The Dialog - A Forum for Like Minds

Making, Manufacturing, Art, Crafting => Traditional & New Age Arts & Crafts => Woodworking => Topic started by: Michael (the Dodd) on 2015-07-06 02:07 PM

Title: Box Joints
Post by: Michael (the Dodd) on 2015-07-06 02:07 PM

So, I just finished making a box joint jig using plans very similar to these:
http://www.popularwoodworking.com/projects/tablesaw-box-joints (http://www.popularwoodworking.com/projects/tablesaw-box-joints)

My only previous experience making box joints was using the Porter-Cable 4212 jig, pictured here:
(http://www.homedepot.com/catalog/productImages/400/b9/b912dd60-a2f6-4782-abe2-91bbb73cbb10_400.jpg)
It performed pretty well, but I hard time getting just the right fit-  there's no fine tuning to be had, and the difference between kinda sloppy and too tight depends on which side of the jig's "fingers" you apply pressure on.  In the end, I opted for "too tight" and pounded the box together with the biggest hammer in my shop. The plywood I was using to make the box ended up getting kind of split up and shredded in places, so I had to do a lot of extra sanding and patching with 2-part epoxy and I had a lot of problems to cover up with a dark stain so it really wasn't an optimal result:
(http://www.bgonet.com/box.jpg)

Most woodworkers actually use a jig like the one in the first link (or some variation therein).  The idea is that it's a sled that you run through your tablesaw blade (or dado stack) that uses an indexing pin the same width and offset as your blade width to make a nice joint that fits together snugly. 

I finished mine last night- here are my thoughts in handy list format:
I've only done test cuts so far, but I'll post a picture of some "real" work with my new jig as soon as I've got a finished project.
Title: Re: Box Joints
Post by: Michael (the Dodd) on 2015-07-06 02:07 PM
Apparently this:
http://www.incra.com/product_rtf_ibox.html (http://www.incra.com/product_rtf_ibox.html)
Is the new hotness when it comes to box joints.  It's about 160 bucks, but it's one jig that can cut a variety of sizes of box/finger joints without the need for multiple inserts or anything like that.