Router Table Box Joint Jig

  • Advertise with us
Project by bvdon posted 07-02-2011 12:57 AM 15913 views 41 times favorited 7 comments Add to Favorites Watch

This project is loosely based on the Rockler Router Box Joint Jig. Just a glance, then came up with my own design. It cost less than $10 to build and was a good way to waste away a Sunday.

I will be using this for other projects, but to test things out I made a utility guitar speaker riser out of cherry. The joints came out nearly perfect first time, but the router bit was a 1/2 inch mortise bit so there was a little tear-out. Not that bad. Will try out an spiral up-cut bit next time.

Last photo is the result.

To make:
The Base: used 3/4 ply, sized to sit on the router table (arbitrary). Slides left to right (you want to center it relative to the router bit) with oak stock cut to fit in the router table miter slot. I used a combo-square to attach the oak perfectly on the base. On the top side I used a dado blade to cut slots for the sled to ride on.

The Sled: used 3/8 MDF with melamine on both sides – slides nice and easy. Cut to fit oak on the bottom of the sled (screwed from the top) to ride on the base, careful to keep things square.

Front of the sled has solid maple stock for support after the sled is cut by the bit.

Furthest most back is a fixed fence with a slot to hold an adjustable sacrificial fence. The ‘sacrificial’ part of the fence has the notch that is the same size as the bit…. if I want to use a different size bit I need to build that part of the sled—fairly easy.

Since glue would be useless on a melamine board, lot’s of screws were appropriately sized for the small pieces, pre-drilled and counter-sinked.

P.S. – I did some new up-spirial router bits (1/4 & 1/2 inch), not yet tried out. I did have some scrap cherry and figured out how to get no tear-out. Simply cut from the back (pulling the sled into the back of the piece) just a tad, but not all the way through the wood. Then bring the piece behind the bit and push the sled as normal. Should eliminate most tear-out problems.

7 comments so far

View bigike's profile


4057 posts in 3767 days

#1 posted 07-02-2011 01:21 AM

very nice, I like this one. Can you use smaller bits though?

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

View bvdon's profile


502 posts in 3494 days

#2 posted 07-02-2011 01:31 AM

Yes, you can use smaller or larger bits. To use a different size bit you create a new sacrificial board with a block-notch and two holes to adjust left to right. It only takes about ten minutes to create a new one—in fact, I screwed up the first one when drilling the holes and made another in no time.

View bvdon's profile


502 posts in 3494 days

#3 posted 07-02-2011 01:36 AM

I need to build some shop drawers, and real curious if I can cut 4 boards at once ;) Will let you know how it works out.

View scarpenter002's profile


617 posts in 4384 days

#4 posted 07-02-2011 01:50 AM

Very nice idea. I like it. Thanks for sharing.

-- Scott in Texas

View cranesgonewild's profile


344 posts in 3387 days

#5 posted 07-02-2011 03:10 PM

This is a different twist on things.
I never thought of making a sled on a router table.
Thanks for sharing your ideas with us.

-- I'm a Fungi --

View James Frederick's profile

James Frederick

191 posts in 4199 days

#6 posted 07-02-2011 11:15 PM

Very nice and simple, just the way I like it. Well Done.

-- Change begins somewhere may as well be with me.

View kimball's profile


323 posts in 3776 days

#7 posted 07-08-2011 04:04 PM

Super sled! I have to make one. After thinking about it some, I decided to use my dado blade to make shallow dados to insure main runner is square to router table. I will also use it to cut through the melamine in order to glue and square the runners to the sled. The runner that holds the base square to the bit will have a full length runner to aid in the indexing of the base. Hope my thoughts work out and thank you.

Have your say...

You must be signed in to post the comments.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics