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Tablesaw Box Joints Loudon TN

Box joints have alternating pins and sockets. To fit together, one piece has pins where the mating piece has sockets (Fig. B, page, 70). The challenge is to cut pins and sockets that are virtually the same size, with paper-thin tolerances for fitting the joint.

The Home Depot
(865)986-6116
250 Abbie Drive
Lenoir City, TN
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 8:00am-8:00pm

The Home Depot
(865)983-6200
943 Foot Hills Mall Dr
Maryville, TN
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Mon-Sat: 6:00am-10:00pm
Sun: 8:00am-8:00pm

Co/Op Ace Hardware
(865) 458-2057
2084 W Lee Hwy
Loudon, TN
 
Foothills Farmers Co-op
(423) 337-3551
776 New Highway 68
Sweetwater, TN
 
UNITED RENTALS/Knoxville, TN
(865) 693-5761
10224 Kingston Pike Knoxville, TN, 37922
Knoxville, TN
 
The Home Depot
(865)691-9500
9361 Kingston Pike
Knoxville, TN
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Mon-Sat: 6:00am-10:00pm
Sun: 8:00am-8:00pm

Fastenal- Loudon
865-458-0404
155A Natalie Blvd Loudon, TN, 37774
Loudon, TN
 
Ace Hardware of Dixie Lee Jct
(865) 988-5285
19670 Highway 11 E, WATT ROAD
Dixie Lee Jct, TN
 
Sweetwater - D
(423) 337-2870
902 S Main St
Sweetwater, TN
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Mon:8-22
Tue:8-22
Wed:8-22
Thu:8-22
Fri:8-22
Sat:8-22
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Mon:8-22
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Browder's Ace Hardware
(865) 376-7606
1100 Ladd Landing Blvd, Ladd Landing Shopping Center
Kingston, TN
 

Tablesaw Box Joints

Tablesaw Box Joints

A shop-made jig with micro-adjust guarantees perfect joints.

by Tim Johnson

Box joints are the savvy woodworker’s alternative to dovetails. Strong, great-looking and quickly made, box joints are an especially good choice when you have a large number of items to produce. To make them, you need your tablesaw, a miter gauge, a dado set and a simple shop-made jig (Fig. A, below). I’ll show you how to build the jig and use its micro-adjust system to dial in perfect-fitting box joints. 

Box joints have alternating pins and sockets. To fit together, one piece has pins where the mating piece has sockets (Fig. B, page, 70). The challenge is to cut pins and sockets that are virtually the same size, with paper-thin tolerances for fitting the joint. Fortunately, the jig can make paper-thin adjustments. It also automatically positions both pieces so their pins and sockets are correctly offset.

Design Details

Pins and sockets can be wide or narrow to suit your project. To size them appropriately, you merely adjust the width of the dado set. For example, to cut 1/4-in.-wide pins and sockets, use a 1/4-in.-wide dado set. The blade’s height determines the length of the pins and sockets. This length matches the thickness of your box pieces. Flat-bottomed dadoes are a must for good-looking joints. 

It’s best to start with your box pieces oversize and trim them to final width after you cut and fit the joints. Box joints usually turn out to be wider than the sum of the pin and socket widths because of the fit-tolerance between each pin and socket. Starting oversize allows you to compensate. 

Photo 1: Set the blade height using a piece from your project. Place the piece on the jig’s carriage and raise the blade. 

A scrap piece held on top tells you when the blade is exactly even with the workpiece. Before moving on to the next step, make sure the miter gauge bar slides smoothly without any side-to-side play. 

Photo 2: Clamp the adjustable fence temporarily to the carriage and cut a slot through both pieces. After cutting, thickness-plane a 12-in.-long piece to exactly fit the slots’ width. Cut this piece into three keys. Trim one key to two-thirds the size of the slot’s height. 

Photo 3: Use three hardwood keys to position the adjustable fence on the carriage. Glue one key in the fence slot. Fit the second key in the carriage slot and sandwich the spacer key in between. Securely clamp the fence to the carriage while butting the three keys snugly together. Drill pilot holes and fasten the fence. Remove the clamps and the two temporary keys. 

Photo 4: Micro-adjust blocks allow you to fine-tune the jig by paper-thin amounts. Attach one block to the carriage base. Butt the second block against the first, with two pieces of paper between them. Fasten this block to the adjustable fence. The space between the carriage bloc...

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