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making-a-router-box-joint-jig-art Put a backerboard in the upper clamp. After cutting two practice boards, slide the pieces together and inspect jif joint. Same Day Shipping Find a Store. Kink Jarfold allanm Reply 1 year ago. Test-fit your joint. When finished, you should have perfect complementary joint parts, as shown below right.

Precision is important; if you have one, use a dial caliper to sneak up on the exact dimension, as shown below. Make a practice box joint using your jig. Use a caliper to compare the size of the pin and spacer strip to the first notch cut. It might help to remove the miter-gauge fence to test the fit. Set the pin spacing for the side by placing the spacer between the registration pin and the blade. Tighten the wing nuts to secure the fence to the miter gauge.

Butt your workpiece against the registration pin and make the first cut. Use clamps to support larger boards. Place the notch you just cut over the registration pin and make your second cut. Repeat the process until you reach the opposite edge of the board and final pin. Butt your workpiece against the registration pin and make your second cut. Test-fit your joint. Box joints rarely come out perfect at first cut.

After cutting two practice boards, slide the pieces together and inspect the joint. Ideally, your joints should be perfectly flush, but this is not always practical. A slight amount of finger protrusion is acceptable and easily leveled with a sharp hand plane or a block of wood wrapped with sandpaper.

Conversely, if your fingers are too short, raise the blade. A loose joint not only looks bad, but also may not hold together no matter what glue you use. On the other hand, if a joint requires force to get it together, the glue will swell the fibers and make the joint impossible to assemble. Move the registration pin to the right for a tighter joint or to the left for a looser joint. Note that wider workpieces require more careful setup because tiny errors multiply by Making A Router Box Joint Jig 20 each pin. If you plan on rows of box joints, you may want to consider a dedicated box-joint cutter.

Neither setup requires shims. As an added plus, the tooth geometry creates perfectly square and smooth flat-bottomed joints. Your notches should have clean exit cuts like the first workpiece shown in the photo on the left. While dull blades can cause blowout, more often a worn fence is the culprit. Two common ways let you make box joints with a router. One is on a router table with a straight bit and a miter gauge fixture that resembles the table saw jig; the other faster and easier way relies on a router dovetail jig with a box-joint template.

Box-joint templates come packaged with some jigs. If not, you can buy them as a reasonably-priced upgrade. The size of the jig will also limit the width of the boards you can use.

Note: Unlike table saw and router table jigs, the tightness of a template-routed box cannot usually be adjusted. If you use a good quality jig, bit, and guide bushing, this is usually not an issue. Each jig is a little different, but here we worked with one of the most popular models to offer a step-by-step overview. First, install the appropriate guide bushing and bit in your router. Now insert your workpiece into the vertical position and align the guideline on the template with the rear edge of your workpiece.

Clamp your workpiece and backerboard securely and rout the fingers, moving from left to right, as shown below left. Rotate the workpiece and cut the other fingers on the other end. The opposite side is made in the same fashion. To make the adjacent sides, move over to the right side of the jig and set the right stop. Put a backerboard in the upper clamp. Insert your workpiece in the vertical position against the right stop. Secure the clamps and rout from left to right.

When finished, you should have perfect complementary joint parts, as shown below right. You must be logged in to write a comment. Log In. Find a Store. My Account.

My Cart. Go to Home Page. Mobile Navigation. Same Day Shipping Find a Store. I found a chunk of 2 x 4 and used it as the back fence and ran the router blade up to it. I screwed the fences through the base and counter sunk the screws. Make sure this fence is square to the base. I've seen some people secure right angle wedges to the back of the fence to keep it square.

It took me a bit of finessing, but eventually I got a perfect fit. I cut two pieces. One is secured to the base and is one router bit width away from the cut made by the bit.

The other is used to basically eliminate any space and will allow the router bit to cut a hole in the end of a board. I raised the router bit a skosh above the thickness of the wood I'd be using. It is easier to sand off a protrusion than to fill in a depression.

Then ran it into the rear fence and tested the keys. I made that error and knocked out the key and trimmed it down and the spacer down to the proper height. Now to test the jig. I cut two pieces of wood the same size.

Then I removed the spacer and staggered and aligned the two notches on and up to the fixed key. It then became a matter of leap-frogging over the key until I reached the end of the board. The same result can be gotten by doing each separately. The first goes against the permanent key, Making A Router Box Joint Jig 77 the second goes against the spacer. Basically, you are creating Making A Router Box Joint Jig Effect tongues and groves that will go together to form a joint.

I was very pleased with the result. Now I must admit I looked at dozens of How Tos on making this jig and Frankensteined my own version to fit my router. You'll notice I only have one runner where as most I saw have two. Even one I saw made a second runner off the side of the table. Some were so elaborate it'd take me forever to build it. The simple one I show here took a few hours on and off while doing other things around the house.

It meets my needs, and that is the whole purpose. Make a jig to suit your personal requirements. I'm making my jig now. One question. In fig. Anyway to fix that? Reply 1 year ago. Hi, Allan, yes there is a way to eliminate that offset.

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