Manual - Woodstock International, Inc.

INSTRUCTION SHEET
D3157 1⁄2", D3158 1⁄4" & D3160 5⁄8"
Box Joint Templates
INTRODUCTION
When combined with the D2796 Dovetail Jig, these
Woodstock Box Joint Templates allow you to quickly and
accurately produce high quality box joints. Additional tool
requirements include a hand-held router, a guide bushing,
and a straight-cutting router bit. Refer to the table to the
right for specific guide bushing and router bit information.
Read and follow the manufacturer’s instruction
manuals for all power tools used when making box
joints. Serious personal injury could result from failure to follow this warning.
TECHNIQUE SELECTION
SET UP
One of three techniques are used when making box joints
with these templates. To determine which technique should
be used, plug the workpiece width measurement into the
formulas below. Note—Whenever possible, cut workpiece
widths so Technique 1 can be used.
All Techniques
1.
Use the chart below to select which router bit and
guide bushing to use.
Template
Use Technique 1 if:
(Workpiece Width) ÷ (Template Size) = (Even Number)
Example: 4" ÷ 1⁄2" = 8
1
D3157 ⁄2"
D3158 1⁄4"
D3160 5⁄8"
Router Bit
Guide Bushing
1
5
1
5
⁄2" Straight Bit
⁄4" Straight Bit
5
⁄8" Straight Bit
⁄8" Guide Bushing
⁄16" Guide Bushing
3
⁄4" Guide Bushing
2.
Install the correct router bit and guide bushing on the
router.
3.
Adjust the router bit depth according to the formula
below:
This technique is the fastest and simplest for routing box
joints.
Use Technique 2 if:
(Workpiece Thickness) + (Template Thickness) =
(Correct Router Bit Depth)
(Workpiece Width) ÷ (Template Size) = (Odd Number)
Example: 41⁄2" ÷ 1⁄2" = 9
This technique requires making and using a spacer board to
rout 1 of the 2 box joint halves.
4.
Prepare a scrap board that is 1⁄2" wider and 1⁄4" thicker
than the workpiece.
Use Technique 3 if:
5.
Loosen the adjustment bolts on the left-side stops and
adjust them to the far left of the dovetail jig.
(Workpiece Width) ÷ (Template Size) = (Uneven Number)
Example: 41⁄4" ÷ 1⁄2" = 81⁄2
6.
This technique often results in very thin joint fingers on the
sides of the workpiece. These fingers can break easily during routing. Whenever possible, plan workpiece widths so
Technique 1 or 2 can be used.
Place the scrap board under the top clamp with the
front edge flush with the front of the jig. Note—Do not
worry about the precise location at this time.
7.
Place the workpiece vertically in the front clamp with
the top edge of the workpiece against the bottom face
of the template. Note—Do not worry about the precise
location at this time.
9.
ROUTING BOX JOINTS
1.
Unclamp and rotate the workpiece to rout the opposite end as shown in Figure 2.
Follow these steps according to the technique being
used.
Techniques 1 & 2 Only:
Position the left edge of the workpiece exactly 1⁄16"
(1⁄32" when using the 1⁄4" template) to the left of one of
the template fingers.
Technique 3 Only:
Center the workpiece under the template as shown in
Figure 1.
Figure 2. Flip the workpiece.
10.
Example 2
Example 1
Figure 1. Workpiece centered under template.
All Techniques
2.
Clamp the workpiece into position.
3.
Slide the front side stop against the left side of the
workpiece and retighten the adjustment bolt. Note—If
the side stop cannot be adjusted against the left side of
the workpiece, re-adjust the workpiece farther to the
left.
4.
Adjust the scrap board until both edges protrude equally past the workpiece edges.
5.
Follow these steps according to the technique being
used.
Technique 1 Only:
Perform the same routing operation that was performed on the opposite end. The components of this
box joint are complete.
Techniques 2 & 3 Only:
A. Position a spacer block equal to the width of the
template size against the left edge of the work
piece as shown in Figure 3.
Workpiece
Spacer Block
Clamp the scrap board into position.
Figure 3. Spacer block.
6.
Before starting the router, position the router on the jig
and make sure the bit will not hit the template or the
jig.
7.
Start the router and carefully rout the fingers of the
box joint.
B. Slide the spacer block/workpiece assembly
against the side stop, and clamp it into position.
C. Reposition the scrap board as described in step 4.
8.
Turn off the router.
D. Slowly and carefully rout the fingers of the box
joint. The components of this box joint are
complete.
COPYRIGHT © BY WOODSTOCK INTERNATIONAL, INC.
WARNING: NO PORTION OF THIS DOCUMENT MAY BE REPRODUCED IN ANY SHAPE
OR FORM WITHOUT THE WRITTEN APPROVAL OF WOODSTOCK INTERNATIONAL, INC.
JULY 2003, PRINTED IN CHINA