Double duty jig - box joint and small circle and ring jig

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Project by woodenwarrior posted 06-07-2015 01:56 AM 1926 views 6 times favorited 3 comments Add to Favorites Watch

Every project has a story so here’s this one. My wife and daughter are in Maine visiting family. What does that mean? Pure, uninterrupted shop time!

I have wanted a quality box joint jig for some time. I’m not willing to pay $170 for Incra’s no matter how awesome it is. I’ve built at least three with varying degrees of success but getting my dado stack exactly 1/4 inch with shims is so exasperating that I ended up trashing each one. Someone will suggest the Freud box joint blades…if I were to spend that money I may as well buy the Incra. Rockler’s router jig looked neat….but not $90 dollars neat. So scavenging ideas from that jig I built the one pictured. Additionally, I’ve added a coolio feature so that circles can be routed and rings can be made, ala Izzy Swan (not something that a bandsaw circle jig can do). The whole idea came about because I have a 3/4 in blade installed in my bandsaw and didn’t feel like taking the time to change it out to a 1/4 to cut some circles.

It mounts to the router table via the miter slot with locking bars from Rockler. I added a small strip of sand paper to the sides of each of the bars to assist in their grip….and grip they do!

The base is 1/2 in ply and the dados for the box joint sled were made using 1/4 in MDF with the 1/4 in thick oak miter slides used as spacers so it guarantees a perfect fit. The sled is a simply made with 3/4 in ply with the joint spacer being a 1/4 in steel bar key I bought at HD a while ago ( happens to be a perfect 1/4 in). The jig is adjusted by moving the whole thing either left or right and tightening down the miter bar slides. Lastly, I drilled holes at 1/4 in increments to facilitate a pin to spin the circle blank on while I incrementally raise the bit into the work. It will handle circles or rings up to 20 in in diameter.

It works like a champ and cost about $ 8 for the miter bars and the scrap for the jig itself.

-- Do or do not...there is no try - Master Yoda

3 comments so far

View Jim Jakosh's profile

Jim Jakosh

23193 posts in 3584 days

#1 posted 06-30-2015 09:32 AM

Nice build job on that jig. You’ll appreciated it more because you made it yourself!!
You get a good feeling every time you use a hand made jig and it gets the job done so well!!

Nice going!!!!!!!! Cheers, Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View kocgolf's profile


397 posts in 2657 days

#2 posted 02-16-2017 06:39 PM

That is awesome. I have been trying to figure out just how extensive of a box joint jig I wanted to build, but with your circle jig inclusion, I think we have a winner. I just love double duty jigs!

View helluvawreck's profile


32086 posts in 3345 days

#3 posted 11-20-2017 01:26 PM

This is a very nice jig and you have done fine job on it. It will be a nice addition to your shop.

helluvawreck aka Charles

-- helluvawreck aka Charles,

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