Box Joint

Jig Instructions
3 4

With this innovative jig, you’ll

soon be making beautiful, PARTS LIST - BOX JOINT JIG Quantity
precise box joints in material
up to 3/4" thick! Like all 1 Platform 1
Rockler Innovations, the Box 2 Mounting Hardware 2
Joint Jig was designed with 3 Backer Sled 1
simplicity and ease-of-use in 4 Pre-drilled Hole for Sacrificial Face 2
mind. Nevertheless, to ensure 5 1/4" Indexing Key 1
safe and proper operation
6 3/8" Indexing Key 1
please read and understand
7 1/2" Indexing Key 1
these instructions completely
prior to setup. Thanks again RECOMMENDED BITS Quantity
for choosing Rockler!
1/4" Up-Cut Spiral Bit 1
3/8" Up-Cut Spiral Bit 1
1/2" Up-Cut Spiral Bit 1

1
RTD10000594AA
Fig. 1

Setup Instructions:
Sacrificial Fence 1. With the desired bit (either 1/4", 3/8",
or 1/2" in diameter) in your router,
position the jig on your router table so
the bit comes through the oblong hole.
Fig. 1. For best results, use an up-cut
spiral bit.
Notch cut for
2. Place the backer sled on the platform.
indexing key To prevent blowout, attach a sacrificial
fence (not included) to the backer sled
using the pre-drilled holes.
Note: You will need to notch out a slot
on the sacrificial face to accommodate
the indexing keys. Fig. 2.

3. Install the appropriate indexing key in

the jig. For 1/2" box joints, use the 1/2"
key. For 3/8" joints, use the 3/8" key
Up Cut Spiral Bit and so on.

Fig. 2

2
Fig. 3

4. Adjust the height of the router bit

above the surface of the table to match
the thickness of your stock plus a
small amount for sanding flush. Fig. 3.

5. Adjust the gap between the bit and the

indexing key to equal the diameter of
the bit. 1/4" box joints, for example,
would require a 1/4" router bit, a 1/4"
indexing key, and a 1/4" gap between
the two. To adjust the gap, move the
jig side-to-side in the miter track. Then
lock it in place with the 5-star knobs.
Note: Use a test piece to be sure your
settings are correct and your joints fit
tightly. For best results use Rockler’s
Precision Brass Setup Bars (36918).
Fig. 4.

Fig. 4

3
 A A
T T B

Backer with
sacrifical face

Fig. 5 Fig. 6

A B B
T T T B

Fig. 7 Fig. 8

Cutting Instructions: T T
6. Layout all four sides with inside face up. Label each A
piece on the inside face and mark the top and
bottom edges. B B
7. To make the first cut, position the top edge of
workpiece (A) flush against the indexing key’s left T B B T
edge and slide the backer sled forward. Fig. 5.

8. For successive cuts, reposition workpiece (A) with

the previous cut over the indexing key. Repeat. T = Top
Fig. 6.
B B = Bottom
D

9. To make the first cut in the adjacent side piece (B),

use the original piece (A) as a spacer. Position
piece A with the top edge positioned as shown in T B B T
Fig. 7. Butt the second piece (B) against the first
and make the cut. B B

10. Remove the original piece (A), push the second C

piece (B) against the indexing key and make the
second cut. Fig. 8. For sucessive cuts reposition T T
workpiece B with the previous cut over the indexing
key. Repeat.
Note: The box joint finger pattern on the box's front and
11. To make the cuts in workpieces C and D, repeat back panels should be the same. The two side panels
steps 7 - 10. should also match.

Rev 12/08 29502

Distributed by Rockler Companies, Inc.
© 2008 Rockler Woodworking and Hardware 4