Rockler Router Table Box Joint Jig User manual

Review full manual instructions prior to use for important safety information.
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Router Table Box
Joint Jig Instructions
Effective January 2018

2
This product is designed for specific applications as defined in the instructions and should not be modified and/or used for any
other applications. Before using the Router Table Box Joint Jig, read, understand and follow all instructions and safety information
provided. KEEP THESE INSTRUCTIONS FOR FUTURE REFERENCE.
GENERAL SAFETY WARNINGS
> Always confirm that you are using the most recent
version of the Instructions and safety warnings for
your product. To find the most recent version, find
the product page on Rockler.com and click on the
link to the Instructions.
> For any tool used in conjunction with this product,
always read, understand and follow the instructions
and safety warnings in the owner’s manual for that tool.
If you do not have the owner’s manual, obtain one from
the tool’s manufacturer before using it with this product.
> Before using this product, review and verify that all
tools to be used with it have safety equipment
installed and are in proper working order as
defined by the tools’ owner’s manuals.
> Do not use this product until you have read and
are confident you understand:
• Product Specific Safety Warnings (p. 3);
• Parts List (p. 4);
• Setup (pp. 5-7);
• Use (pp. 7-8).
> Do not use this product in any manner other than
what is described in these instructions. Use only
recommended accessories.
> Remain alert and use good judgment when using
this tool. Do not use this tool if you are in any way
impaired by medications, alcohol, drugs or fatigue.
> Dress appropriately and remove all jewelry, secure
loose clothing and tie up long hair before using
this tool.
> It is the sole responsibility of the purchaser of this
product to ensure that any third party whom you
allow to use this product reads and complies with all the
instructions and safety precautions outlined in this
manual prior to use.
> Maintain these instructions and warnings as long as
you own the product. Keep this booklet in a place where
it will be readily available for reference.
> The user assumes all risk and responsibility for the
proper use of this product and for ensuring product
suitability for intended application.
> Always wear safety glasses in compliance with ANSI
safety standards and hearing protection and follow all
standard shop safety practices, including:
• Keep your work area well lit and clean;
• Unplug all power tools before making any
adjustments or changing accessories;
• Use dust collection tools and dust face masks to
reduce exposure to dust;
• Use accessory safety equipment such as
featherboards, push sticks and push blocks
whenever appropriate;
• Do not use power tools in explosive
environments (e.g., in the presence of
flammable liquids, fumes or dust);
• Keep children and bystanders away from
the tool operating area;
• Maintain proper footing at all times and
do not overreach;
•Do not force the tool.
> These warnings and instructions do not represent the
total of all information available regarding tool safety,
use and technique. Please read the full manual before
using this product and always seek out opportunities to
learn more and improve your skills and knowledge.
Drilling, sawing, sanding or machining
wood products can expose you to wood dust, a substance
known ot the State of California to cause cancer. Avoid
inhaling wood dust or use a dust mask or other safeguards
for personal protection. For more information go to www.
P65Warnings.ca.gov/wood.
Danger indicates a hazardous situation that, if not avoided, will result in death or serious injury.
Warning indicates a hazardous situation that, if not avoided, could result in death or serious injury.
Caution indicates a hazardous situation that, if not avoided, may result in minor or moderate injury
or property damage.
Notice indicates important or helpful information and/or user tips.
BP0617

3
PRODUCT SPECIFIC SAFETY WARNINGS
> To avoid serious injury, keep hands and fingers away from rotating cutter.
> 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 (4, 5 or 6) and MDF Sacrificial Fence (7)
MUST be securely attached to Sled (3).
> Sled (3) must be able to slide smoothly in Platform (1) slots.
> To avoid risk of serious injury, unplug the router before
installing, removing or adjusting the router bit.
> To avoid the chance of serious injury, keep fingers away
from spinning router bit.
> Maintain control of the Sled and workpiece at all times by
holding workpiece securely or clamping the workpiece to
the Sled’s flat clamping areas.
> To avoid risk of serious injury and damage to the jig, never
set the bit cutting height more than 1" above the surface of
the jig Platform (1).
> If you encounter excessive resistance when routing, turn
off the router immediately and determine the cause (for
example, a dull bit).
>Do NOT attempt to machine more than one workpiece at
a time (for example, by stacking).

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Quantity
1 Platform 1
2 Five-star Knob 2
3 Washer 2
4 Expandable Miter Bar 2
5 Miter Bar Bolt 2
6 Sled 1
Quantity
7 1/4" Indexing Key 1
8 3/8" Indexing Key 1
9 1/2" Indexing Key 1
10 MDF Sacrificial Fence 1
11 1/4"-20 Machine Screws 2
12 1" Panhead Screws 2
PARTS LIST
6
10
8
9
7
1
11
12
2
3
4
5

5
Setup
1. Assemble the jig, but leave off the MDF Sacrificial
Fence (7) for now.
2. Select the appropriate Indexing Key (4, 5 or 6) for
the width of box joint fingers you want to cut and
securely install the key in the Sled (3), using the
provided 1/4"-20 machine screws (8). 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.
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 Miter Slot Hardware (2) fits in your table’s miter slot
and the bit extends up through the oblong hole in the
Platform. Do not tighten then Miter Slot Hardware (2)
yet. Fig. 2.
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.
To avoid risk of serious injury, unplug the
router before installing, removing or adjusting the router 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 (4, 5 or 6) and MDF Sacrificial
Fence (7) MUST be securely attached to Sled (3).
> Sled (3) must be able to slide smoothly in
Platform (1) slots.
> Maintain control of the Sled and workpiece at all
times by holding workpiece securely or clamping
the workpiece to the Sacrificial Fence/Sled’s flat
clamping areas.
> 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.
Fig. 1 Fig. 2

6
5. Set the cutting height of your router bit so that the
top extends above the Platform surface just a hair
more than the thickness of your material. (This will
make the fingers of the joint stand a little proud
when assembled so that you can sand them flush
for a perfect joint.) Fig. 3.
6. Place the Sled (3), with Indexing Key attached, on the
Platform (1) so that its runners slide in the slots in
the Platform (1).
7. With the Sled (3) slid back away from the bit, install
the MDF Sacrificial Fence (7). Fit the notch in the
MDF Sacrificial Fence (7) over the Indexing Key and
align the Fence with the sides of the Sled (3). Before
attaching, place a few thicknesses of paper or another
thin spacer under the MDF Sacrificial Fence (7) to
raise it off the surface of the Platform (1) slightly
to ensure that the Sled (3) will slide freely. Attach
the MDF Sacrificial Fence (7) with the included
1" Panhead Screws (9) through the mounting holes
in the Sled (3). Test to be sure the Sled (3) will slide
smoothly. Fig. 4.
8. Slide the Sled (3) forward in its slots until the Indexing
Key is even with the bit.
9. Adjust the Platform (1) side to side until the space
between the bit and Indexing Key is equal to the
diameter of the bit (and width of Indexing Key).
For example, box joints with 1/4" fingers require
a 1/4" gap between the two. We recommend
Precision Brass Setup Bars (36918 or 51936, sold
separately) for easy, accurate setup. Fig. 5.
10. Once the precise spacing has been achieved, lock the
Platform (1) in position by securely tightening the
five-star knobs of the Miter Slot Hardware. Test to
be sure the Platform cannot shift.
11. Plug in the router and, using test pieces that are the
same thickness as your final workpieces, make test
cuts to verify that the spacing is correct and the joints
will fit snugly together. After each pass, fit the area
just cut over the Indexing Key for the next cut.
Fig. 3
Fig. 4
Fig. 5
If you have a router lift on your table, you
might need to drill a hole in the Platform (1) to be able to
access the adjustment mechanism. Drill a hole that’s large
enough to allow adjustment of the Platform location for
differing box joint finger widths.
To avoid risk of serious injury and damage
to the jig, never set the bit cutting height more than 1" above
the surface of the jig Platform (1).
The Five-star Knobs (2) MUST be securely
tightened to avoid the chance of the Platform shifting,
potentially causing serious injury.

7
12. If needed, adjust the spacing between the bit and
Indexing Key. Unplug the router and loosen one of
the five-star knobs on the Platform (1). If the fit of
your box joints is too tight, nudge the Platform
slightly so that the Indexing Key is closer to the bit.
If the fit is too loose, nudge the Platform to move the
Indexing Key a hair farther from the bit.
Use
1. After setting up the jig for your application, lay out
all four sides of your box with the inside faces up.
Label each piece on the inside face (A, B, C and D)
and mark the top and bottom edges (T and B). Fig. 6.
2. To make the first cut, position the top edge of
Workpiece A flush against the Indexing Key’s left edge
and hold or clamp it there. Make the cut by sliding
the Sled forward across the bit and then back to the
starting point. Fig. 7.
You will need to make dedicated MDF
Sacrificial Fences for the other Indexing Keys. Simply cut
a piece of 1/2" thick MDF 31⁄8" wide x 6" long and notch it
to allow clearance for each Indexing Key. You can use the
original MDF Sacrificial Fence as a guide for laying out the
notched area.
The Router Table Box Joint Jig is intended
for use in cutting end-grain joints like those shown. Joints
cut across the grain could result in significant tear-out
unless an additional sacrificial backer is used.
Fig. 6
Fig. 7
T
A
> 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 (4, 5 or 6) and MDF Sacrificial
Fence (7) MUST be securely attached to Sled (3).
> Sled (3) must be able to slide smoothly in
Platform (1) slots.
> Maintain control of the Sled and workpiece at all
times by holding workpiece securely or clamping
the workpiece to the Sacrificial Fence/Sled’s flat
clamping areas.
> If you encounter excessive resistance when
routing, turn off the router immediately and
determine the cause (for example, a dull bit).
>Do NOT attempt to machine more than one
workpiece at a time (for example, by stacking).
THESE WARNINGS PERTAIN
TO ALL REMAINING STEPS:
> To avoid serious injury, keep
hands and fingers away from
rotating cutter.
TT
BB
A
T
T
B
B
B
TT
BB
C
T
T
B
B
D

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Check Rockler.com for updates. If you have further questions, please
contact our Technical Support Department at 1-800-260-9663
or [e-mail]
Distributed by Rockler Companies, Inc.
Medina, Mn 55340
59032
Rev 01/18
Fig. 8
Fig. 9
Fig. 10
3. For successive cuts, reposition Workpiece A with
the previous cut over the Indexing Key and hold or
clamp in place. Slide the Sled forward across the bit
and then back to the starting point to make the cut.
Repeat until all cuts have been made on that edge.
Fig. 8.
4. To make the first cut in the adjacent side
piece (Workpiece B), use the original
piece (Workpiece A) as a spacer. Position
Workpiece A with the top edge positioned as
shown in Fig. 9. Butt Workpiece B against
Workpiece A, hold or clamp the workpieces
and make the cut.
5. Remove Workpiece A, reposition Workpiece B so
the area just cut is on the Indexing Key, hold or clamp
it in place and make the second cut. Fig. 10. For
successive cuts, reposition Workpiece B with the
previous cut over the indexing key. Repeat until all
cuts have been made on that edge.
6. To make the cuts in workpieces C and D, follow
the process outlined in Steps 2-5.
B
T
A
TT
A B
B
T
B