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Box Joints are one way of connecting corners in woodworking. They look great and when they are glued together they make a very strong joint which makes them suitable for drawers and boxes, especially ones that get high usage. The problem with most box joint jigs is that they are often finickity to use and very often will only make one, or at the most two sides at the same time. From what we have been able to gather, this jig was originally conceived by Lynn Sabin and later modified by others.
We have taken the original plans and modified them yet again, by primarily making the base much wider. The advantage to making the base wider is that the jig can now be adapted to cut wood flat side down. This means a type of weave pattern can now be cut into wood and not just on the edges.
Anyone who has tried to cut trivets manually on a table saw will be doing back flips when they see just how easy it is to make multiple cuts, accurately and easily.
Making a Box Joint Jig - UPDATED
We made the original version of this jig first of all to see how it worked and what problems we might encounter along the way. We were so happy with the first version that we decided to re-make the jig with a few modifications and changes to make it even better and more versatile. For more info and links, read on ...
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Making boxes with the router is argueably one of the most fun things you can do with a router table. Not only that, you get to turn out objects that almost everybody loves and can use ... and it makes you look great. The other thing with boxes on the router table is by taking a design like this and modifying the sizes a little bit, you can make a whole range of different sizes, with or without hinged tops and all sorts of different and unique add-ons. Boxes are one of the most popular items for many people because they look great and are functional. They can be varied in so many different ways, different woods, contrasting woods, stains and dyes, final finishes, glossy, satin, matte, or by making them from laminated veneer woods and highlighting with contrasting wood, the variables are endless.
In this article we are making what we call the One Piece Box because it can be made from on piece of wood. The finished box is 4 inches square and if you can make it either with a routed lift off top as shown in the video, or you can leave the top on and cut it off on your table saw, then use hinges to open the lid. To make the 4 inch by 4 inch box, you need to start off with a board that is at least 26 inches long and 4 inches wide, by three-eighths of and inch thick.
Making a One Piece Box on the Router Table
In terms of tools, you will need a router and router table with a fence and you will also need a rabbeting bit that can be set for 3/8" (this is normally done by selecting the correct bearing on top) and you will need a spiral bit, you can use a 1/4" but will find that a 3/8" spiral bit is slightly more forgiving when it comes to cutting the top off the box. The 1/4" will work fine, just make sure you are absolutely correct with your cuts.
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Fastening corners of picture frames can be challenging. There are a number ways to accomplish this task and some are better than others. When you are manufacturing picture frames it becomes more and more important that the corners of the frame be held fast as the frames get bigger and bigger. It becomes even more important when glass is used in the picture frame.
There are many options for fastening corners. The first and easiest (note I did not say 'best”) is to use some kind of a mechanical fastener like nails, staples, steel straps, headless pins or screws. Each one of these mechanical connectors has it own problems. Small finishing nails that are driven in with a hammer tend to loosen joints. Screws need to be pre-drilled and look ugly, staples also have to be hammered and using an air nailer and 18 or 23 gauge pins may not be sufficient for larger frames.
The best way to fasten the sides of a picture frame is to glue “splines” into the corners. Yes, it is more more, but the splines look more professional and are unquestionably the best option. They hold the corners firm, they are permanent and they add a nice detail to the frames. To see how to make splines in the corners of your frames … read on.
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Many of you have requested information on how to make the picture frame clamping device so we have finally decided to publish our own information on this device. Before we get into the building of the device a word of safety. This clamping device uses a few small pieces which can be somewhat challenging to cut on some power tool equipment. We recommend making the smaller components on a band saw. If you do not own a band saw or are not familiar with it's use we recommend cutting them by hand with a hand saw using a bench vice to hold the work.
Picture Frame Clamping Device
For the list of materials and the methodology, please see the following section.