This came up in a conversation elsewhere so I thought I would share. Any simple rig will get you through a box or two or three.
[attachment=23638]
I got talked into a box-swap a while back and had to make a batch. I took a break and made a jig that was a little more versatile, quick to use and included a replaceable insert for a ZCI effect on the exit side. I wanted an adjustable stop.
[attachment=23639]
Rabbet for the ZCI insert.
[attachment=23640]
I used a spline to join the beds so I wouldn't have to dodge any metal fasteners.
[attachment=23641]
The spline runs the length of the joint.
[attachment=23642]
The inserts are held with 2 screws. I put them high enough to stay out of the way. This dictated the inserts size to some extent. Whenever I make ZCI's, inserts and other disposable things, I make a bunch even if I am not sure I will need them right away. The setup for things like this is 90% of the effort so just make a batch while you're setup; you'll be much more inclined to use them.
[attachment=23643]
The clamp block is keyed to the slot and uses a cheap Harbor Freight version of a Destaco toggle/push clamp. This lets me un-clamp the box to flip to the next side and re-clamp with a flip of the lever.
[attachment=23644]
[attachment=23645]
[attachment=23646]
And that's about it.
[attachment=23647]
I sized mine based on the boxes I usually make. Include room for the clamp block in your design. I added about 4" to the width of the jig to accommodate the tallest box I thought I might make. Works great for picture frames too.
[attachment=23638]
I got talked into a box-swap a while back and had to make a batch. I took a break and made a jig that was a little more versatile, quick to use and included a replaceable insert for a ZCI effect on the exit side. I wanted an adjustable stop.
[attachment=23639]
Rabbet for the ZCI insert.
[attachment=23640]
I used a spline to join the beds so I wouldn't have to dodge any metal fasteners.
[attachment=23641]
The spline runs the length of the joint.
[attachment=23642]
The inserts are held with 2 screws. I put them high enough to stay out of the way. This dictated the inserts size to some extent. Whenever I make ZCI's, inserts and other disposable things, I make a bunch even if I am not sure I will need them right away. The setup for things like this is 90% of the effort so just make a batch while you're setup; you'll be much more inclined to use them.
[attachment=23643]
The clamp block is keyed to the slot and uses a cheap Harbor Freight version of a Destaco toggle/push clamp. This lets me un-clamp the box to flip to the next side and re-clamp with a flip of the lever.
[attachment=23644]
[attachment=23645]
[attachment=23646]
And that's about it.
[attachment=23647]
I sized mine based on the boxes I usually make. Include room for the clamp block in your design. I added about 4" to the width of the jig to accommodate the tallest box I thought I might make. Works great for picture frames too.
When I was young I sought the wisdom of the ages. Now it seems I've found the wiz-dumb of the age-ed.
