Box joint jig

Well, the re-built table saw is working pretty good. I made some zero clearance inserts for a few different sizes in order that I can go to the next step….making a box joint jig. I decided on the one in Shop Notes, for no other reason than it looks like it is robust and handy in the fact that it is convertable for sizes. Also, I had the issue with the plans. I stuck with the plan with a few minor exceptions. The carrier base and the sacrificial part of the fence is made from 5 mm luan instead of 1/4” hardboard..it was less than 1/2 the price for the luan. I also made the sacrificial part of the fence 2” wide, for no particular reason. The key (made from ash) is also let into the fence back as well as the carrier base. I thought it would be a bit sturdier that way. I did not put an access hole for a screw driver in the adjusting tab. Once the removable fence is set, the instructions say it does not need readjusting. Last modification was that it is 2” narrower in the fence, being 16” instead of 18”. The sled got 2 coats of wipe on poly and a coat of wax…the rest of it will get it too…eventually. Except for the luan, and nuts, bolts and washers ($5.60 CDN), everything was made from scraps and cut offs. Thus the reason for some altered dimensions. I did a few tests, the first fit but was tight, the second was a touch loose, and the third is in the pics. Made from some 3/4” ply cut offs, the joint is nice and snug, I suppose they are a hair deep, I will shoot for 1/2 the amount sticking up when I put it into use. I am pretty happy about how it turned out. I have one other carrier fence blank ready for the next size I need. Thanks for looking in

Doc

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