find you handsome, at least they ought to find you handy"~ Red Green

View BusterB's profile

BusterB

1372 posts in 633 days


#10 posted 299 days ago

Monte- Thank you sir…

Jim- Thanks buddy. There was only one box. Not sure why the color was so different between the two pictures. I remember you telling me you had a wobble blade you used on your RAS… whew…thats a real man…lol

Dean- Thank you sir. It really was pretty simple once I got the danged thing built….lol side 1 butts up against the guide for the first pass, side 2 butts up against a 1/2” spacer for first pass. Works pretty fast after those first passes.

L2L- Thanks buddy. You know me Lee, i am the king of simple-ville. Leave it you to do the bells and whistle builds…lol

-- Buster, Ocoee TN (Critics are men who watch a battle from a high place then come down and shoot the survivors - Hemingway)

View hoss12992's profile

hoss12992

2565 posts in 517 days


#11 posted 299 days ago

Great job buddy. I need to make one of these, and def could have used it today in the shop. After I finish the project we are on, I think I will be making one of these. Thanks for sharing

-- The Old Rednek Workshop https://www.facebook.com/theoldrednekworkshoptn

View doubleDD's profile

doubleDD

2371 posts in 667 days


#12 posted 299 days ago

Nice simple jig Buster. Great work. It’s about time I get one in the shop. I may be using this idea for mine. Thanks for sharing.

-- --Dave, Downers Grove, Il. When you run out of ideas, start building your dreams

View ASUAlumni02's profile

ASUAlumni02

164 posts in 584 days


#13 posted 299 days ago

I’ve been trying to make one of these for a while with multiple fails. I think I will give your version a shot.

-- www.facebook.com/GarageTherapyWoodworking

View CFrye's profile

CFrye

2797 posts in 464 days


#14 posted 299 days ago

Nice jig Buster with great results. Learned something new. I thought your reference to a wobble blade was about an out of tune saw. Now I know better. Thanks for sharing.

-- God bless, Candy

View Todd Barrone's profile

Todd Barrone

465 posts in 896 days


#15 posted 299 days ago

Hey what ever works! I like it.

-- "Courage is being scared to death but saddling up anyway" John Wayne https://www.facebook.com/BarroneContracting

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