Small(ish) Precise Cuts - Which Tool?

[ddr90036]

Hi All,

I'm not only new to Festool, but new to woodworking.  I want to make large-ish(2"?) box joints (as shown in linked photo) but not sure which tool to use.  I just got a 1400 Router, the 55 Track Saw and the Carvex.  I really don't know where to begin so any and all help would be seriously appreciated.  Link below.

Thanks!

ddr

 

[Holmz]

Look at Incra jigs.
(Usually people use a table saw)

one can also hand cut with a dovetail saw, or a pull saw and use a chisel.

 

[tjbnwi]

Any of the tools will work.

1400--probably the easiest to accomplish the cut. Make a jig/template use a bearing guided housing, square up the corners with Carxex of by hand. You could remove most of the material with the Carvex prior to using the 1400.

Carvex--carefully follow the layout lines.

TS 55---clamp the sides together, use scrape to build up the sides, set the depth of TS, make a lot of cuts to clear out the material.

Tom

 

[bkharman]

My vote is to make a jig (if you have a bearing template bit) and use the jigsaw to take out the mass of it. Then use the template clamped on to trim up everything but the corners and bust out a trusty chisel. If you don't have a chisel, buy a few decent ones as they are invaluable. You can use other tools to do the cuts but a chisel will "finish" it for you.

Look forward to your progress on this. Neat style!

Cheers. Bryan.

Sent from my iPhone using Tapatalk

 

[ddr90036]

Thanks for all of the suggestions.  I like the idea of the jigsaw and router combination.  Are the bearing template bits self-explanatory?  I've never used one before.  Also, so you suggest just a simple ply as the template?

Thanks again!

 

[nclemmons]

Thanks for all of the suggestions.  I like the idea of the jigsaw and router combination.  Are the bearing template bits self-explanatory?  I've never used one before.  Also, so you suggest just a simple ply as the template?

Thanks again!

Bearing guided bits will have either a bearing at the top or one at the bottom.  For this application, I think you will be best to use one with a bearing at the top.  You can use any number of materials for a template.  I personally prefer 1/4" masonite - inexpensive and it has a hard edge with no voids.  You can use plywood but you'll want something with no voids so that you get an accurately guided cut.

Use extra care in making your template as the bearing following the template will just mirror any bad form into the final piece!  (Don't ask me how I know this!)  I'd suggest either clamps or perhaps double stick tape to hold the template in place to cut the fingers.  As Tom suggested you could get close (within 1/8" or so) with the carvex and then use the template and a bearing guided bit in your router to finish things up.  You will need to accommodate cleaning out of the corners where the rounded bit will not make a square corner.

I'd suggest you look for a 1/2" bearing guided router bit.  You'll need a length of cut to accommodate the 3/4" material and a bearing to run along the masonite or similar template.  You'll need a set of sharp chisels to clean out the corners, but practicing on some scrap pieces should give you good confidence.

Good luck, welcome to the FOG and please share progress pics!

neil

 

[tjbnwi]

I prefer plywood or HDPE for templates. I find masonite edges deform to easily.

There's always the MFS.... [wink] [sad]

Tom

 

[Daver]

Thanks for all of the suggestions.  I like the idea of the jigsaw and router combination.  Are the bearing template bits self-explanatory?  I've never used one before.  Also, so you suggest just a simple ply as the template?

Thanks again!

Everyone has their favorite, but for me, a book that answered a lot of questions was Router Joinery by Gary Rogowski from Taunton Press. Good luck with your project and  [welcome] welcome to the FOG!

Dave

 

[ddr90036]

Tom - When you mentioned the MFS, I recalled someone also telling me about that.  Am I right in that I could accomplish what I'm talking about in one-step with the MFS 400 (vs. having to chisel)?  (BTW - The MFS 700 is either nowhere to be found or has an outstanding markup on Amazon).  Take a look at this video to see what I'm talking about mimicking for my joints with squared corners:

 

[Holmz]

...
Everyone has their favorite, but for me, a book that answered a lot of questions was Router Joinery by Gary Rogowski from Taunton Press. Good luck with your project and  [welcome] welcome to the FOG!

Dave

^That^ make sense.
You will need some way to hold the parts to route them.
This is usually some form of a vice, and some form of template on the top to ride the router on.

Usually it is:
1) Pull saws or dovetail saws, and chisels (which means a good bench).
2) Tablesaw and something like an Incra or other mechanism (which means a table saw is needed).
3) Routing, which could be a router table with an Incra type fence system.

Building your own templates would be some amount of work.

 

[tjbnwi]

Tom - When you mentioned the MFS, I recalled someone also telling me about that.  Am I right in that I could accomplish what I'm talking about in one-step with the MFS 400 (vs. having to chisel)?  (BTW - The MFS 700 is either nowhere to be found or has an outstanding markup on Amazon).  Take a look at this video to see what I'm talking about mimicking for my joints with squared corners:

The MFS has been discontinued in North America. This was the reason for the emoji's at the end of my statement.

I have 1/8" bits, you will not get a square corner. The corner radius will be 1/16"

If you do choose to remove the waste as one piece you must secure it some how. I use 3M ATG or 3M Mounting tape. These will keep the slug from shifting and jamming into the bit.

Pictures of a simple jig to route in a hinge.
View attachment 1View attachment 2View attachment 3

ATG, used it to hold the piece of solid surface.View attachment 4View attachment 5View attachment 6

Tom

 

[ddr90036]

The MFS 400 is still available through some dealers and I can buy the extensions still.  I guess I should try a few methods and see which is best?

 

[tjbnwi]

The MFS 400 is still available through some dealers and I can buy the extensions still.  I guess I should try a few methods and see which is best?

If this is the case, grab one. Most here have reported not being able to get the MFS or individual pieces.

Tom

 

[Holmz]

...
Pictures of a simple jig to route in a hinge.
View attachment 1View attachment 2View attachment 3
...

I have one of those, but I put a vertical peice extending down from the bottom in order to clamp it to the door... (For the frame I take vert piece off, and screw it down under where the jam part goes... just like you are doing)

It pretty much could be the same as a single section of the box joint template.

 

[suds]

I would suggest the Incra LS system. Especially if you plan on doing more if this type if work. You won't be disappointed.

 

[ddr90036]

I would suggest the Incra LS system. Especially if you plan on doing more if this type if work. You won't be disappointed.

Thanks Suds.  Will I still be looking at a 2-step process or is the Incra system magical in some way?  Again, I'm a beginner so just trying to figure out before I plunge in further.

 

[Holmz]

I would suggest the Incra LS system. Especially if you plan on doing more if this type if work. You won't be disappointed.

Thanks Suds.  Will I still be looking at a 2-step process or is the Incra system magical in some way?  Again, I'm a beginner so just trying to figure out before I plunge in further.

Pretty much yes, but it is you that needs to figure out a method. There are a few, including 'by hand'.

Personally I would start with the book that was mentioned earlier.
Later with the book in hand, see if there are some youtube examples to clear things up.

Then ask follow up questions after you conceptually are following the various methods.

 

[suds]

There is a series of 3 You Tube videos on the Incra LS making Dovetails that really shows the setup and use of the system.  The guy doing the demo makes it look so easy.

 

[bkharman]

There is a series of 3 You Tube videos on the Incra LS making Dovetails that really shows the setup and use of the system.  The guy doing the demo makes it look so easy.

"That guy" is a big reason I have the setup I have!!

I caught on pretty quick that he has at least three plates with three router setups. That way he can go from task to task very easy and quickly.

Even without that, the Incra fence is something I would never leave out of my shop. Love it!

Cheers. Bryan.

Sent from my iPhone using Tapatalk

 

[nclemmons]

In looking at their site, the Incra LS seems to require the router to be under a table.  Given the size of that piece, you are looking at a need to move a piece vertically through the bit that is probably 40+ inches long and maybe 18" wide.  And you have to repeat it accurately for each piece of each joint.  Consistently.  I personally would not want to do that on a router table trying to hold the piece upright and square. 

A bearing-guided bit and a template let you use the router above the work.  I have both the 400 and 700 MFS templates, but I would not use them for this particular application.  I'd much prefer a custom cut template that could be used to guide the router over the end of the work rather than trying to move a large piece over the bit of a router.

neil