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.