Box joint jig

This box joint jig (also called a finger joint jig) is made from reclaimed wood and a strap hinge. This project involved making a carriage and cutting slots in the router table. To be honest I didn’t expect it to be that challenging. The first slot is slightly too wide (I’m working on the solution), but the second one is OK. A utility knife and sandpaper were more than helpful.

The holes in the hinge were drilled and countersunk.

Making the fence wasn’t complicated. Cutting the slot was the first thing to do. Next, I cut the peg and the second slot and used the peg as a spacer. All these three were supposed to be 1/2 inch in width.

The peg had to be flush cut on a table saw. I didn’t expect it to be that easy. No tear-out, a 90º angle – perfect cut.

Now the holes. The assembly had to be adjustable, so the holes had to be slightly oval. I used my drill, chisels and rasps.

The jig does a decent job, however, it may need some adjustments. It’s hard to tell because I used scrap wood to try it and the joint wasn’t actually that loose.