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Cutting box joints on long boxes

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Forum topic by JJohnston posted 09-18-2009 02:42 AM 4115 views 1 time favorited 11 replies Add to Favorites Watch
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JJohnston

1614 posts in 2751 days


09-18-2009 02:42 AM

I’ve got a project in mind that’s essentially a box 5 to 5.5 feet long and about 10” high and wide. How would one handle side pieces this long in order to cut box joints?

-- "A man may conduct himself well in both adversity and good fortune, but if you want to test his character, give him power." - Abraham Lincoln


11 replies so far

View CanadaJeff's profile

CanadaJeff

207 posts in 3069 days


#1 posted 09-18-2009 03:02 AM

With a size that big, my first thought would be forget the power tools and grab a few saws. If you want to go with power tools I would suggest using a dovetail jig with a straight bit.

View LesB's profile

LesB

1235 posts in 2903 days


#2 posted 09-18-2009 06:21 AM

Not knowing what tools you have available leaves this question wide open.
There are several commercial dovetail/box joint jigs out there you could use with a router. The best one probably being a Leigh (expensive). They would be the best and easiest.
With care and good supporting jig it could be done on a table saw or with a band saw and chisel. Careful cutting with a jig saw and some chisel clean up would work. With some imagination you could most likely come up with a home made jig to guide your router. Sort of an upside down table saw jig. Finally as CanadaJeff says, use a hand saw and clean up with a chisel.

-- Les B, Oregon

View TopamaxSurvivor's profile

TopamaxSurvivor

17654 posts in 3136 days


#3 posted 09-18-2009 06:25 AM

I would cut them by hand just like dovetails. If I was in a hurry, I might use power tools to help me along.

-- 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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TopamaxSurvivor

17654 posts in 3136 days


#4 posted 09-18-2009 09:39 AM

Suppose I should clarify that. I’d cut the first side with power tools, then mark up the second pice for the fitting if I ws in a hurry. Sort of hard to do it by hand with power tools ;-))

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

View Kindlingmaker's profile

Kindlingmaker

2656 posts in 2986 days


#5 posted 09-18-2009 06:34 PM

Make a clamp on finger jig and use a router… I would try the table saw but I don’t have 14 foot ceilings, (just kidding on the table saw). ; )

-- Never board, always knotty, lots of growth rings

View JJohnston's profile

JJohnston

1614 posts in 2751 days


#6 posted 09-18-2009 07:35 PM

Actually, that’s the main reason I asked, and left it open-ended. Even if I had a tall jig to hold the long pieces vertically, my ceiling height wouldn’t allow it.

-- "A man may conduct himself well in both adversity and good fortune, but if you want to test his character, give him power." - Abraham Lincoln

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JJohnston

1614 posts in 2751 days


#7 posted 09-18-2009 07:43 PM

Trying to do it on the table saw, I meant.

-- "A man may conduct himself well in both adversity and good fortune, but if you want to test his character, give him power." - Abraham Lincoln

View Doug S.'s profile

Doug S.

295 posts in 3168 days


#8 posted 09-20-2009 02:01 PM

Trying to do this by TS I think I’d try the following.
Make your llong sides 1 ft longer then machine all 4 sides to width.
Cut 6” off each end of the long sides then cut box joints on the TS using the normal dado/shop made jig setup as if you were making a 6” x Short side box.
Line up the 6” pieces onto the actual long sides and clamp them down.
Hog out the bulk of th waste with a bearing guided router bit, then switch to handsaws/chisels which can be guided by the 6” box joint cuts.

-- Use the fence Luke

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JJohnston

1614 posts in 2751 days


#9 posted 09-20-2009 05:37 PM

Interesting approach. Must resist urge to make “outside the box” joke.

This would probably work pretty well, since at this point a router and a table saw are about all I have.

-- "A man may conduct himself well in both adversity and good fortune, but if you want to test his character, give him power." - Abraham Lincoln

View RetiredCoastie's profile

RetiredCoastie

999 posts in 2643 days


#10 posted 09-20-2009 05:58 PM

A Japanese fine cut saw, and a good sharp chisel. How thick is your stock?

-- www.thepatriotwoodworker.com Proud Supporter of Homes For Our Troops

View JJohnston's profile

JJohnston

1614 posts in 2751 days


#11 posted 09-20-2009 07:31 PM

1/2 or 3/4.

-- "A man may conduct himself well in both adversity and good fortune, but if you want to test his character, give him power." - Abraham Lincoln

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