Thread: dealing with chipout on router cut box joints

Hey guys I thought I would share with you all my recent experiences making some 'secret santa' presents for colleagues at work.

I am making some small wooden boxes out of 50 year old cedar fence posts. I faced 2 sides on the jointer and then resawn on the table saw with a freud thin kerf blade (I think it is called a glueline blade and I am very impressed with it so far). The box sides, ends top and bottom were selected for the 12 boxes (approx 220 x 120 x 90). The timber did have many cracks that needed gluing up before I christened the new box joint jig based on a 6mm spiral solid carbide bit. The timber, being very dry, has the tendency to chip out a little despite using a backer board and my original idea was to use the linisher to remove the top mm or so but after 1 box took considerable time I had a brain wave.
I got some 75mm x 35mm timber and jointed all sides and then clamped this to either side of the box and then use a flattening bit in the router table raised to 1.5mm above the table and proceeded to take this off the 4 sides of the box leaving the flattened edge of the side timber un touched. I can't believe how well it did! I did do the joint area first and made sure the router bit was cutting into the side reducing tendency to chip out. It took a matter of 5 mins per box and has removed enough material so that I look like a master joiner rather than a student of the botch it and scarper school.

Sorry I didn't take any photos but I am sure you get the picture.

Mike