Cut Cauls when Cutting Box Joints

When cutting box joints on the tablesaw or router table, I attach a scrap piece of Baltic-birch plywood to the back of the workpiece with double-stick tape. After the joint is cut, I remove the plywood backing and turn it into a caul by paring a little off the inside corner of each pin with a chisel.

This keeps the pins from interfering with the joint assembly and reduces problems with glue squeezeout. I give the caul a quick spray of shellac and attach it to the workpiece with double-stick tape, lining up the fingers. Two of these, one at each corner, ensure a tight joint.

Illustration: Jim Richey

Fine Woodworking Recommended Products

Freud Super Dado Saw Blade Set 8" x 5/8" Bore

Leaves a dado with a flat bottom and even performs excellent on plywood and melamine.

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Suizan Japanese Pull Saw

A versatile saw that can be used for anything from kumiko to dovetails. Mike Pekovich recommends them as a woodworker's first handsaw.

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MicroJig Matchfit dovetail clamps

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