I make 8-sided boxes using a bird-mouth bit. If I make 4-sided boxes I used the tablesaw to make miters. I have no problem aligning the corners.
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When I use the bird mouth bit, I use a piece of MDF as a push block. The router bit ends the cut in the work piece then enters the push block for 3/4 inch or so. This prevents tear out of the work piece. Also on that router table my fence is an Incra fence so I can adjust in thousands of inches. I generally make around 1-box each day. Well, last year I know I donated 200 boxes and wooden baskets and all cut with the bird mouth bit. They were all 8-sided. I also make funeral urns for people and pets using the same design.If you go with a lock miter bit, the Lock Miter Master gauge will let you set up the bit and fence position easily. They will work with any brand of lock miter bit. (Hint - you don't need both sizes- the larger one will work for all).
Lock Miter Master Jigs
Set up lock miter router bits for perfect joints in minutes, with minimal setup and less hassle!
I have the Lock Miter Master gauges and have used lock miter joints, but I could never get very clean cuts. Always way too much tear-out to suit me. I went back to cutting spline slots the full length of both halves of the joint, and I cut cross grained splines to fit using my table saw and tenon jig. Biscuits will work in larger mitered joints too. The attached photo shows one of my cross grained spline joints. The miters and the spline slots were cut on my table saw. Then I used my table saw tenon jig to cut thin cross grained splines from the ends of a donor board (the spline is actually the waste from cutting a tenon). Then I cut the spline free and to the correct width using my miter saw and a pre set stop block. The spline width should be equal to 2X the depth of the spline slot in the mitered ends of the box sides.
Charley
I have made probably over 1,000 boxes that are 4-corner instead of 8-corner. I use the tablesaw the cut them. Then I glue them up using Titebond II wood glue. Afterwards I used the tablesaw using a sled to cut slots in the corners to apply splines. I use contrasting splines for the corners. Here are what that looks like. Malcolm / Kentucky USAIf you go with a lock miter bit, the Lock Miter Master gauge will let you set up the bit and fence position easily. They will work with any brand of lock miter bit. (Hint - you don't need both sizes- the larger one will work for all).
Lock Miter Master Jigs
Set up lock miter router bits for perfect joints in minutes, with minimal setup and less hassle!
I have the Lock Miter Master gauges and have used lock miter joints, but I could never get very clean cuts. Always way too much tear-out to suit me. I went back to cutting spline slots the full length of both halves of the joint, and I cut cross grained splines to fit using my table saw and tenon jig. Biscuits will work in larger mitered joints too. The attached photo shows one of my cross grained spline joints. The miters and the spline slots were cut on my table saw. Then I used my table saw tenon jig to cut thin cross grained splines from the ends of a donor board (the spline is actually the waste from cutting a tenon). Then I cut the spline free and to the correct width using my miter saw and a pre set stop block. The spline width should be equal to 2X the depth of the spline slot in the mitered ends of the box sides.
Charley
Yes I have made boxes out of Kentucky Coffeewood. It is a lot like hickory. I can't find any photos of boxes or baskets that I made of it. It does look nice.
I'm a big fan of splines, use them all the time for picture frames. Like to use purple heart for them for the contrast. I have the little lock miter jigs somewhere, but they are so tiny, they've gotten lost. If you use them, find a box to store them or they will go to the sock monster for dessert.
Hi, Harry.
