1” Box-joint dilemma.

Hi

The only thing that come to mine is to make a templete (use hardboard) and use a pattern bit with the bearing on the bottom of the bit,1/2" one should work fine,then clamp the stock to the work bench and clamp the templet to it.

Then use the plunge router and cut out the pins, you can also use brass guides but the templet needs to be over size in the slots and they must on the button.
Use carpet tape to make the templet that's to say stick a board on it and use it to make a stop point when you cut the slots out on the band saw in the templet.

http://www.grizzly.com/products/c1309
OR
http://www.grizzly.com/products/c1306


Hope this helps

Bj

Making a template was the first thing I did as you can see from the pic.
It’s ¾” pins by 1-1/4 space with 2” on center which yields a 1” box joint using a 5/8 template guide with ½” router bit but the results are disastrous.
The reason is when the router goes in the feed direction is normal clockwise. That works for ½” box joint since the stock is removed at one shot, but using that to make a two pass results in pins breaking due to the out direction of the router bit.
The only thing I haven’t tried that might work but it’s very time consuming is to use the original ½” box-joint template and use two ½” off-set bars and make two passes. But the chances of all pins coming out perfect is very slim.
More cuts = more variation.
I guess that's why no one makes 1" box-joint template.And that’s made on a table saw ( the EZ way)