|Forum topic by DFlatMinor9||posted 04-22-2011 05:05 PM||2759 views||0 times favorited||8 replies|
04-22-2011 05:05 PM
Hello everyone! I’ve been a long time reader/lurker of Lumber Jocks and this is my first posting. I’ve really learned and enjoyed the content I’ve found on this site, as well as seeing all of the amazing work you all are doing. It’s very, very inspiring. =0) I apologize if this is the wrong forum category to post in. I hope it is the correct one. If not please let me know and I’ll be sure to post to the proper category.
I’ve been practicing box joints in 1×6 Poplar on my table saw using a jig similar to the many seen all over the web (small scrap of MDF with a key and a couple of notches). I have quite a few different box projects that that I want to do, and some are need to do’s. I’d like to make them as beautiful as my skill level and tooling will allow. They’re close to fitting nicely but I’m still having a little trouble. I’m positive it’s something I’m missing with either the making/setup of my jig, my cutting technique, or something ::scratching head::.
Thankfully I solved my tear out issue by using a piece of hardboard backer and slowing my feed after reading some advice given to another person on this forum regarding it. Now if I could just get them to fit nicely and seat all the way…lol.
The problem I’m having is tiny gaps where the pins meet the bottom of the notch. I’ve tried using a piece of the key material as a punch of sorts and tapping them gently to get them down, but they just won’t go all of the way. The gaps are very small but definitely noticable – plus I see small gaps on the inside too. I’ll list a breakdown of my jig materials/setup below for your critique. I’m sorry for the wordy first post, but I don’t have any pictures of the fit issue at the moment. Easy to see, tough to describe succinctly.
They only time I’ve seen my test cuts seat all the way is when the fit was too loose. I’ve been having a devil of a time trying to dial in this jig, do it quickly, and get snug fitting, gap free joints. As a quick aside, and odddly enough at that, I tried some test cuts in some home center grade birch I had lying around to try and slow chewing up what little bit of the Poplar I have left, and the box joints came out flawless! Right fit and noooo tear out. Weird. My joinery experience with ply has been a rocky road, but has been the opposite the past couple of days between the ply and poplar.
Any advice/tips you all would be willing to share to help me troubleshoot my fit/setup would be greatly appreciated.
Thanks everyone and sorry again for the wordy first post! I look forward to seeing more of everyone’s inspiring work as well as learning and improving from all of you.