Lots of box joints - Woodworking Talk - Woodworkers Forum
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  • 7 Post By Kerrys
  • 1 Post By Packard
  • 3 Post By GeorgeC
  • 1 Post By Kerrys
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post #1 of 20 Old 09-19-2019, 07:05 PM Thread Starter
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Lots of box joints

One box to make sure it all works. Test pieces. Parts for two more boxes 12 x 18 x 12. These will be ammo boxes for my two sonsí Christmas presents.
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post #2 of 20 Old 09-19-2019, 07:23 PM
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Nice looking project.
Learning to make box joints in high on my list.

Jim

"I've learned the hard way that I can't afford to buy cheap tools"
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post #3 of 20 Old 09-20-2019, 02:46 PM
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I don't have the patience to glue up that many fingers. I use through dovetails and they seem pretty strong and there is just a handful of tails to paint with glue.

Nicely done.
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post #4 of 20 Old 09-20-2019, 03:39 PM Thread Starter
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I don't have the patience to glue up that many fingers. I use through dovetails and they seem pretty strong and there is just a handful of tails to paint with glue.

Nicely done.
I havenít glued anything up yet. Iím still trying to decide on the best approach, strap clamps or bar clamps with cauls. Either way I will need to purchase more clamps
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post #5 of 20 Old 09-20-2019, 03:51 PM
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If the joints are a snug fit you will not need to clamp. Clamping really does not do much good with box joints anyway.


George
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post #6 of 20 Old 09-22-2019, 02:08 PM
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If the joints are a snug fit you will not need to clamp. Clamping really does not do much good with box


George
they don’t if your boards are perfectly flat.
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post #7 of 20 Old 09-22-2019, 02:40 PM
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KERRY

Did you make them with your Incra jig?

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post #8 of 20 Old 09-22-2019, 02:43 PM Thread Starter
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KERRY

Did you make them with your Incra jig?
Yes.
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post #9 of 20 Old 09-22-2019, 02:50 PM
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If I ever do put a shop together again, I will definitely buy it. Well worth the money even if I dont have much call for it. Sometimes you can create a demand.

Are you going to Dado in the bottom?

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post #10 of 20 Old 09-22-2019, 03:14 PM
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I have never done a production run of box joints, usually just a one off, is it possible to stack several boards to save time?

Wise men speak because they have something to say; fools because they have to say something -Plato

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post #11 of 20 Old 09-22-2019, 03:36 PM Thread Starter
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Are you going to Dado in the bottom?
No dado in the sides of the box but I am going to do a 3/8 x 3/8 dado on all 4 edges of the bottom piece of the box for more glue surface.
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post #12 of 20 Old 09-22-2019, 03:43 PM Thread Starter
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I have never done a production run of box joints, usually just a one off, is it possible to stack several boards to save time?
Good question. Iím using 3/4 stock and looking at the Ibox jig I could do 2 pieces at once. I did not do that mainly because I didnít think of it. Also, the long sides are 18Ē and because they are milled standing upright any time saved by milling 2 at a time might be used up getting and keeping everything in line. Iíll experiment with this on the next box joint project.
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post #13 of 20 Old 09-22-2019, 04:48 PM
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No dado in the sides of the box but I am going to do a 3/8 x 3/8 dado on all 4 edges of the bottom piece of the box for more glue surface.
Yes, that is what I meant. Thanks

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post #14 of 20 Old 09-22-2019, 05:21 PM
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I really like box joints. They are easy to cut, attractive and very strong.
They almost square themselves and don't require a lot of clamping. I do use some clamps to make sure they all seat.
From your photos it appears that you need to raise your blade just a bit so the pins sit just proud of the surface. I'ts easier so sand them flush than the other way around.
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post #15 of 20 Old 09-22-2019, 06:32 PM Thread Starter
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I really like box joints. They are easy to cut, attractive and very strong.
They almost square themselves and don't require a lot of clamping. I do use some clamps to make sure they all seat.
From your photos it appears that you need to raise your blade just a bit so the pins sit just proud of the surface. I'ts easier so sand them flush than the other way around.
The pins stand proud. Nothing is together yet. Just fitted.
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post #16 of 20 Old 09-22-2019, 07:51 PM
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post #17 of 20 Old 09-23-2019, 08:14 AM
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For me, the best tool for clamping box joints seems to be the mallet. :-(
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Last edited by Tool Agnostic; 09-23-2019 at 08:30 AM.
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post #18 of 20 Old 09-23-2019, 03:38 PM
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I make a lot of boxes and usually just use clamps to pull the joints together and square up the box, but this only works well when the boards are flat. I don't use cauls, just Bessey clamps for pulling the joints together during glue-up. The box then just gets left to dry. I might check it to assure that all joints are tight and the box is remaining square, but there is no need to leave the clamps on after the glue is setting up. It's easy to box the box sides from too much clamp pressure, so there is benefit to not leaving them on, as long as the wood is flat.

I use an Incra I-Box jig on my table saw to cut my box joints, because I've found that I get the best results, and mostly use a Freud SBOX8 blade set, cutting 1/4 & 3/8 joints, but also a 1/8" FTG (flat tooth grind) blade that I use for 1/8" box joints. I have used my dado blade set for larger box joints, but don't need to do this very often. They don't have as clean and flat of a bottom in the cut, but for larger joints this isn't as obvious. It's very important to move the sacrificial strip in the I-Box jig to a new position just before you begin cutting the joints with the jig. This will minimize tear-out of the edges of the cut. This strip can be used many times and even inverted to the second edge before it needs replacing. I used the original as a pattern and cut about 16 duplicates from a 2' X 4' piece of 1/4" MDF, so I have enough to last me a very long while at a cost of about $6.

Most of my boxes are made from Baltic Birch plywood. I was once told "you can't cut box joints in plywood", but using the combination of the I-Box jig and Freud blade set above I have no problem, as evidenced by the attached photos.

Charley
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post #19 of 20 Old 09-23-2019, 03:54 PM
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A few more photos.
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post #20 of 20 Old 09-29-2019, 02:00 AM
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Quote:
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I have never done a production run of box joints, usually just a one off, is it possible to stack several boards to save time?
Yes, you can clamp four boards together and cut all four at the same time. Two are offset the width of a tooth. If the boards are too large then the weight becomes a major issue. I use at least two metal C clamps to hold the boards together during the cutting process.
I cut the depth so the tooth will be a bit proud of the edge and will be sanded flush. Fill any cracks with glue and sawdust.
By cutting all four boards at the same time it ensures all the teeth are positioned correctly.

I've cut 1/2" and 3/4" baltic birch with no problems but for my usage, the 1/2" is the best.

I use the Incra jig, it is super accurate.

When I glue up I use pipe clamps, at least one on each side. If the box is deep enough then I will use a caul with at least two clamps on each side. If you use more than two clamps on each side the weight becomes an issue.
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