How to Make a Box Joint Without a Table Saw
In this blog post, we will be discussing how to make a box joint without a table saw. Although it is not as simple as using a table saw, it can be done with a few simple tools and some practice. So, if you are looking for an alternative way to create box joints, keep reading!
This is an important skill to have if you don’t have access to a table saw or if you want to save on materials. We’ll show you how to make a jig that will help you make perfectly-aligned box joints every time. Stay tuned!
Why Should You Make a Box Joint
The Box Joint is very useful. It’s extremely strong for its size, and it’s also easy to make with only a few tools. The most important aspect of the box joint is its use in any woodworking project. It can be used to join together drawers, frames for pictures/mirrors, boxes, and the list.
The box joint is also known as a finger or box lock joint because of its finger-like appearance. Before you start cutting, you should take some measurements to know how long each board should be cut. Once you have taken the sizes cut your pieces accordingly.
Material and Supplies Required
1. A Thick Piece of Wood
2. A Thin Saw Blade
3. An Exacto Knife
4. A Ruler or Measuring Device
5. Sand Paper
6. A Pencil
7. Wood Glue
Step by Step Guide: How To Make A Box Joint Without A Table Saw
Step 1: Install the Stacked Dado Blade Set
Install the stacked dado blade set into your table saw. With both blades in place, position your saw’s fence so that the outside of the larger dado blade is about an inch away from the edge of your saw’s table.
Step 2: Cut the First Slot
Place a piece of scrap wood on your work table. Set up another fence for this piece, set back 1/4 inch from your main fence. Position the throat plate so you are cutting along the grain perpendicular to the length of the wood.
Align one edge of this board against your main fence and cut a dado that is as wide as your board will be thick. This means you’ll need to start this cut with the blade initially at 0, raise it until your wood is under the center of the blade, and then slide it back down again, so the blade’s teeth are below your workpiece.
Step 3: Cut Out the Pieces for Your Joints
Cut pieces of stock to create two box joints. One should be slightly longer than the width of your dado slot. Place this piece besides the first cut you made and make a second cut at least as deep as one board’s thickness.
Insert this board into the first dado and slide it to its end. Move it back an inch, raise your blade slightly, and make a third cut. Repeat the process with your second piece of wood, so it fits in the opposing slot.
Step 4: Assemble Your Joints
Slide one board into the slot on the right, and push it up against your fence. Then slide its matching piece into the left side’s dado, lining them up flush at each end. Clamp the pieces together and remove them from your table saw. Use a chisel to pare down each face of the joint, so they fit together tightly.
Step 5: Attach the Board to the Miter Gauge
Mount a small scrap of wood to your saw’s miter gauge, acting as a backer. Position the box joint, so it rests against this scrap, and slide it to the point where both joints meet lines up with your saw’s blade.
Step 6: Cut Half-Blind Tenons
Place one board into the dado you created earlier and push it to the end. Slide it back to your saw’s blade, raise it slightly, and cut a half-blind tenon. Trace the shape onto the second board, then remove both pieces from your saw.
Step 7: Cut a Notch in the Backer Board
Turn your miter gauge around and lay your backer board on top. Position the box joint against the edge of this scrap, mark where you need to notch it out to clear the tenon and cut this section away using a coping saw or any other means at your disposal.
Step 8: Adjust the Box Joint Jig
Turn your miter gauge back around and reinstall the box joint. Slide it up to the blade again and make a test cut. If this did not cut through, adjust your jig by dropping its backer board or moving its fence inward. Do this until you can remove all of the waste from both joints in one pass.
Step 9: Fit Your Joints Together
Now that both joints are complete slide them together and test their fit. If they do not come together tightly, adjust the depth of your blade and make another pass through your cuts. Keep doing this until you can push the pieces together while keeping your hands clear of the saw’s blade.
Step 10: Finish Your Joints
Use a chisel or other means to pare down each piece of your joint to fit together tightly. Finish the surface with sandpaper, round over the top edges with a router and round over bit to make a decorative joint.
Some Helpful Tips and Suggestions
Here we have given some helpful tips on how to make a box joint without a table saw.
1. This is a guide to making box joints using hand tools. If you have access to power tools, do use them!
2. There are many ways to cut perfect box joints; this is just one of them. You can experiment with different lengths, widths, and angles until you find something that works for you.
3. If you find that the guide is not accurate enough, experiment with different measurements.
4. You can make these joints as long or as wide as possible and use them whenever a box needs to be closed.
5. If your saw does not allow you to cut corners off the lines you drew, don’t worry about it. These parts of the joints can be cut off afterward, and doing them now may make cutting very difficult later on.
6. The measurements given here are the width of the box joint, not the size of your saw blade. If you have a thin kerf blade, you will need to use slightly thinner stock.
7. If you honestly can’t make a perfect box joint without a table saw, do not fret. Just make the joints however you can and cut grooves inside each piece to receive splines or dowels.
How Do You Cut a Box Joint Without a Jig
Box joints are a great way to connect pieces of wood, made popular by wooden boxes and handmade drawers. A traditional box joint requires a miter saw with a special jig on it that allows you to make repeated cuts quickly and accurately. While this is not very difficult, many people don’t have access to table saws and would like to learn how to make a box joint without one.
If you want to do some handcrafted woodworking but don’t have access to the tools you need, there are still some great methods for making this type of joinery. This article has discussed making a box joint on the drill press and using only essential tools.
How Do You Make a Box Joint by Hand
Before the advent of power tools, box joints were made using a chisel and mallet. First, a groove is cut across the face of one board at a specific width. The exact distance is then measured onto the adjoining board, whose end must also be milled to fit precisely in the grooves of both boards. The same procedure is then performed across the entire surface of both boards, making for a tight-fitting box joint.
A special jig must be used to cut the grooves at specific widths. This method can be time-consuming, but if you are ambitious, you could use it as practice before taking on more complicated joints, like dovetails. It can be done by hand with some planning and patience. There is no simple way to do it, but you will get there with some sawing, fitting, and chiseling.
Conclusion
You can use a table saw, or band saw to cut the rabbet for this joint, but that will sacrifice some accuracy and increase your setup time. The best way to make box joints without a table saw is the careful layout and cutting on the bandsaw. Box joints are a strong and attractive joinery method, and with the right tools, they can be made quickly and easily.
In this blog post, we’ve shown you how to make a box joint without a table saw, but it will make the process much faster if you have access to one. We hope you give this project a try; it’s a great way to use scraps of wood and practice your woodworking skills. Thanks for following along!
