Ultimate Box Joint Jig
The Ultimate Box Joint Jig is a leap forward in box joint jig design, but is also easy to construct using commonly available material. The plans are very easy to follow, taking a detailed step-by-step approach.
– No complex parts to make and the jig can be built using common woodworking tools.
– No fancy joinery used, just glued and screwed butt joints.
– No specialized hardware, just common fasteners and threaded rod.
Most of the cuts are straight and done on a table saw, and the majority of the jig is made from just one thickness of plywood.
It features two guide bars for better tracking plus a large base for stable operation. Like the Advanced Box Joint Jig, it is perfect for creating a wide variety of box joints. Its unique design allows faster setup and much better user safety, when compared to all other box joint jig designs – hands are always well away from the blade during operation. Along with that, it is easy to use and fairly compact in size for storage.
This jig is best suited for the table saw, using a stack dado blade for wider joints 1/4″ and up. Use a single regular saw blade for finer joints, as small as 1/16″. The jig can also be set up to work on a larger router table.
Highly versatile, the jig can produce box joints from 1/16″ right up to 1″, and can handle stock up to 1-1/2″ thick, and can cut four pieces of 1-1/2″ stock (or eight 3/4″ thick pieces) in a single pass, saving you setup time and errors.
It has a huge operating capacity and will handle stock up to 17″ wide in one pass. It can handle stock twice that width (34″!) in two passes. Even with this much capacity, it can still handle smaller stock with ultra-fine box joints.
There are 27 printable drawings and a materials list, plus cut diagrams for the 3/4″ (18mm) plywood.
There are 11 parts drawings showing every part in detail, and there are 12 assembly drawings covering each step of the assembly process.
For your convenience, this plan has both imperial and metric dimensions, with the metric dimensions (millimeters) in brackets. Please note that the plan was originally designed in fractional inches, and these dimensions were converted to millimeters.
Screw sizes and other hardware are in imperial units.
Please read these important notes before buying these plans.
These plans are made to be used along with the build article, which has photos of the build and a detailed assembly video.