Instructables

How to Make a Box Joint Box

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Picture of How to Make a Box Joint Box
Anyone that reads my profile may notice that woodworking is first on my list of interests. So where are all the woodworking articles? Fact is I don't often document those projects. Making box joints is something I have done so much I have had a chance to photograph the process.

If you're really going to do this then read the entire set of instructions before you begin because some things are revealed later that you should be aware of earlier. This is done for reasons of brevity and conciseness. This is already long enough! Maybe that is why this technique seems tricky. Once you know it all it is actually pretty simple and easy.

I'm pretty sure with my instructions anyone can do this, but if you've any questions well, leave a comment, and I'll try to elaborate on anything you are unsure of.
 
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Step 1: Do a Jig

Picture of Do a Jig
JigGraphic.png

I don't mean any Dancing With the Stars sort of thing. No, to make box joints a fixture jig is used.

Hopefully the graphics here will explain all but if not this is how I make mine.

First I take a piece of wood and screw it to my miter gauge for my table saw. Make sure the wood is flat flush with the table.

Now determine the width of finger joints desired, set a dado blade accordingly. Put blade into the saw, set height etc.

Run the miter gauge with the piece of wood screwed to it over the blade making a notch.

Remove wood from miter gauge and carefully measure the notch.

Step off the measurement of the notch and cut an identical notch into the wood piece.

Make a square pin piece that fits right into your new notch and affix it into there using glue, maybe a nail or something too.

Reattach your completed jig back onto your miter gauge exactly where you took it off. If you need to make a pencil mark to get it right back where it was whatever it takes. It is vitally important that your jig is in the exact right spot on your miter gauge though.

The accuracy which you construct your jig will transfer to the box joints you will make with it so do a good job. I measure my notch with calipers accurate to .001 of an inch. I'm not really too sure if anything else would work. But you're more than welcome to try. I undersize the stuck out part of my pin a little to make it a bit easier to get the box parts on and off it. I just sand the pin a little after it is put together.

The astute observer will notice that the jig is a pattern of one box joint that we will simply repeat over and over in order to cut the successive joinery.
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macgyver711 year ago
Thank you for an excellent instructable, and double thanks for recycling pallets into something beautiful
mikeasaurus2 years ago
Thanks for showing us how this done, your finished box looks great!
pfred2 (author)  mikeasaurus2 years ago
Would it look any better if I told you I made it out of an old shipping pallet? Because I did :)

I'm thinking about writing an article on this site about how to break old pallets down. I even made a special tool for doing it.
ripper.jpg
Yes, that tool is nice! I want to make one. Is that welds I see? I don't have a welder. Is there a way to make it with nuts and bolts, without welding anything? My brother has torches and the like, maybe he will help out! Thanks again! Triumphman
pfred2 (author)  triumphman2 years ago
I welded it. If I had to use a torch I'd probably braze it together. If you are going to try to make one here is another picture where you can see the tool more clearly. The other picture I attached to my comment on this page is more a how it is used picture:

http://i.imgur.com/2QnxS.jpg
drewgrey pfred22 years ago
Its amazing how good pallet wood can be. I planed down a bunch today that is almost like rosewood.
pfred2 (author)  drewgrey2 years ago
It'd be more incredible if people were so foolish as to use inferior materials to ship valuable merchandise on. What is amazing is how few put the fact together.

Most hardwood pallets I see are poplar and oak, though sometimes I run into other unidentifiable woods as well. I think this is flame maple. It really blew me away after I stained and finished it.

Before finishing it didn't look like anything special to me.
SB1-001.jpg
drewgrey pfred22 years ago
A friend of mine scored a pallet for heavy machinery that had a few oak beams about 16 feet long. Best freeby ever
pfred2 (author)  drewgrey2 years ago
Your friend must have a big truck.
I love your pallet 'breaker upperer', I could have used that on a number of occasions!
pfred2 (author)  bricabracwizard2 years ago
Just one more tweak and it is ready to market! heh
Really, pallet wood?!  That box is now new measures of awesomeness, I think it was the worn pallet grain that totally drew my eye.

I've been brainstorming projects for pallets for some time now, I definitely think you need to post your pallet-deconstruction tool and tutorial; it's got to be better than my hammer/crowbar method.
pfred2 (author)  mikeasaurus2 years ago
While I was making toothpicks out of many pallets using a crowbar I kept thinking if I could just get a hammer shot up under the board. So I made that tool out of 3 inch C channel and some scrap pieces of angle iron. I smack the top of it with a heavy hammer, it goes down, and the board pops up!

Here is another picture of it:
ripper1.jpg
I used to know a guy in Atlanta who went around collecting and repairing pallets or 'skids' as they're called back here in Michigan! At any rate, he would be able to make a nice pile of greenbacks selling these pallets when repaired. "Primitive, yes, but he was effective for his wife and kids' appetites! He fed his family. I like what you've shown me here, today, and will remember what is means to me, in the future. I am a pretty good carpenter, too. What I like to do is collect old dock wood from the beaches of Lake Michigan and build tables of them. You would be amazed at the kind and amount of great, usable wood, that washes up on the beach after a long winter. pfred2, you have shown genius in your work, and a knack for using solid and strong wood for good purposes! It's manner or source, only adds to the brilliant way you have used what otherwise would be scrapped! That is where the 'genius' comes in! The perfect joints you make for the boxes are incredible and clean! I'm not surprised you found "rosewood" on some of the skids; I'm shocked just short of miraculous wonder! Keep up the magic work, pfred2. You are my hero, man! Thank you! Kind Regards, Robert T.
pfred2 (author)  Robert T.2 years ago
Thank you for your kind comments.
kenbob pfred22 years ago
Like!
pfred2 (author)  kenbob2 years ago
Primitive but effective is my motto.
Eromanga pfred22 years ago
Excellent - thanks for that photograph of your pallet tool. Looks very practical and better than my current method. I'm a pallet collector too, for the cheap wood source.
pfred2 (author)  Eromanga2 years ago
To use it I smack the top with a big hammer about a 2 pound hand sledge.
skylane pfred22 years ago
Nice job on that!

Years back, I had quite a few oak pallets. I'd seen a back yard shed made of used pallet wood that was pretty impressive.
Unfortunately for me, the pallets I acquired were put together with "twisted" nails.
I'd tried every which way I could think of to get them apart without destroying them. I even tried a hydraulic (jack?) that fit in the 4" space. I found nothing to work.
Sadly, they ended up making some pretty nice firewood... :-(
pfred2 (author)  skylane2 years ago
All pallets I run into are put together with twisted nails. Depends what style they are how I rip them apart. Block riser types I jack apart. But stringer style I use my fork device after I saw off the ends with a circular saw and a cheap carbide blade I don't care if I hit a nail with.

Usually the heads pop off the nails. I use vise grips on the nail shanks and a pry bar to salvage the stringer wood.
triumphman2 years ago
I made some honey bee hives that way. I have a video of some guys who show that very same setup. I had to write it down from each step, pause the video, write, then watch the next step. I finally got to make the jig and try it on my old craftsman table saw. They don't make them like that anymore. New stuff is junk! I can't believe how cheap the new saw are! The quality has gone to a new low of "made in china" ! Even Craftsaman saws are cheesy quality! I also go yard sailing and flea marketing! I have found some great old tools out there that just needed a new power cord or switch. Old is better ! I always say. New is junk! For sure. Our landfills are getting full of stuff made in china. I heard a guy say "when in doubt throw it out", what a looser he was! He lost big time because he kept throwing out stuff and buying more junk to replace it! I got away from him fast. He made me angry, he and many others today have the same attitude. The Wally movie hit it right on the head! Keep up the good work. Love your ideas! Triumphman
jefeickert2 years ago
I am trying to find some way to cut an circle out of 3/4 plywood. 12" dia
check out this video
http://www.youtube.com/watch?v=Wxbzrf4z_cg
pfred2 (author)  SWV17872 years ago
That is one variation of the trammel point method that is used with a router, band saw, or jig saw.
pfred2 (author)  jefeickert2 years ago
A band saw, jigsaw, or router would do it. I've even seen people do it on a table saw come to think about it. It is even possible to make a disc that big on some wood working lathes. So I guess it depends what tools you have and how you'd like to go about it.
shazni2 years ago
Is there anyway i can make a box joint without dado blades? i have a table saw...and a jig saw with a jigsaw table(it's like a band saw). Dado blades are very expensive here and since it's just a hobby i'm starting on i don't want to spend more as i just bought a circular saw ( which i have converted to a table saw i have mentioned!)
your help would be wonderful. thanks
pfred2 (author)  shazni2 years ago
When I first started out I did not have a dado blade myself so I stacked regular blades together and it worked. Just try to use a group of the exact same blades. You also need to stagger the teeth a bit from each other for it to work best.

Then for a long time I used a wobble dado blade. The one I have is not very expensive at all. If I had to characterize it I'd have to say it is a cheap piece of garbage. But it got the job done.

Just recently I finally managed to run across a nice chipper dado blade set at a yard sale priced very reasonably. I made a throat plate out of phenolic sheet for my new to me tablesaw for it. I still have not done anything more than a test cut with it, but the results of that were promising. So I'm looking forward to enjoying using it in future projects.

I should also add that some people use routers mounted in router tables to make box finger joints. I tried it, I did not care for it myself. Perhaps if my router table was a bit different I'd have liked it more? I still like how circular saw blades cut better over router bits though.

When I get the time my next box project will be to make a storage box for my chipper dado set. The cardboard box I got it in is a bit beat up. Guy even threw in some other circular saw blades with it too. He was a cabinet maker who moved into just sales.

I've a picture of all the junk I bought running around that day that I will attach to this post. I used it in my magnetic motor starter article because it was the same day I bought my contactor. I got all those saw blades for $10 USD I think. Might have been $20 I can't remember.
Sept-24_Sales.jpg
shazni pfred22 years ago
Thanks for your reply....I'm from sri lanka....where the cheapest blade is $10+ !
garage sales are practically non existing for these items.. :-(
Woodworking here is like only for professional males! not the average male as the cost for a circular saw is very expensive!
pfred2 (author)  shazni2 years ago
I find the price of items to be flexible and dependent on what I am willing to pay for them. If one object is too much I keep on looking until I come across another more to my liking. It is a big world so someplace everything can be had if I just look hard enough.

It does help to look at the right times in the right places though. I work hard to make it happen for me. A lot harder than the average male.
Another question, Fred - when you do your overhang - do you do it for both sides and how much do you do? I experimented with overhanging 1 side only and then using a router to smooth it out - but i didn't account very well for blade kerf. I was thinking I would make one overhang longer than the other so that i could route one and sand the other. any tips there?
pfred2 (author)  DisplacedMic2 years ago
Well the less overhang you can get the better. But there should always be some. Far easier to sand them to fit than it is to fit them perfectly.

When you see the finished box the fingers are flush to the sides and it has the appearance of careful skilled workmanship. That is the image I wish to convey the most easily I can. Sanding things to one and another is a technique I employ often to achieve a "perfect" fit without putting myself out too much getting it .

Really end grain needs to be sanded some before finishing anyways. Just looks better that way. Rough sand then route if you're going to perform another machining operation on the work. Running over the protruding fingers is not desirable.

The only scenario where you'd want some fingers to stick out more than others is if you are using box sides of unequal thicknesses. In that case set your overhang so fingers stick out of the thickest sides.

If your fingers really stick out a lot you can nip them off a little with a saw, then sand what remains. That can happen if you're doing a box run with different thickness sides and do not adjust the blade height between the boxes. It happens. Just don't try to saw the fingers all the way down and hit the side of the box with the saw blade. By saw I mean on a table saw though I imagine some other saws would work as well.

By sand the fingers down I mean use a belt sander with about 36 grit on it, or maybe a disc sander to really bring the fingers down quickly. This sanding is separate to any finish sanding the box may receive. It is a machining process in and of itself. Done right it goes quickly.
Thanks Fred!

have you ever tried rounding the box corners themselves? i wonder how that would look
pfred2 (author)  DisplacedMic2 years ago
I have. It's OK
Also - out of curiosity, how do you seal up your boxes when you're done? Do you just use gorilla glue or do you also use fasteners?
pfred2 (author)  DisplacedMic2 years ago
I use yellow wood glue. Dry it is stronger than wood itself. I like some Elmers, their Probond is nice or Titebond 2 Gorilla glue is that the foamy glue isn't it? If it is I don't really care for it. It makes a real mess and I don't find it to be as strong as yellow glues. The foamy glue doesn't store very well either. When I had it it was always going bad on me.
I totally agree! It also expands out of the joint and then you have to clean that up!
pfred2 (author)  bricabracwizard2 years ago
I was never too keen on scraping the foam myself. I think the newer yellow glues are higher performance too. Maybe the foamy glue made them up their game?
We can only hope!
pfred2 (author)  bricabracwizard2 years ago
I'm pretty sure the newer yellow wood glue is better than the older stuff was. It looks a little darker to me. Maybe they're just not thinning it down so much?
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