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Project Information

Hey Folks!

My dad and I were trying to build some box joints with a simple router jig that I had built awhile ago. Needless to say, that didn't go well at all! We both spent the better part of the day in the shop and ended with nothing but loose joints, wasted boards, and frustration.

So that evening I spent some time researching options for box joint jigs. I came across these excellent plans from Matthias over at woodgears.ca. At first I thought it would be impossible to build, but as I worked on it step by step, it really wasn't that hard.

I've only built one 48 tooth gear that is meshed with a 12 tooth gear. Since it is running on a 16 TPI rod, one revolution of the large gear produces four turns of the rod, or 1/4 inch. This is a great jig and makes cutting box joints easy and fun! (Plus the gears are a lot of fun to build and they look cool in the shop!)

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Comments

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I love Matthias' stuff! You're giving me confidence to try to build some of his very intimidating projects. Great job!
 

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When I first looked at the picture I though I was looking at a Rube Goldberg machine. Then, after reading the narrative and taking a closer look, I realized this is a pretty good idea and making it would not be as hard as I first thought.

Well done. Thanks for sharing.
 

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Matthias is quite the engineer. He has a video on this jig on You Tube; cool to watch. He also built his own bandsaw from scratch among other things. I was going to build this jig myself but was concerned it was a timely project. Glad to see someone tackled it and succeeded. Looks like it worked great. Thanks for posting.
 

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Looks like you did a great job. Good to know it's doable :) I also love Mathias' site and stuff. You are encouraging us to follow suit. Thanks for sharing.
 

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Really cool project, Do you have a way to take video of it in action? That would be cool. You can upload to utube for free.
 

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Thanks for the thoughts guys!

Steve - Matthias has a youtube video of this same jig in action already. Go to www.woodgears.ca and look for the box joint jig.
 

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Congratulations. I'm glad to see someone make one of Matthias's box joint jigs. Nice work!
 

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Nice job, Mechanical wood engineering at it's finest :)
 

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hey is this project possible without a drill press?
and whats the hardest part about it?
i can't dimension any lumber very well as well. my jointer needs to be fixed.
 

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Ben,

I'm sure this could be done without a drill press, although you do drill a lot of holes, especially for the gears. There really isn't one thing that is super hard. I found that it was important to get the measurements spot on and to align things properly. The plans came with metric dimensions, and it would be pretty tough to switch them to inches as you would have some pretty ridiculous fractions to deal with. So you'll need a tape that has a metric side to it.

And yes, you do have to do some dimensioning of lumber as various parts require various thicknesses. You might be able to do it with a planer and table saw if your jointer isn't working.

Overall I was impressed with how easy it was to follow the instructions and put together.

If you notice, mine doesn't currently have the idler wheel assembly as I felt that the box came together tight enough in the rails to eliminate the need for it.
 

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Hi Jesse. You did a great job on that jig and obviously you are enjoying it. The resulting box joints look good too.
 

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That's a very interesting jig and you did a wonderful job on it. I love his web site.
 

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It's nice to see how many we are to know and appreciate Mathias's stuff :)
Good take on the jig Jesse!
 
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