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I don't know what the jig looks like but since you have spent time making it maybe if someone could post a picture "we" might be able to suggest a fix. Or maybe someone has already thought up one??????

Ed

 

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Sure, the easy way is to use the Go Advanced button on the reply. Then attach them using the Manage Attachment button. When it comes up browse to the location of the pictures (they take bmp, jpg etc.) and when you have them appearing in the files to upload: hit the Upload button. You may need to reduce the size of the files to meet the requirements (97.7 KB). It takes a few seconds to upload (more on slower links) then they should be with the message when you hit Submit Reply. If you don't know how to resize them let me know I'll give you a my email address so you can send them and I will resize them and post them for you.

Ed

 

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OK, now let me ask now you clamp the pieces to the jig? The only thing I can see that might be an issue is that the wood being cut will have to be clamped to be held in place you can not use the angle bracket to hold the wood in place. The bar stock you now have could be changed to wood or plastic the heavy metal should not be needed.

The jig I use on my table saw is not adjustable it is how ever very simple to make and you can make one for 1/4" and another for 3/8" and if you want one for 7/16". If you want detail let me know I will do a step by step for you (in a few days).

Ed

 

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The stock to be cut is simply held by hand on the guide pin and fence. See the picture of this at http://store.yahoo.com/plansnow/boxjoint.html . The jigs I used before building this one were of the "fixed" pin type probably similar to the ones you describe. I still use them if I want a different size box joint, but this one looked really neat with all it's fancy micro adjustments and I thought it might be more versatile. Mostly I use the 1/4" box joint for about every thing i need to do.

Thanks again

On a table saw the parts can be handheld as shown but with a router the bit will try and move the part and as you have said it bends the metal. For router use you will have to clamp it and maybe add some sandpaper to the jig to help hold the wood in place. That will slow down the process but if you get a quick acting clamp it might not be to bad. The closer you clamp to the cutter the better.

I have a miter gauge that has the same general features of the jig but I still use the hand made ones....

I hope this helped.

Ed