Router Table Box Joints
The perfect fit comes easily with a simple shop-made jig.
By Tom Caspar
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Box joints are a cinch to make on a router table. All you need are a sharp bit and a basic plywood jig.
The biggest problem in making box joints has always been getting a precise fit, because the line between success and failure is only a few thousandths of an inch thick. Fortunately, the solution simply requires that your jig be easy to adjust, not difficult to make. I’ve added a microadjust system to my jig that is incredibly precise but takes only a minute to put together.
This jig is designed to make 1/2 in. box joints in stock up to 5 in. wide. It’s dedicated to only one size of router bit. To make wider or narrower box joints, you must build another jig. For box joints wider than 1/2 in., you’re better off using a tablesaw and a different kind of jig. If your project requires box joints that are more than 5 in. wide, widen the jig accordingly.
This story originally appeared in American Woodworker March 2005, issue #113.