Box joint jig for router table - Router Forums
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post #1 of 24 (permalink) Old 11-29-2015, 11:50 PM Thread Starter
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Default Box joint jig for router table

For my next project I'm planning on using box joints for the first time, so I started thinking about making a jig I could re-use in the future. I came up with this idea for a jig that can cut 1/4, 1/2, 3/4, and 1" box joints on a router table. Just separate the fence from the shuttle and reorient them for the joint you want. My biggest concern is trying to keep the workpiece perpendicular to the table. I think that the wider handle and long tongue will keep me well referenced to the table, and adding the dowels should make sure that the pieces are oriented correctly.

What do you think?
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post #2 of 24 (permalink) Old 11-30-2015, 12:31 AM
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Since the dowels have to slide through the holes to be able to reverse it for the other configurations I would be concerned about them moving if I put pressure on the jig which would allow the jig to tilt forward. I would say you need some way to lock them in place.

Someone I consider a master woodworker once told me that a master woodworker is not someone who never makes mistakes. He is someone who is able to cover them up so that no one can tell.
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post #3 of 24 (permalink) Old 11-30-2015, 12:44 AM
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Jeff, do yourself a big favor and do not try to re invent the wheel. Of all the box joint jigs out there the easiest to use is the Oak Park style which has been copied by both Peachtree and MLCS. It would be easy enough for you to duplicate this outstanding jig in different sizes. This will also allow you to make angled box joints easily.
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post #4 of 24 (permalink) Old 11-30-2015, 01:41 AM Thread Starter
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Quote:
Originally Posted by Mike View Post
Jeff, do yourself a big favor and do not try to re invent the wheel. Of all the box joint jigs out there the easiest to use is the Oak Park style which has been copied by both Peachtree and MLCS. It would be easy enough for you to duplicate this outstanding jig in different sizes. This will also allow you to make angled box joints easily.
Thanks Mike, I've seen your previous posts re. the Oak Park style jig. It does seem like it would do a great job in maintaining the spacing, but I don't see any way to keep a tall workpiece perpendicular to the table without building something additional to provide vertical support.
Besides, I kinda like reinventing the wheel
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post #5 of 24 (permalink) Old 11-30-2015, 01:58 AM
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A suggestion - look at the right angle fixture that Incra uses. Basically it runs on a fence and you hold the wood at right angle to the fence. It shouldn't be too hard to make something similar. I use one with my LS Positioner all the time and it works pretty well. I've made a lot of box joints with it. You could incorporate a key mechanism and it would be pretty easy to use.

Measure twice, cut once and CROSS OUT THE WRONG MARKS.
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post #6 of 24 (permalink) Old 11-30-2015, 02:06 AM Thread Starter
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Originally Posted by Cherryville Chuck View Post
Since the dowels have to slide through the holes to be able to reverse it for the other configurations I would be concerned about them moving if I put pressure on the jig which would allow the jig to tilt forward. I would say you need some way to lock them in place.
I see your concern Chuck. The dowels will be glued to the fence and I'm thinking of using some extruded aluminum bar instead of wooden dowels so the parts will mate smoothly.

I think that adding the red support in the attached picture will help mitigate any issues with torsion in the fence. The cutout in the 3/4" thick fence will be a tight fit with the shuttle which will also help keep the fence in alignment.
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post #7 of 24 (permalink) Old 11-30-2015, 02:19 AM Thread Starter
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Originally Posted by PhilBa View Post
A suggestion - look at the right angle fixture that Incra uses. Basically it runs on a fence and you hold the wood at right angle to the fence. It shouldn't be too hard to make something similar. I use one with my LS Positioner all the time and it works pretty well. I've made a lot of box joints with it. You could incorporate a key mechanism and it would be pretty easy to use.
Phil, that Incra fence is amazing. With your LS positioner, referencing the workpiece to the fence makes perfect sense. Since I don't currently have any micro-positioning on my fence I opted for something more like Mike's Oak Park 'style' jig. I like the fact that you're reference the previous cut to make the next one, guaranteeing correct spacing.

Thanks for your input!
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post #8 of 24 (permalink) Old 11-30-2015, 08:32 AM
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I use a short section of 3 x 3" as a push block Jeff. Sides cut for 1/4", 3/8" and 1/2" box joints. Our late friend BJ used a taller push block made from two pieces of pine with a handle on the back. And using an angled push block makes it very easy to create many projects.
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post #9 of 24 (permalink) Old 11-30-2015, 11:47 AM
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Originally Posted by Ratbob View Post
Phil, that Incra fence is amazing. With your LS positioner, referencing the workpiece to the fence makes perfect sense. Since I don't currently have any micro-positioning on my fence I opted for something more like Mike's Oak Park 'style' jig. I like the fact that you're reference the previous cut to make the next one, guaranteeing correct spacing.

Thanks for your input!
I was responding to your concen about keeping a tall workpiece properly aligned. The RA fixture does that. I was suggesting using something like that with a "key" which is what the Oak Park jig does. Micropositioning (actually, it's incremental positioning) isn't really a part of that idea.

Though, I personally don't want to use anything other than an incremental positioner these days. Especially with Furboo's template making software - all sorts of spacings are possible now.

Measure twice, cut once and CROSS OUT THE WRONG MARKS.
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post #10 of 24 (permalink) Old 11-30-2015, 04:16 PM
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Quote:
Originally Posted by Mike View Post
Jeff, do yourself a big favor and do not try to re invent the wheel. Of all the box joint jigs out there the easiest to use is the Oak Park style which has been copied by both Peachtree and MLCS. It would be easy enough for you to duplicate this outstanding jig in different sizes. This will also allow you to make angled box joints easily.
Mike, your last post about that jig had me hunting, only to find out Oak Park is liquidating everything. They no longer offer that jig.

If you have any other source for it, please share.
Otherwise, stop teasing those of us desperately trying to find a good box joint jig...You're killing me!
*tries to grab Mike's jig and run away like Gollum - "My PRECIOUS!!!!"

~M
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