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"Universal box joint jig"

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Re: "Universal box joint jig"

Postby 9fingers » 11 Oct 2016, 17:21

Acid Test time!

Well here is the jig set up (using the method I described way up the thread) for a 10mm wide socket.

Image

I'd previously planed up some pine to 14mm thick and 40 wide and cut my first joint and it fits perfick!!

I would say that two pins and two sockets is not exactly an onerous test as the errors build up with the number of pins & sockets. From and engineering point of view all the cutts should be referred to the same datum but these jigs just don't work like that and the position of one socket depends on its neighbour.

I next cut a couple of test joints using my 4mm blade and boy were they tight and over 40mm (5 pins & 5 sockets is much more of a testing situation.

However adjusting by the thickness of a piece of paper made all the difference and number 3 attempt at 4mm was spot on - I'm a pleased as a dog with two -----successful box joints!

Image

I would say if you are going for multi fingered joints then allow quite a bit of clearance in the set up say 0.2 0.3 mm and set the righthand finger to be a tightish fit. Any slack here can get multiplied up by the number of sockets. As with any joint preparing some extra stock of the same dimensions for test cuts takes little extra time and can even be of different (scrap) wood to the project pieces. Also dont forget the test strip which needs to be more than one socket with and no wider than two socket widths.

I did try Stu's alternative method of the kerf finder but it depends on setting against a tooth tip which could be a source of error if there is any blade wobble. My original method relies on the actual dimnsion cut by the saw and I prefer it.

A minor refinement to the design could be made regarding the guarding.

If like me you conveniently leave the adjusting spanner on the jig like this

Image

then there will come a time when it slips into the slot left by the blade behind the fence with disasterous results.

This small area needs a cunning guard to sort the problem and yet not get in the way of the adjustment nuts.

Image


All in all very pleased.
Before anyone asks there will be no video as I've not got the gear, inclination or editing software etc.

If you are going to make one and i hope you will then all the principles are laid out in this thread and a detailed written description of how to use it. The dimensions are going to depend on your saw or router table.

Good luck and happy box joint cutting.

Bob
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Re: "Universal box joint jig"

Postby Andyp » 11 Oct 2016, 20:08

Well done Bob. I use magnets on a few tools to hold allen keys, check keys and spanners in place.

Now what is the project that requires these box joints?
I do not think therefore I do not am.

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Re: "Universal box joint jig"

Postby StevieB » 11 Oct 2016, 21:32

9fingers wrote:
If you are going to make one and i hope you will <SNIP>

Bob


Or could you make them and offer at a reasonable cost to offset your materials and time? :eusa-think: :eusa-shifty:

Either way - nicely done Sir, nicely done!

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Re: "Universal box joint jig"

Postby 9fingers » 11 Oct 2016, 22:55

Andyp wrote:Well done Bob. I use magnets on a few tools to hold allen keys, check keys and spanners in place.

Now what is the project that requires these box joints?


That is a great idea Andy. I might follow that up although magnetised tools can be a real PITA in the engineering workshop.....

The first application will be to make some drawer boxes for the final stage of my barrister bookcase project which I really must get back to working on.

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Re: "Universal box joint jig"

Postby 9fingers » 11 Oct 2016, 22:59

StevieB wrote:
9fingers wrote:
If you are going to make one and i hope you will <SNIP>

Bob


Or could you make them and offer at a reasonable cost to offset your materials and time? :eusa-think: :eusa-shifty:

Either way - nicely done Sir, nicely done!

Steve


Thanks Steve.

To be honest as I'm retired I'm relatively time rich and all the materials came from stock with the exception of the Rivnuts for which I purchased a small stock from Fleabay for a few quid.
If anyone wants a couple for little more than the postage in order to make this jig then just PM me.

Bob
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Re: "Universal box joint jig"

Postby stu » 12 Oct 2016, 20:01

That works well Bob.

Whats the approx set up time from pulling the jig out of the cupboard to dry fitting a box? (Assuming stock already prepared)

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Re: "Universal box joint jig"

Postby 9fingers » 12 Oct 2016, 20:16

stu wrote:That works well Bob.

Whats the approx set up time from pulling the jig out of the cupboard to dry fitting a box? (Assuming stock already prepared)

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Its only a few minutes assuming the test joint works first time. if it turns out tight then shifting the guides by a paper thickness and a re-test costs another few minutes.
Using a greater number of pins/sockets does make the fit more critical due to cumulative error build-up

For perfection some sort of CNC set up, always working from a single datum would be the engineering way to go.

Assuming pre-prepped stock also assumes the relationship between the dado stack and stock size has already been worked out.

On the basis that most projects will need a number of drawer boxes making then the set up time is pretty negligible.

Bob
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Re: "Universal box joint jig"

Postby stu » 12 Oct 2016, 21:01

9fingers wrote:
stu wrote:That works well Bob.

Whats the approx set up time from pulling the jig out of the cupboard to dry fitting a box? (Assuming stock already prepared)

Sent from my SM-G935F using Tapatalk


Its only a few minutes assuming the test joint works first time. if it turns out tight then shifting the guides by a paper thickness and a re-test costs another few minutes.
Using a greater number of pins/sockets does make the fit more critical due to cumulative error build-up

For perfection some sort of CNC set up, always working from a single datum would be the engineering way to go.

Assuming pre-prepped stock also assumes the relationship between the dado stack and stock size has already been worked out.

On the basis that most projects will need a number of drawer boxes making then the set up time is pretty negligible.

Bob

So when's the CNC version happening????
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Re: "Universal box joint jig"

Postby 9fingers » 12 Oct 2016, 21:05

I think that is off the bottom of the round-2-it list already Stu.

I mentioned it as a precise way of incrementing the cutting position from a single datum.

Bob
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Re: "Universal box joint jig"

Postby 9fingers » 04 Jul 2017, 11:42

I did a little decorative job with this jig yesterday and although I should not blow my own trumpet I'm mighty pleased that it proved extremely accurate and reliable.

The fingers are 4mm and there are about 30 finger/slot pairs across the original width. The design changed mid project and is cut down to around 25 pairs and about 200mm wide.

This is for a needleworking friend and I wanted to give an impression of the wood being stitched. An unashamedly stark contrast between ash and American black walnut.

Image

The jig was set up with a 4mm kerf blade and a clearance of two paper thicknesses in the joint to allow for glue. A very fiddly staged glue up one joint at a time, needing to apply glue on one half only to save time. I just got each joint together before it "grabbed". Phew!

I continue to be pleased with the jig.

Bob
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Re: "Universal box joint jig"

Postby TrimTheKing » 04 Jul 2017, 11:57

Very nice Bob

I had forgotten about this jig but it will absolutely be on my tuit list...

Cheers
Mark
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Re: "Universal box joint jig"

Postby Malc2098 » 04 Jul 2017, 12:03

I like that! Nice.
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Re: "Universal box joint jig"

Postby Tusses » 04 Jul 2017, 13:53

tidy end result there bob :-)
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Re: "Universal box joint jig"

Postby Andyp » 04 Jul 2017, 15:11

Very neat Bob, but what is it?
I do not think therefore I do not am.

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Re: "Universal box joint jig"

Postby 9fingers » 04 Jul 2017, 15:34

Andyp wrote:Very neat Bob, but what is it?


I will post more photos from different angles when it is complete but in the mean time, answers on a post card to ..... :lol:

Not very fair as that view is really only there to show the joints.

Bob
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Re: "Universal box joint jig"

Postby 9fingers » 05 Jul 2017, 17:46

A couple more pics of the completed item.

Can you guess what it is now Andy?

Image

Image
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Re: "Universal box joint jig"

Postby Andyp » 05 Jul 2017, 17:47

yep, a hoop-la for the needlework club's summer fete :)

Haven't got a clue.
I do not think therefore I do not am.

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Re: "Universal box joint jig"

Postby 9fingers » 05 Jul 2017, 17:53

Andyp wrote:yep, a hoop-la for the needlework club's summer fete :)

Haven't got a clue.


Well you have picked up on the needlework thread so develop that a bit more...
Ask Valerie, she might be able to guess better?

When the varnishing is compete and full dry I can perhaps take a photo of it in use.

Bob
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Re: "Universal box joint jig"

Postby TrimTheKing » 05 Jul 2017, 18:05

Some kind of crocheting machine, or for keeping wool on...

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Re: "Universal box joint jig"

Postby Rod » 05 Jul 2017, 18:46

Bobbin holder but why the slope?

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Re:

Postby 9fingers » 05 Jul 2017, 18:51

TrimTheKing wrote:Some kind of crocheting machine, or for keeping wool on...

Cheers
Mark


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There is one good word in there Mark. "Keeping"
Overall size of the face with the pins is 200 X 130 mm if that helps and the pins are 6 mm diameter.

Bob
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Re: "Universal box joint jig"

Postby StevieB » 05 Jul 2017, 21:22

Sorting/storing cross stitch threads?

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Re: "Universal box joint jig"

Postby 9fingers » 05 Jul 2017, 21:26

StevieB wrote:Sorting/storing cross stitch threads?

Steve


Off Cold verging on Warm Steve

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Re:

Postby 9fingers » 05 Jul 2017, 21:29

Rod wrote:Bobbin holder but why the slope?

Rod


Quite Warm Rod. The slope is mainly for interest.

Bob
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Re: "Universal box joint jig"

Postby Malc2098 » 06 Jul 2017, 09:06

6mm - Cotton reels or those spool thingies that go inside sewing machines?
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