Calling All Boxmakers

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Forum topic by wookie posted 01-21-2010 04:19 AM 1554 views 1 time favorited 10 replies Add to Favorites Watch
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154 posts in 3325 days

01-21-2010 04:19 AM

Topic tags/keywords: box joints tip

I am trying to practice on some 1\4” box joints. Been studing the video on by Chuck Hedlund. Made a jig and index pin. Both are very close to 1\4”. For the life of me I can’t even get them to fit together. Tried tapping the fence over and everthing and can’t find anyway of remotely getting them to slide in at all. All you boxmakers, ” HOW THE HECK DO YOU DO IT?”

-- Wookie=Wood Rookie

10 replies so far

View TJ65's profile


1381 posts in 3291 days

#1 posted 01-21-2010 10:47 AM

OK I just learnt it. And it is easy when you get the idea of it. I used a scrollsaw to cut out the fingers though. I first use a printed grid line glued onto the timber and work out your cuts for two sides. Stack then cut. The matching one to fit into this has to be copied from the areas you have already cut out. So… You put the ones you have already cut out on top of the uncut ones. Use these as a template and mark (with a mechanical pencil ) the timber where you need to cut (make sure you mark out the waste!). When you have marked the lines and go to cut make sure you cut on the inside of the line and the base line is as straight as you can get it. Atually the straighter all the lines are, the better. It’s that easy!!!!!!!!!!!!!!!!!!

-- Theresa,

View Eagle1's profile


2066 posts in 3306 days

#2 posted 01-21-2010 01:14 PM

Pratice, Pratice, Pratice..

-- Tim, Missouri ....Inside every older person is a younger person wondering what the heck happened

View Sawdust2's profile


1466 posts in 4329 days

#3 posted 01-21-2010 01:33 PM

Same concern. Trying other methods we just made the Woodsmith box joint jig. A ,kit will all the parts except wood is $15.

Last night we made box joints for a project I will post later this week. With one set of practice pieces we had it staffed out and had short work of the joints for the project.

In my case my dado blades are over 50 years old so I think I am going to buy a set of box joint blades when the Wood Show comes to town later this month.


-- No piece is cut too short. It was meant for a smaller project.

View coloradoclimber's profile


548 posts in 4309 days

#4 posted 01-21-2010 05:21 PM


It sounds like you are using a standard box joint jig with an indexing pin. Possibly you don’t have the pin spacing to cutter size matched. Here’s a previous discussion on cutting and fitting finger joints, maybe it applies.

View danr78's profile


74 posts in 3290 days

#5 posted 01-21-2010 05:29 PM

there are so many adjustments that can be made, it’s hard to know what to advise without more information. In short, the pin, gap between pin and blade, and kerf all have to be indentical—- not as easy as it sounds. After that, fine tune the height of the blade to make the pins longer or shorter.

View Raspar's profile


246 posts in 3390 days

#6 posted 01-21-2010 05:41 PM

I had the same problem with the first jig I made years ago. My issue was getting the spacing of the jig to the blade and the blade thickness to match. I gave up and have done a few by hand since then. A while back I was in Rockler and saw the new one they have for the router table, and this sparked a interest again. I went home and built from memory what they had. It worked wonderfully, I did the bar out of wood for the first one and this worked fine. I now have the jig at my brother inlaws shop and he is going to cut the registering bars from metal on the C and C machine for me. With the hardware and everything I will have about 10 to 15 dollars into it. Much less than the 70 Rockler is charging although now that I have used it its worth that money. I like making my own jigs and found this one easy.

-- Have thy tools ready. God will find thee work.

View wookie's profile


154 posts in 3325 days

#7 posted 01-21-2010 09:07 PM

Thanks everybody. I will go back thru and check to see if everything is indentical, probably not, and give it another shot.

-- Wookie=Wood Rookie

View PurpLev's profile


8548 posts in 3890 days

#8 posted 01-21-2010 09:10 PM

obviously something with the setup is not correct- either the pin is too close/far from the blade, or similar. if you post pictures of what you get and what your jig looks like it might help people notice the cause.

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View lcurrent's profile


125 posts in 4057 days

#9 posted 01-21-2010 10:17 PM

This link is to a box that the top was done on a home made jig if you want send me an email and I will send some plans to build yourself


-- lcurrent ( It's not a mistake till you run out of wood )

View wookie's profile


154 posts in 3325 days

#10 posted 01-22-2010 02:19 AM

Went thru eveything again this afternoon. Made sure both pins and dado were close, very close. Made a couple practice pieces, same thing to big. Tapped the aux. fence to the left and got a real good fit. Now if the set-up stays put. Thanks Boxmakers, I really admire and envy your beautiful work. Larry I will send you an e-mail.

-- Wookie=Wood Rookie

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