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I have received countless emails and messages about adapting the Lynn Sabin Box Joint Jig to the router table, and that is what this article and video are about.
Some time ago, I made a video using the Lynn Sabin plans that are available on sharkguard.com, very kindly provided by Lee Styron ... thanks Lee, for doing this. The Leeway Workshop LLC provides quality safety devices for table saws, like Shark Guard, splitters and riving knives. The link to specific plans is further down this article.
The plans, as I understand it, were originated by Lee Sabin for use on a table saw, using single blades, dedicated box-joint jig blades, such as Freud Tools, or using a stacked dado blade set-up. If you have never made this jig before, it is best to read these and the instructions provided with the plans, before you begin.
This jig works great on the table saw using dado blades, unfortunately, dado blades are not available in most European countries. I understand it is not illegal to own them but it is illegal to sell them. The plans I used are basically identical to those provided on the sharkguard.com website, with a couple of small alterations.
For everyone who is on the metric system, you will have to do all the conversions yourself. I do not know what router bits sizes, or threaded "ready-rod" types you have to work with. All the components I used were Imperial.
The way this jig works is based on the the "ready rod". I used a 16 threads per inch version. This means that if you have a nut on a rod like this, and turn the rod 16 times, it will advance that nut one full inch. Converting that to a 1/4" box joint, from the start position, you make one cut, turn the rod 8 times and that will advance the carriage 1/2" inch which means the second cut will leave a 1/4" pin, then make the cut at the 1/2" mark, and so on ... thus making the beginnings of the box joint cuts.