Router Sled For Cutting Box Joints...

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Project by BusterB posted 10-24-2013 09:47 PM 3426 views 14 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


1267 posts in 2320 days

#1 posted 10-24-2013 09:49 PM

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


1970 posts in 2181 days

#2 posted 10-24-2013 09:57 PM

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

4168 posts in 3029 days

#3 posted 10-24-2013 10:03 PM

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


-- 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


2068 posts in 2361 days

#4 posted 10-24-2013 10:09 PM

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


1970 posts in 2181 days

#5 posted 10-24-2013 10:11 PM

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

29959 posts in 2511 days

#6 posted 10-24-2013 11:04 PM

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

-- Nature created it, I just assemble it.

View Jim Jakosh's profile

Jim Jakosh

21514 posts in 3278 days

#7 posted 10-25-2013 12:01 AM

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

View Mean_Dean's profile


6890 posts in 3320 days

#8 posted 10-25-2013 12:26 AM

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

-- Dean -- "Don't give up the ship -- fight her 'till she sinks!" Capt James Lawrence USN

View luv2learn's profile


2866 posts in 2476 days

#9 posted 10-25-2013 12:37 AM

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


1970 posts in 2181 days

#10 posted 10-25-2013 12:43 AM

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


4071 posts in 2066 days

#11 posted 10-25-2013 01:27 AM

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

View doubleDD's profile


7770 posts in 2216 days

#12 posted 10-25-2013 02:23 AM

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


165 posts in 2132 days

#13 posted 10-25-2013 03:39 AM

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


View CFrye's profile


10440 posts in 2012 days

#14 posted 10-25-2013 04:15 AM

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 Cedar Furniture Lodge 's profile

Cedar Furniture Lodge

819 posts in 2445 days

#15 posted 10-25-2013 06:53 AM

Hey what ever works! I like it.

-- "The Cedar King"

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