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Table saw box making ideas,storage racks for lumber,shed plans barn style extensions - New On 2016

18.08.2013 admin
Making box joints — among the strongest joinery methods for square corners — is quick and accurate on the table saw with an easy-to-make jig.
STEP 6: The fingers and slots of box joints are offset from each other, meaning that opposite sides of the box will be in matching pairs. The adjustable box joint fence for the dado crosscut sled allows the woodworker flexibility when he or she is creating wood joinery on the table saw. The adjustable box joint fence is comprised of (2) 1″ rails of straight grained maple.
Note: The adjustable box joint fence is simply a great accessory for the dado crosscut sled. Use your cordless drill or corded power drill to drive a pair of wood screws through the slots or holes in the miter gauge, and into the block of wood. Slide the gauge back toward your body (clearing the blade again) and then turn off the saw. There are two viable tools for making box joints in the home workshop, the router and the table saw. Ideally, your test cuts should be made with the same wood you'll be using to build your box. It's important to understand what's going on when the fingers of the joint don't fit together like they should. Only move the fence .002" at a time, making a test cut after each adjustment to check the finger fit. With the jig properly adjusted, we can now move on to making box joints for our project box.
If you want to start and end with a full finger, add a half finger width to the width of your boards. I don't know about you, but I'm making a storage box that will hold the change gears for my metal lathe. With the four sides cut to size, set them up the way you want them to look as a finished box. The extra material can now be trimmed from the box and lid pieces, bringing them to their final dimensions. I simply lined up the edge of a finger with the outside edge of the blade and locked down the fence.

After sanding, the corners should fit together easily with a few light taps of a rubber mallet.
A useful work-around for this is to glue up your test cut before you even cut the fingers for the box. You have to work somewhat fast when applying the glue, especially if there's a lot of fingers on a wide board. Spreading glue on just the tops of the fingers will save some valuable time and allow you to finish quicker. Although I've no doubt made it sound more complicated than it really is, making box joints is not difficult.
The INCRA I-Box is the most advanced tool ever produced for creating a stunning variety box joint and finger joints. While they lack the locking characteristic of their angled cousins, their uniformity means box joints can easily be created and repeated quickly using mechanical methods. This small piece is the exact size of your joint slots, and will act as an index key on which to register your workpiece as you make the cuts.
In Photo 5, I’m using a small offcut from my actual workpiece so the distance between the key and blade is perfect. Now, reposition the workpiece by sliding it sideways so the slot you just cut slips over the index key. The box joint fence is simply a woodworking accessory used to assure uniform spacing when making wood joinery such as box joints (finger joints) and evenly spaced dadoes. The rail closest to the woodworker is stationary while the interior rail can slide laterally. While a through dovetail joint is stronger than a box joint, it's also more complicated to create.
Position enough chippers in between the two outer blades so that the final width of cut will match the desired width of the box joint fingers you determined in the previous step. Slip the miter gauge into the miter slot to the left of the saw blade and check to see that the miter gauge is set to 90-degrees (perpendicular to the saw blade). Be certain that the screws are short enough that the point doesn't poke through the face of the board. Finger joints are perfect for box joinery, case construction without dovetails, shop furniture, and more.

It's revolutionary design allows faster setup, greater versatility, and improved user safety compared to conventional jigs. With an extremely simple jig — just two pieces that go together in a flash — your table saw is the perfect way to add these strong, versatile joints to your repertoire. Hold or clamp the workpiece securely to the jig, power up the saw, and make your next cut by sliding everything through the blade again as I’m doing in Photo 7. As before, hold or clamp everything securely to the jig, and slide everything through the dado blade (Photo 8).
Also, by employing the adjustable box joint fence on the dado crosscut sled, the woodworker can quickly make the repetitive cuts necessary for creating decorative dentil moulding. See how to make and use Theisena€™s jig in the animation below then follow these links for written instructions and a plan with dimensions. Hold or clamp the workpiece firmly against the fence and slide everything through the dado blade (Photo 6).
The addition of the optional box joint fence enhances a woodworker’s ability to work systematically, accurately, and efficiently while at the same time, working safely.
This adjust works well for dadoes, finger joint operations, or for creating dentil moulding. In issue #214, we featured another one: a dedicated tablesaw sled by Dennis Theisen of Grand Rapids, Mich. Holes are drilled thru the stationary fence so that the T-bolts can extend thru this fence. This block provides additional safety for the woodworker as it helps to conceal the dado blades from the woodworker’s hands.
The jig is super easy to make (some can be highly-engineered like this one by Matthias Wandel) and cuts one size of fingers. The threaded T-bolts are then fastened with the black star knobs.To adjust the box joint fence simply loosen the star knobs, adjust the box joint fence left or right so that the peg is aligned from the dado saw kerf the desired amount. The replaceable backer board is easy to reposition for different size fingers and it's easy to make your own once you have used up all the spots.

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