Reply by Loren

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Posted on Can this be done without an CNC?

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10477 posts in 4102 days

#1 posted 12-18-2017 06:51 AM

Cut some plywood rectangles, then cut out
rectangles inside. Assuming you want to
cut the joints symmetrically you’d position
these “windows” on a guide board in a way
that allows some lateral adjustment. Fuss
with the adjustment until you have the windows
spaced correctly so two routed parts will
match. Use as many windows as you need.

The concept is similar to those door hinge
router jigs with the 3 windows, one for each
hinge and spacer bars in between.

Use a router guide bushing for cutting the joints.

You could also make the guide board from a
single piece with cutouts on one side, but
your math and layout would have to be dead-on.

I made a box joint jig this way once. I had
an Incra fence on my table saw which made it

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