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  1. #1
    Join Date
    Jan 2014
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    Sydney Upper North Shore
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    4,464

    Default Yet another box joint jig

    Some people like to collect and restore old machinery, some like to restore old furniture, some like to build new furniture, I like to build jigs
    The last box joint jig I built required a new template board for each size router bit and the finger spacer glued into the template board had to be the EXACT size of the router bit.

    I found this one after a search on the WEB and it was designed by a German woodworker and teacher. From what I can tell (looking at pictures), it appears to have some similarities to the Incra Box Joint jig.

    What I like about it is that it is fully adjustable with slots and screw adjusters to suit any size router bit from 8 mm to 18 mm (may go down to 1/4" with a little modification) and the fit is also adjustable with the turn of a screw thread at the side. So no more swapping templates, backboards or spacers

    To rout a new box joint, the procedure is as follows:
    a) Fit desired router bit and rout a channel in a piece of scrap - you can label this and keep it for the next time you use that size bit so you can eliminate this step next time.

    IMG_0111.jpg

    .
    .

    b) Fit routed channel over fingers and adjust fingers to channel width by sliding rear panel then lock black adjusting knob
    IMG_0113.jpgIMG_0112.jpgIMG_0101.jpg
    .
    .

    c) Set fit adjuster to the width of the router bit by turning side screw to move the fingers and lock rear wing nuts

    IMG_0100.jpgIMG_0115.jpgIMG_0116.jpg
    .
    .

    d) rout slots on the ends of two bits of scrap and check fit. Adjust, if required with side screw adjuster.

    Process takes less than 90 seconds if all bits and pieces are on hand.

    All set up so you can now rout the box sides.
    IMG_0103.jpg

    Next modification will be a sacrificial panel where the router bit goes through the jig to prevent tear out.

    Cheers

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  3. #2
    Join Date
    Aug 2013
    Location
    Montmorency Victoria
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    554

    Default

    Hi Lappa
    nice work, great idea.


    any chance to put a link to the source material, please?

  4. #3
    Join Date
    Jan 2014
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    Sydney Upper North Shore
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    Default

    Quote Originally Posted by woodPixel View Post
    This is exactly how an Ibox works
    I saw the side adjuster on the Incra jig in a picture (I've never seen one in person or in action) that's why I mentioned the apparent similarities with this jig. Thanks for the confirmation

  5. #4
    Join Date
    Jan 2014
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    Default

    Quote Originally Posted by Tahlee View Post
    Hi Lappa
    nice work, great idea.


    any chance to put a link to the source material, please?
    Ask and Ye shall receive
    Preview - Build a Router Table Box-Joint Jig - Fine Woodworking Article

  6. #5
    Join Date
    Jan 2014
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    Sydney Upper North Shore
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    Default

    Quote Originally Posted by woodPixel View Post
    I love jigs. Profoundly love them.

    Still, I looooovvvveeee my iBox!
    I got an email from Timbercon this week and they have the iBox on special for August

  7. #6
    Join Date
    Jan 2014
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    Sydney Upper North Shore
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    4,464

    Default Modifications

    After using the above jig for a while, I felt the need for a more precise method of adjusting the slot width adjuster and less free play in the bit diameter adjustment.

    The free play was cured by adding a spring over the adjusting thread between the slider and the frame. The slot adjuster was fixed by adding a rod with a spring to better control the sliding motion, then an adjustment screw using a screw with a fine thread to allow precise adjustment.

    image.jpg image.jpg

    The rear slider assembly now looks like so;

    image.jpg

  8. #7
    Join Date
    Jan 2014
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    Default more modifications

    in the original jig, the setting fingers were on their side and on top of each other as per the plans. When moved apart to set the fingers to the width of the slot, they ended up offset. During use, you could get a nice fit when setting to the routed slot, but it was difficult to fit the timber with the slot over the fingers when routing the second, third etc slots.
    IMG_0112.jpg

    I made two new finger bodies with the fingers vertical and beside each other. This fixed the above problems - easy to set the fingers then place the slot over them to rout the next slots.

    IMG_0132.jpg

    I then added a new face on the jig with a replaceable sacrificial insert.

    IMG_0134(1).jpg

    I also bought a selection of metric and imperial key steel which makes it very easy to set the distance between the fingers and the router bit.
    These are also great for setting router bit height, saw blade height etc.

  9. #8
    Join Date
    Apr 2003
    Location
    Perth Western Australia
    Age
    90
    Posts
    783

    Default Smething new about Finger joints

    I was once asked if it were possible to produce finger joints at an angle with the router. My response was, I do not think it were possible. I would be interested in what would be your response especially if you are into Jig making as this type of joint IMHO could not be achieved with the router in the table mode.
    Learn new Routing skills with the use of the template guides

    Log on to You Tube for a collection of videos 'Routing with Tom O'Donnell'

  10. #9
    Join Date
    Apr 2003
    Location
    Perth Western Australia
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    783

    Default Smething new about Finger joints

    Forgotten how to add pic
    Attached Images Attached Images
    Learn new Routing skills with the use of the template guides

    Log on to You Tube for a collection of videos 'Routing with Tom O'Donnell'

  11. #10
    Join Date
    Jan 2014
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    Sydney Upper North Shore
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    Default

    If that joint can be done out of the table, it can be done in the table. Just a modification to the jig. Runner at an angle and piece held in the jig at an angle. Only problem is, for larger bits, it would need a wider clearance hole in the base.
    My other jig shown on this site would probably be better as it's easier to modify.

  12. #11
    Join Date
    Apr 2003
    Location
    Perth Western Australia
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    90
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    783

    Default

    Quote Originally Posted by Lappa View Post
    If that joint can be done out of the table, it can be done in the table. Just a modification to the jig. Runner at an angle and piece held in the jig at an angle. Only problem is, for larger bits, it would need a wider clearance hole in the base.
    My other jig shown on this site would probably be better as it's easier to modify.
    Looking forward to your answer using the Table Mode
    Learn new Routing skills with the use of the template guides

    Log on to You Tube for a collection of videos 'Routing with Tom O'Donnell'

  13. #12
    Join Date
    Jan 2014
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    Sydney Upper North Shore
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    Default

    I answered before, Tom.

  14. #13
    Join Date
    Aug 2010
    Location
    Horsham Victoria
    Posts
    5,713

    Default

    Quote Originally Posted by Template Tom View Post
    I was once asked if it were possible to produce finger joints at an angle with the router. My response was, I do not think it were possible. I would be interested in what would be your response especially if you are into Jig making as this type of joint IMHO could not be achieved with the router in the table mode.
    I imagine a tilting router table could do it?

    Dave TTC
    Turning Wood Into Art

  15. #14
    Join Date
    Apr 2003
    Location
    Perth Western Australia
    Age
    90
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    783

    Default

    Quote Originally Posted by Lappa View Post
    I answered before, Tom.

    Lappa
    I was interested in the method you would use so maybe you could have a go I still have a couple of routers set up in the table mode its all about finding new techniques with the router
    Learn new Routing skills with the use of the template guides

    Log on to You Tube for a collection of videos 'Routing with Tom O'Donnell'

  16. #15
    Join Date
    Apr 2003
    Location
    Perth Western Australia
    Age
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    783

    Default

    Quote Originally Posted by DaveTTC View Post
    I imagine a tilting router table could do it?

    Dave TTC
    Turning Wood Into Art
    Dave I suppose your correct my table top dose not tilt anyway food for thought
    Learn new Routing skills with the use of the template guides

    Log on to You Tube for a collection of videos 'Routing with Tom O'Donnell'

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