How To Make a Box with a Box Joint - Router Forums
 
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post #1 of 8 (permalink) Old 08-05-2011, 08:21 PM Thread Starter
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Default How To Make a Box with a Box Joint

There are different types of boxes that can be made using your router. We already looked at one that can be glued together. Today, Bob Rosendhal shows how to make a box with joints that can fit together.

Step One

Place a 3/8-spiral bit in the router, with a brass ring. To get started, place a spacer fence on your router table. Bolt it down or clamp it down. Choose 4 pieces of wood and cut them down to the size of the box you want to make. Check for accuracy of height and spacing by taking two pieces of scrap wood, clamping them together and running it through the bit while pressing the edge against the spacer ridge. Mark the width and then place the wood on top of the ridge again and repeat. When you are finished, check to make sure the two pieces fit together.

Step Two

Take a long scrap piece and run a groove in it, using a push piece. Place this block with the groove on the ridge of the fence and clamp into place. Adjust slightly with a hammer. Take your box pieces, find the face side and mark on the side. Line up an end piece against the scrap piece of wood, using a push stick, and run through the bit. Stop the router and take off the scrap wood. Then place hole on the spacer ridge and run again until you come to the other side. Switch to the next side and repeat with both pieces until both ends of the end pieces are complete.

Step Three

Since the sidepieces are thinner, raise the height of the bit to the thickness of the end pieces plus the two sides on top. Clamp the sidepieces together flush and run through the bit, using a push piece. But only cut the ends, not the sides. When you are finished, place the sides into the end pieces and set aside.

Step Four

To make the bottom, first make a mark on all the pieces where the bottom will go. Change the bit to a 1/8Ē spiral bit. Change the fence to the long thin piece with the hole down. Grab an end piece and line it up so the bit is centered between the first pin and the second pin. Lock the fence in place with the second clamp. Cut a groove on the side where you marked the bottom with both end pieces. For the sidepieces, you donít want to cut all the way through. Start and stop just before the end. Make a groove in each piece. Put the box together using a 1/8-inch bottom piece and place sides and ends together. Now, you are ready to glue! Have fun!

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post #2 of 8 (permalink) Old 08-06-2011, 10:00 AM
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Photographs would help.

Cheers,
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I'm not slow, I'm pacing myself!

Isaiah 44:13 Another shapes wood, he extends a measuring line, he outlines it with red chalk. He works it with planes and outlines it with a compass...

Usual kit: Table saw, band saw, dual base router and table, lathe, various saws, planer, sanders, and a multitude of hand tools.

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post #3 of 8 (permalink) Old 08-06-2011, 11:25 AM
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It appears you have to pay to see these.
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post #4 of 8 (permalink) Old 08-06-2011, 11:28 AM
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Router Workshop: Episode Guide
Router Workshop: Series 100

103 - Magic Boxes,it's only 4.oo bucks via email and worth every penny for this one..


How to make a mystery box that will have everyone guessing just how it is put together.
Easily the most popular of first projects, this box demonstrates just how simple it is to get professional looking wood joints using a router. Don't measure.

Order E-Plan

U.S. Customers Click Here!

Canadian Customers Click Here!

http://secure.campaigner.com/Campaig...spx?fid=225670

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Last edited by bobj3; 08-06-2011 at 11:33 AM.
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post #5 of 8 (permalink) Old 08-06-2011, 11:44 AM
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Quote:
Originally Posted by mickleuk View Post
It appears you have to pay to see these.
Mike, it is truly worth the price of admission.

Brian


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or by imbeciles who really mean it.

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post #6 of 8 (permalink) Old 08-06-2011, 01:30 PM
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Roger and Mike: The first post in this thread is an attempt to convey the lessons learned by building the "Magic Box" BJ posted links for. This box is easy and quick. It features a ship lap joint for the lid and takes a minimal amount of wood. This really is one of the best first projects to build. Another easy project is a simple trivet; a box joint jig gives you fool proof results on the first try.
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post #7 of 8 (permalink) Old 08-07-2011, 07:05 AM
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Default box jig

this jig i made. you can do 4" high box with it. i use a 1/4 inch bit,i also have one to make 1/2" joint as well please look at my photos
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post #8 of 8 (permalink) Old 08-07-2011, 07:07 AM
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Nice job Ray. Looks like it does a great job.

Brian


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