American Woodworker
Contact Us | Help | Report a Bug
Sign in | Join
 

Router Table Box Joints Castle Rock CO

The biggest problem in making box joints has always been getting a precise fit, because the line between success and failure is only a few thousandths of an inch thick. Fortunately, the solution simply requires that your jig be easy to adjust, not difficult to make.

The Home Depot
(303)688-8790
333 W Allen Street
Castle Rock, CO
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 7:00am-8:00pm

The Home Depot
(303)706-1500
8477 S Yosemite Ave
Lone Tree, CO
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 7:00am-8:00pm

Woodcraft - Denver, CO
(303) 290-0007
6770 S. Peoria St
Centennial, CO

Data Provided by:
The Home Depot
(720)870-8839
6000 South Gun Club Road
Aurora, CO
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 7:00am-8:00pm

The Home Depot
(303)794-0352
3000 W Belleview Ave
Littleton, CO
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 7:00am-8:00pm

The Home Depot
(303)805-9991
11111 South Parker Road
Parker, CO
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 7:00am-8:00pm

The Home Depot
(303)799-9071
9401 E Arapahoe Rd
Greenwood Village, CO
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 7:00am-8:00pm

The Home Depot
(720)344-7645
1200 Mayberry Road
Littleton, CO
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 7:00am-8:00pm

The Home Depot
(303)699-5006
5600 South Chambers Rd
Aurora, CO
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 7:00am-8:00pm

Castle Rock - Auth Hometown
(303) 663-5977
826 Park Street
Castle Rock, CO
Store Hours
Hometown Dealers
Store Type
Hometown Dealers
Hours
Mon:9-19
Tue:9-19
Wed:9-19
Thu:9-19
Fri:9-19
Sat:9-19
Sun:11-16
Store Features
Mon:9-19
Tue:9-19
Wed:9-19
Thu:9-19
Fri:9-19
Sat:9-19
Sun:11-16

Data Provided by:

Router Table Box Joints

Router Table Box Joints

The perfect fit comes easily with a shop-made jig.

by Tom Caspar

Box joints are a cinch to make on a router table. All you need are a sharp bit and a basic plywood jig.

The biggest problem in making box joints has always been getting a precise fit, because the line between success and failure is only a few thousandths of an inch thick. Fortunately, the solution simply requires that your jig be easy to adjust, not difficult to make. I’ve added a micro-adjust system to my jig that is incredibly precise but takes only a minute to put together.

This jig is specifically designed for the jewelry box on page 64. You can certainly use it for other projects, but there are some limitations. It’s dedicated to only one size of router bit. To make wider or narrower box joints, you must build another jig. For box joints wider than 1/2 in., you’re better off using a tablesaw and a different kind of jig. If your project requires box joints that are more than 5 in. wide, widen the jig accordingly. 

Setting up this jig does require some test cuts. Plan ahead by milling some extra parts from the same wood or wood of equal hardness. In addition, make all the pieces extra wide by 1/4 in. or so. It’s much better to rip your pieces to final width after all the box joints are cut. Then the last finger or notch will be exactly the same size as all the others.

Photo 1: Rout a groove down the length of a piece of plywood to begin making the jig’s base (Fig. A, below). Make the base the same length as your router table. 

Use the same size bit that you’ll use for the box joints. Here, it’s 3/8 in. A spiral bit makes the cleanest joints (see Source, below), but a straight bit works fine.

Photo 2: Fasten a runner to the jig’s sled section (Fig. B, below). The runner’s fit in the base is crucial, so begin slightly oversize. Rip the runner on the tablesaw so it barely slides in the base’s groove. Then sand one edge with a block until it slides smoothly.

Photo 3: Clamp both ends of the base to the router table so the bit is approximately centered in the hole. The base’s groove goes in front of the router bit as you face the router table. Raise the bit so it’s exactly as high as your workpiece is thick (see inset). 

Photo 4: Position the base so the runner is exactly 3/8 in. away from the bit. Use a drill bit as a measuring device. To adjust the base, withdraw the drill bit, loosen one of the clamps and gently tap the base’s edge with a hammer. Recheck the spacing with the drill bit and tighten both clamps.

Photo 5: Rout the first notch in test piece A. Mark one edge as the bottom. Butt the workpiece up to the runner, and slide the sled back and forth 1/2 in. or so to cut the notch all the way through. Press down on the sled so it doesn’t tip forward.

Photo 6: Continue routing notches all ...

Click here to read the rest of the article from American Woodworker