Box joint jig

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Project by JimDaddyO posted 06-13-2010 07:37 PM 4829 views 6 times favorited 8 comments Add to Favorites Watch

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” 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


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8 comments so far

View a1Jim's profile


118161 posts in 4589 days

#1 posted 06-13-2010 07:44 PM

View Routerisstillmyname's profile


763 posts in 4521 days

#2 posted 06-13-2010 07:55 PM

Oooooo, Nice n tight joints. Good work.

-- Router รจ ancora il mio nome.

View Dusty56's profile


11863 posts in 4700 days

#3 posted 06-13-2010 08:05 PM

Nice and tight , but not too tight…..gotta leave some room for expansion when the moisture from the glue hits them : ) Nice work on the jig !

-- I'm absolutely positive that I couldn't be more uncertain!

View Richard 's profile


394 posts in 4133 days

#4 posted 06-13-2010 09:24 PM

Good job, I tried making one once, it took a long time to align, also my dado wasnt quite wide enough, lost some pieces over time. I like the use of scrap and the wideness of it on yours

-- Richard Boise, Idaho

View woody57's profile


650 posts in 4439 days

#5 posted 06-13-2010 10:32 PM

good job
which issue was that in. I think I’ll make one.

-- Emmett, from Georgia

View Badltl510's profile


6 posts in 4063 days

#6 posted 06-13-2010 10:51 PM

I built the same one I used BB and hardboard for mine and it works great. Very easy to adjust to get the perfect fit.

View JimDaddyO's profile


663 posts in 4091 days

#7 posted 06-14-2010 02:53 AM

It was in a special edition full of table saw jigs etc.

-- my blog: my You Tube channel:

View donjoe's profile


1360 posts in 4042 days

#8 posted 06-14-2010 02:54 AM

Great job on your jig.

-- Donnie-- listen to the wood.

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