Box Joint Cutting Jig on Router Table

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Project by woodworm posted 10-28-2008 03:15 PM 15518 views 6 times favorited 12 comments Add to Favorites Watch

This is not my latest project acually.
When I posted my clamping square box, I did mention using box joint cutting jig on the router table. So Jockmike2’s commented why not show it here. I could not find the soft copy in my photo album, thus I shot a few for LJs to view.

I built this jig the very moment (frankly speaking, planned to build) I saw the featured Video & Slides in FW presented by Guido Henn.

I made first test cut using 1/4” bit on 3/4”T X 3-5/8”W stock. By right I should have 7 nos full 1/4” fingers + 1 half finger (1/8”). But that was not the case. As can be seen in the third pic the last finger was only 1/16”. It took me about 1/2 hour to figure out the mistake. I double checked every part of the jig but not the slider. then I found out that the slider is not snugly fit the miter channel. So to overcome that problem, I constantly put pressure to the right while pushing the jig.

Thank you for viewing and any comment are welcomed.

-- masrol, kuala lumpur, MY.

12 comments so far

View hairy's profile


3385 posts in 5027 days

#1 posted 10-28-2008 03:53 PM

Thanks for the post. I need to do that,yours looks like a real good one. The big pictures are a big help.

-- I still love you baby, but I sure don't want you back... Clarence "Gatemouth" Brown

View Woodwrecker's profile


4240 posts in 5071 days

#2 posted 10-28-2008 04:12 PM

Good Job Woodworm.
It was smart of you to solve that thickness problem.
Thanks for sharing your experience.

View John Gray's profile

John Gray

2370 posts in 5381 days

#3 posted 10-28-2008 05:33 PM

I really like your idea but could you tell us about the “attachment” in picture 2?

-- Only the Shadow knows....................

View Timber4fun's profile


218 posts in 5096 days

#4 posted 10-28-2008 06:22 PM

Nice setup. On my list of things I would like to try. Tim

-- Tim from Iowa City, IA

View woodworm's profile


14477 posts in 5086 days

#5 posted 10-28-2008 06:32 PM

Thanks Hairy, Woodwrecker, John Gray and Tim for viewing and comment.

To answer John Gray : The attachment with threaded bar is actually the “indexing pin” carrier.
There are 2 independent indexing pins (made from L bracket trimmed into approx. 3/16” wide). These pins are attached to two separate adjustable carriers, and they are overlap.
If I want to cut 1/4” finger/box joint for example, I move the carrier of the second indexing pin away from the first pin to make up both combined size : 1/4” wide. Then I lock both carriers using the 2 knobs. By loosing the wing nut at the centre, now I am able to move both carriers simultenously using the welded wing nut on the threaded bar to achive the desired distance (in this instance 1/4” from the edge of the router bit). Tighten the wing nut at the centre so both carriers are locked to the fence. Place the workpiece until it’s edge touchs the indexing pin and made the first cut. Place the first cut slot on top of the indexing pin, and make second cut.

To make the cut on mating workpiece, place the first finger of the first workpiece in between the indexing pin and the router bit. Place the 2nd workpiece to be cut where it edge touchs the edge of the first workpiece iand make first cut. Take out the first workpiece, make the second & subsequent cut follow as we do on the first workpiece.

I can use this jig to cut box joint of any size from 1/4” , 3/8” or 1/2” without changing the indexing pin (just adjust it to make desired size).


-- masrol, kuala lumpur, MY.

View clieb91's profile


4267 posts in 5430 days

#6 posted 10-29-2008 02:13 AM

Woodworm, Thanks for the post I too have been contemplating making something for my routertable as I have no dado blade for the saw. May have to look real close at yours.

Looks like it does a fine job.


-- Chris L. "Don't Dream it, Be it."- (Purveyors of Portable Fun and Fidgets)

View woodworm's profile


14477 posts in 5086 days

#7 posted 10-29-2008 02:37 AM

Thanks for viewing Chsis. For a clean cut and less noise, I use solid carbide bit – spiral down cut.

-- masrol, kuala lumpur, MY.

View John Gray's profile

John Gray

2370 posts in 5381 days

#8 posted 10-29-2008 05:17 AM

Thanks for the update on the attachment!!!

-- Only the Shadow knows....................

View Douglas Krueger's profile

Douglas Krueger

420 posts in 5219 days

#9 posted 12-10-2008 07:46 PM

A well designed and constructed jig Woodworm, it’s always nice to have a repertoire of jointing methods to choose.

-- I can so I wood but why are my learning curves always circles

View woodworm's profile


14477 posts in 5086 days

#10 posted 12-10-2008 08:36 PM

This jig was built based on plan presented by Guido Henn in FW featured video and slides.
I’m still not happy with the jig I made because the 1/4” ply base is not very flat (not the furniture grade ply).

-- masrol, kuala lumpur, MY.

View POPSHOP's profile


125 posts in 4747 days

#11 posted 07-03-2009 03:55 AM

i love it !


View bigike's profile


4059 posts in 4784 days

#12 posted 11-22-2009 08:11 PM

nice job

-- Ike, Big Daddies Woodshop, http://[email protected]

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