3.
Chuck a straight router bit with a diameter matching
the width of the Indexing Key in your table-mounted
router. For example, 1/4" wide box joint fingers would
require a 1/4" diameter bit. For best results, use an
up-cut spiral bit.
4.
Position the Platform (1) on your router table so that
the Expandable Miter Bars (4) fit in your table’s miter slot
and the bit extends up through the oblong hole in the
Platform. Do not tighten the Five-Star Knobs (2)
yet.
Fig. 2.
5
Setup
1.
Assemble the jig, but leave off the MDF Sacrificial
Fence (10) for now.
2.
Select the appropriate Indexing Key (7, 8 or 9) for
the width of box joint fingers you want to cut and
securely install the key in the Sled (6), using the
provided 1/4"-20 machine screws (11). The Router
Table Box Joint Jig includes Indexing Keys for 1/4",
3/8" and 1/2" box joints. Make sure that the Indexing
Key extends out the front side of the Sled and that
the flat face of the Key is down.
Fig. 1.
Store the Indexing Keys that aren’t being
used in the onboard compartments incorporated in the Sled.
For the jig to work, the width of the
Indexing Key must match the diameter of the router bit.
For best results, we strongly recommend applying a blade
and bit lubricant such as Bostik GlideCote (97594, sold
separately) to the router bit before cutting box joints. This
will greatly reduce heat buildup and scorching, which are
likely to produce poor results and shorten the life of your bit.
To avoid risk of serious injury, unplug the
router before installing, removing or adjusting the bit.
>
Use only with wood and MDF no more than 1" thick.
>
Platform (1)
MUST
be secured in the router table
miter slot by fully tightening the five-star knobs of
the Miter Slot Hardware (2).
>
Indexing Key (7, 8 or 9) and MDF Sacrificial
Fence (10)
MUST
be securely attached to Sled (6).
>
Sled (6)
MUST
be able to slide smoothly in
Platform (1) slots.
>
Maintain control of the Sled and workpiece at all times.
Rockler recommends securing the workpiece with
clamps to the Sacrificial Fence/Sled’s flat clamping
areas. Holding the piece securely with your hands is
possible, but maintain awareness of your fingers,
hands and the bit, as serious injury could occur.
>
If you encounter excessive resistance when routing,
turn off the router immediately and determine the
cause (for example, a dull bit).
THESE WARNINGS PERTAIN
TO ALL REMAINING STEPS:
>
To avoid serious injury, keep
hands and fingers away from
rotating cutter. Maintain
awareness of the rotating
cutter at all times.
Fig. 2
Fig. 1
The Router Table Box Joint Jig is designed
for use with router tables that have a standard 3/4" x 3/8"
miter slot. The near edge of the miter slot must be between
4
1
⁄
2
" and 6
1
⁄
4
" from the center of the router bit for the jig to
work without modification.
