Whiskey Tango F.. Box #2: BJTS: Box Joints with a Track Saw

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Blog entry by PurpLev posted 01-03-2021 07:42 AM 503 reads 0 times favorited 5 comments Add to Favorites Watch
« Part 1: A light in the Chaos: rough cuts Part 2 of Whiskey Tango F.. Box series Part 3: Glugluglug... »

If you’ve seen the last photo in the previous post, you probably saw the hint for the box joints planning. I like box joints in general, and find that they will have a great visual benefit in this project (Beyond the obvious strength and alignment), Since I planned to have more than a few of those than would make sense to hand cut and chisel cut them, I figured I’ll try to setup some fixture for harnessing the track saw for this. Sort of reversed tale saw box joint sled idea (minus the sled). I started with vertical mounting a tall panel that would allow my parts to slide side to side, and added a T panel on top for the saw to rest on (added some support from the front to handle the saw weight and tilting forces when applied):

I left a little overhang of the vertical panel so that I can cut it with the saw and have a kerf guide mark for my cut boards. Also made sure they are dead square:

Using an orphan bolt, I drilled a hole for it to thread into as an anchor to the saw:

Then mount the saw with it and add some rest stop on the front to keep the saw straight:

Make a kerf cut for guidance:

Clamp a board and make a test cut:

Cut too short (that’s a good thing). The nice thing about track saws is the fine adjustments and stops for depth of cut:

I rarely look at the numbers, but adapt to depth of parts, hold saw at cut length, and move the stop to that position. After adjustment looks much better:

Move to other end of slot and make a 2nd cut before ‘rinse-and-repeat’ in between to clean it up:

This jig is a make-up and tear down so nothing fancy. I screwed some support to hold the piece at proper height, so all I need to do is just slide it across as I make the cuts:

All in all, not too shabby, I’m pretty happy about the results:

After completing this, I just took the whole thing apart. Maybe in the future I can come up with a more permanent and adjustable solution, but for now, this did the trick:

While working on this, I did experience the saw starting to drift from it’s straight guide (I only mounted it with 1 bolt). So ended up clamping the other end of it:

Next was the front and back. Used 1/2” material, rough cut the rabbets with the track saw, and cleaned it up with a plane:

Dry fit before calling it a day, did have to adjust and find tune some of the cuts, but we are off to a good day’s work:

Next.. glue up.

-- ㊍ When in doubt - There is no doubt - Go the safer route.

5 comments so far

View CharlieM1958's profile


16292 posts in 5296 days

#1 posted 01-03-2021 02:31 PM

Very creative setup, Sharon. I’m glad to see you getting a little shop time in. We’re going through back-to-back total gut-job bathroom renovations, so my shop has become little more than a storage place for materials since before Thanksgiving.

-- Charlie M. "Woodworking - patience = firewood"

View robscastle's profile


7874 posts in 3282 days

#2 posted 01-03-2021 06:26 PM

A quick fly over with the M134 should fix things

-- Regards Rob

View mafe's profile


13185 posts in 4167 days

#3 posted 01-03-2021 11:37 PM

Less is plenty, love your thinking.
Looks good,

-- MAD F, the fanatical rhykenologist and vintage architect.

View PurpLev's profile


8652 posts in 4726 days

#4 posted 01-04-2021 04:51 AM

Charlie sounds like we share the same woodsho… I mean storage space ;)

Mads – yes, sometimes less is more, and sometimes even less is too much :)

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View mafe's profile


13185 posts in 4167 days

#5 posted 01-04-2021 10:17 AM

Laughs, true. ;-)

-- MAD F, the fanatical rhykenologist and vintage architect.

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