on Step 9. Learn more >, Easy step-by-step instructions and superior customer service. 8 years ago Slide the gauge back toward your body, clearing the blade again, and then turn off the saw. Notice in the picture that the board just barely covers up the notch, which is 1/2 inch away from the spacer block. An interesting point that the box joint is stronger than the dovetail joint, and does not require the custom dovetail jig. Position enough chippers in between the two outer blades so that the final width of the cut will match the desired width of the box joint fingers you determined. I made it at TechShop in Menlo Park (http://techshop.ws). Set one of the sticks down flush to one side of the groove. 8 years ago Be certain that the screws are short enough that the point doesn't poke through the face of the board. It should fit snugly without raising the backer board off of the surface of the ​table saw. - Mitre saw This doesn't have to be pretty, so I screwed them in tightly so as to countersink them below the surface of the rail. To make the first cut, position the board on the edge so that the end edge of the board that will be cut is flat on the table. It's more important that you are perpendicular to the saw cut than to the end of the board anyway, so having both there is a good way to make sure you're square all around. I ripped the strips off using the table saw with the standard blade and tuned them to the right width and height on the sander. What’s more, its inclusion of three different templates will allow woodworkers to use the jig for multipurpose projects. They should glide easily along the groove (sandingwill assist with that too - the guide rails will be smoother). With the box joint fingers on both boards cut, check to see how well you did by dry assembling the box joint. OK Got it? Once you've cut the two wooden pieces for the jig, install the stacked dado blade set in your table saw. Square up at least one end of this board on the mitre saw (that is, make sure it's perpendicular to the sides). Slide the spacer block so that the end is 2 inches past the front face of the backer board, and make a pencil mark on the spacer block against the backside of the backer board. Don't bother trying to screw this one in place, it's too small. http://pictureisunrelated.memebase.com/2012/06/02/wtf-photos-videos-the-magical-land-of-pizza-hut/, Design and 3D Print Your Own Phone Case (in Fusion 360). - Wood glue Once you know the width is correct, fix the rail in place with 3/4" screws, being sure to countersink the screw heads again. You will also need the following tools (all of which are available at Tech Shop! The sizing of your rails may vary with your table saw. Go ahead, I'll wait. 2.loosen and approximately guess where the 4 pieces will goand place in the gap the 4 pieces of wood and make sure the age years go in awave motion. While a through dovetail joint is stronger than a box joint, it's also more complicated to create. Then, position the board on one of the long edges, against the miter gauge, making certain that the board extends at least 1/2 an inch past the stacked dado blade. Congrats! Note: this will be tough at the end, because your smallest piece will be between the blade and the rip fence. Fixed base routers are ideal because they have a lower center of gravity with handles mounted to the router base rather than the motor, as with plunge routers. Instead, you can create this one with scraps and belt out box joints all day long. To align the second board, place the edge of the board against the table and the face against the jig's backer board (as before), but this time, slide the board to the right so that the top edge of the board just barely covers the notch in the jig. The free spacer is there to offset the boards so the grooves actually mate each other rather than meet each other. Let this piece dry. 94 $186.41 $186.41. - Power drill on Introduction. To begin making your box joint jig, determine what width you'll want each of the fingers of the joint to be. Now that you've done allthe rip cuts, it's time to start attaching the rails. I went one step farther and went to a metal shop and picked up some 1/2' square steel. Since you know your width between your rails, measure out the width from the edge of the fixed rail closest to the center, mark your next line, and set the next rail in the same way. The joint should fit snugly, but the fingers should not be too tight. I'm sure you'll figure it out, you're smart) Reply This slight extension can be sanded after the final assembly of the box joint. You've got a jig! Cool jig. Measure the length of your remaining widest piece of 1x12, and the width between your guide rails. When you're done, you'll have a stick that is 1/2" by 1/2". Attach an optional template to your D4R Pro for even more unique joinery styles. Clamp the board to the backer board and cut the first notch. This instructable is for a box joint jig, which is necessary for this particular carpentry technique. or is it available on the market (a link would be absolutely fantastic) ,… Thank you again. Glue one of your rails down to the side of the line closest to the end of the board. Just what I've been looking for to make a case for my next projects. FREE Shipping by Amazon. The model is great for a home use. Subtract the guide rail distance from the length of your board, divide that number in half, and measure that distance from the end. Only the tails need hand cutting. For this step, you'llneed the rails, glue, and the widest remaining piece of your 1x12 (should beabout 6-7" wide by now - I was lucky enough to have a fresh piece, so mybase is a full 12" wide, but it doesn't have to be that wide).Square up at least one end of this board on the mitre saw(that is, make sure it is perpendicular to the sides). Next, remove the miter gauge from the table saw and turn it upside-down, exposing the bottom side of the backer board. Blade guard, Deflector shield, GlideLOCK™ Extras . Turn on the table saw and push the jig all the way through the stacked dado blade. Too long and youwill have too much resistance, and you could potentially hit something on theother side of your table. Accessories . Pass the dado bit through your material. Dovetail joints date back at least to ancient Egypt. So, I come 7" in from one end of the board and mark it with the carpenter square (for now, just do one end). Projects with dovetails imply a level of craftsmanship and detail that adds both inherent strength and pizzazz.You can cut them by hand, but for reliability and quick repeatability, you just can’t beat a good router-assisted jig. However as a foreigner I have trouble to know what exactly is a"dado stack bit set" as stated on the list of required material. The box joint is an alternative to the more popular dovetail joint. However, the length is not as important as the height and the ability to flow smoothly through the channels. Ideally, your guide rails should be at least about 1/3 to 1/2 as long as your table. 8 years ago With the spacer block installed, re-position the miter gauge into the left slot of the table saw. Now, set the groove you just cut over the spacer and make the next pass. The difference is 14", and half of thatis 7". If this jig is secured and clamped on a router table, would it not work as well with a router? Be careful as always! Subtract the guide rail distance fromthe length of your board, divide that number in half, and measure that distancefrom the end.For example, assume I have 24" of board, and the gapbetween guide rails is 10". Awesome instructable. Before making the first cut, adjust the depth of the stacked dado blade on the table saw to match the thickness of the stock being cut. That said, this is an instructable, so I'll go into some detail as necessary. I just found that doing leaving the rip fence at 1/2" for both cuts gave me a perfect square without any thought, but it can get tricky handling such a small stick on a table saw. - Phillips or flat head bit, as required for your wood screws With the jig positioned so that the installed spacer block is now precisely one box joint finger's width past the dado blade, re-attach the backer block to the miter gauge using the two screws you just removed. The difference is 14", and half of that is 7". Before moving on, take a minute to slide your guard rails back and forth and side to side. 3D joint design makes bold design statement, Rout straight or angled end-on-end dovetails at five different cutting depths, Rout endless pairs of perfectly aligned shelf holes and matching notches, For authentic period or reproduction pieces.