Woodhaven 4555: Box Joint Jig - Manual (Page 4)

3
To make the mating cuts on the second workpiece, you
need to offset the first cut on the second workpiece by
the width of the joint (which is the same as the width of
the bit/blade). Take your first work piece and flip it edge for
edge so that the first cutout is indexed on the Stops. Butt the
second workpiece against the edge of the first workpiece. Hold
both pieces and make the first cut on the second workpiece.
Remove the first workpiece and continue cutting
the second workpiece as you did the first.
You can cut multiple parts at one time by clamping like
parts together (fronts & backs, left & rights, etc.) as long
as their edges are aligned. Mark the parts (top or bottom
edges, mating corners, outside faces, etc.) to keep them
in order and positioned correctly as you cut the joints.
ACCESSORIES
Replacement fences (4555F) are
available from Woodhaven, or you can
make your own out of 3/4” material.
We offer an Upgrade Kit (4553)
that includes the following:
Two adjustable Work Platforms which provide a
safe and stable surface for the part to rest on. Made of
slick 1/4” thick HDPE, they attach to the underside of
the Ultra Track and eliminate friction between your saw
or router table and the bottom of your workpiece.
Includes an Adapter Head of 3/4” MDF for attachment
to your miter gauge so you don’t have to make your own.
Includes a Stop that attaches to the back of the
Ultra Track. The Stop indexes against the side of the
Adapter Head to help fine tune the joint size. This
replaces the clamp and wood block in step 6 you’d
otherwise have to supply for the fine adjustment.
Includes a bit/blade Shield that attaches to
the top of the Ultra Track and projects out the back
where the bit/blade exits for safer cutting.
Includes a five piece set of Setup Jigs for quicker
and easier setups of 1/4”, 3/8”, 1/2”, 5/8” & 3/4” joints.
©Copyright WOODHAVEN INC. 2/20/14
(800) 344-6657 or WWW.WOODHAVEN.COM
8
9
First
workpiece
Workpieces
Start of
Second
7
1/2”
After you are satisfied with the fit of the joint,
hopscotch the work over the Stationary Stop, place
the left edge of the cutout (looking at it from behind)
against the Stationary Stop. Loosen the 1/2” screw of the
Adjustable Stop, slide it away from the Stationary Stop until
it butts against the opposite side of the cutout, then retighten
the screw. The work should now be captured between both
Stops so the work can’t shift left or right while cutting.
Continue cutting along the entire width of the work, hop-
scotching each cutout over the Stops to index the work for
each cut. Set the cutting height of the bit/blade to the thickness
of work plus 1/32”, or the minimum 1/4”, whichever is
greater. Any overhang can be removed later after assembly
by sanding or flush trimming. Make sure you allow for this
overhang when figuring the overall length of the workpiece.