• Ultimate Box Jig (2) 2" screws, (4) washers, (2) wing nuts • 3 Indexing Pins (2) 5⁄8" screws • 1 Replacement Face Plates (3) 3⁄4" screws • 1 Safety Guard (2) 3 Point Knobs Optional: • Miter Gauge Adapter Plate Required when mounting to a miter gauge other than a standard gauge with holes 7⁄8" above the table surface.
Figure A
Optional Mounting Plate
Ultimate Box Joint Jig
NOTE: The optional plate requires you to drill two through holes matching your miter gauge face. Indexing Pins – See Step #1 X = Holes you must drill to match your miter gauge face.
Assembly:
Sacrificial Fence Plate
Attach the selected index pin to the jig using 5⁄8" flat head screws. The edge of the pin should align with the edge of the notch in the fence with the pin facing forward (Figure B). Attach the fence to the Ultimate Box Joint Jig Sled, mounting plate or miter gauge using the 2” machine screws, washers and wing nuts. The washers go on the miter gauge end under the wing nut (Figure C). Do not tighten.
Setup: Align the Ultimate Box Joint Jig fence on your router table or table saw so that the notch in the fence will allow the bit or blade to pass through the slot. Make sure the fence aligns with the holes in the Ultimate Box Joint Sled or miter gauge. The Ultimate Box Joint Jig is designed to fit standard miter gauges with holes 7⁄8" above the table surface. If you have a gauge which does not match, see the Miter Gauge Adapter Plate Installation below.
Figure B
Miter Gauge Adapter Plate Installation The adapter plate does not include the fasteners to connect the adapter plate to the miter gauge. Drill the adapter plate so that the holes in the miter gauge align. Countersinking the fence side of the mounting plate and using flat head machine screws with wing nuts will make installation easier. When using the mounting plate, the alignment of the index pin must be set before the sacrificial fence is installed.
Figure C Set Right
Figure C Set Left
WH 0502 03 (Page 1 of 2)
Blade Guard attaches here (see Figure A, above)
#042
Adjustment: Figure D
The index pin should be positioned on the opposite side of the cutter relative to the Ultimate Box Joint Sled or miter gauge (Figure D). Adjust the jig position so it is one pin thickness away from the cutter. For quick and accurate alignment , the use of a setup bar is recommended. Set the cutter height slightly greater than the wood thickness to allow for sanding or flush trimming.
Set-up Bar Saw Blade Index Pin
Attach the sacrificial faceplate, aligning the notch with the index pin (Figure E). Use the 3⁄4" flat head screws provided. Attach the safety guard to the back of the fence using the 3 point knobs. Set guard high enough to clear the cutter.
Stock Prep & Setup Helpful Hint: When setting up jig, use our Brass Set-up Bars to ensure proper spacing. (see www.EagleAmerica.com)
Determine the overall size of the box you choose to build taking into consideration the interlocking corners plus a slight amount for trimming. Prepare the material accordingly. Make some test cuts in wood of the same thickness to confirm the height setting and that the “finger” width is equal to the “notch” width. Adjust as necessary to get a perfect fit. Label the corners as shown in Figure F, then cut all four corners in sequence. Start by positioning one workpiece against the index pin and cutting a slot. Clamping your board to your jig is advisable. Position the slot that was just cut over the index pin and cut another slot. Repeat until you reach the end of the first workpiece (see Figure G). If the first piece ends with a pin, use it as a spacer to begin cutting slots in the mating piece. (see 2P 1P Figure H) 1T
PINS
2T
After gluing your box together, sand or finish with a flush trim bit to get the perfect joint. (See www.EagleAmerica.com for a full selection of flush trim bits)
Figure F TAILS
TAILS
( mark wood to designate inside of drawer )
4T
Figure E
3T
PINS
4P
Helpful Hint: Additional face plates can be purchased separately. (see www.EagleAmerica.com)
3P
Special Note: Wo r k i n g d i rection may b e re v e r s e d d e p e n d i n g o n the location of your miter slot.
Figure G
Figure H
Saw Blade Index Pin
Saw Blade Wood
Index Pin
PIECE #1
Working Direction
Helpful Hint: Cut all fingers slightly longer then necessary, this will allow for sanding a perfectly smooth surface. WH 0502 03 (Page 2 of 2)
Wood
PIECE #2
Working Direction
Helpful Hint: If the first piece ends with a pin, use it as a spacer to begin cutting slots in the mating piece.
