The Ultimate Squaring Jig

[@ehRalph]

I made a similar box a couple years ago when I had to lengthen a 4x4 porch rail post that was already set in concrete. The post was very visible and I needed a near perfect joint. I made the box a good fit but slightly larger than the 4x4 using perfect square and flat 1 1/4” lumber. I only used deck screws to hold butt joints together on 3 sides making a U shape. The last side only had 2 screws near the bottom of the channel so it would flip flop and the jig could be clamped to grab the post. First, I set the jig low and used it as a guide for a circular saw to nearly square cut the post on 4 sides. Then checked for square and moved the jig up to finish the surface with a router. It worked! That was half the problem solved. I had already made a perfect grain matching square patch piece in the shop and tested my cutting method on scrap. The patch was counter bored and drilled for 6” screws on a drill press. The piece was carefully attached using the 4 long screws and glue. Next day pull the screws and re-drill the screw holes for ½” wood dowels. Anyway….. the U channel and flipping side worked fine for pressure treated lumber. Not sure how well it would do with furniture grade builds.

[@EpicWoodworking]

Awesome, that’s a great application!! 👍

[@slavkopraznik856]

What about putting two screws on two sides, 2 each side one over another, so you don't need clamps?

[@1deerndingo]

I think that's a great idea. I'll be off-setting the holes for the clamps. And I'll be placing spacers on the inside of the box so the job isn't touching the inside walls of the box. I can then use my plane to square the top because I don't like the noise and dust that goes with the electrickery router.

[@EpicWoodworking]

Nice ideas, thank you! 👍😎

[@keithrayeski6417]

Okay, I’m gonna be honest….i was just about to “X” out when you said, if it doesn’t work, you’ve got a good start on a bird house!!🤣🤣 Your off the cuff wit and humor interacting with your camera lady, told me I gotta see more of your stuff! Nice way to think outside the “box”!😉🤣

[@EpicWoodworking]

Thank you so much, glad to have you watching! 👍😎

[@lewislevine8095]

That's a great jig. I definitely want to make one. I never realized that cutting end grain with a router was easier on the bit than side grain. Rabbit is an old english word that comes from rebate, as in a recessed cut. Thanks, I'll keep watching.

[@EpicWoodworking]

Ahhh, thanks for solving that mystery for me…from the word rebate, makes perfect sense now!! 👍😎

[@drewhession-kunz425]

Don't even need the birdhouse holes - just clamp at the bottom. The box is big enough that the fixed head end of the clamp can get shoved up from the bottom, and can fit inside between box and post tightening the clamp against the outside of the box. Brilliant idea - will definitely build one

[@EpicWoodworking]

Oh yeah, why didn’t I think of that?! 😎👍

[@williammagee7514]

Thx for the GREAT and simple approach, gets the job done!

[@EpicWoodworking]

Thanks as always! 👍😎

[@jimweisgram9185]

Tom knows all about what i am going to say ... You can do this square end with a crosscut panel saw. A little practice is all you need. Watching a youtube about how to accurately use a handsaw might help you visualize this. First you mark your square line all around the beam. Then cut to the line. This assumes all 4 sides are true. But then, do does Tom's jig. How do you cut a square cut? When you start the first cut, on the top face of the board, look at the saw blade and make sure sure the reflection of the saw plate lines up with your board. When you saw, make sure your body is such that your shoulder, arm, elbow, and hand are linded up and move like a piston. This means right handers step a little to the rihht, left handerd to the keft. Grip the saw handle somewhat softly. Gripping tightly tends yo cause your hand to twist. When you cut, use the whole blade, and let the weight of the blade do the work. By the way, it can help to use paste wax on your blade, apply it, wait a few minutes, and buff the haze off with a clean cloth or paper towel. Cut your first kerf about an inch down. Watch that the reflection shows the blade stays lined up. Then while sawing start tilting your blade down and work down the face of the board. Be sure to cut to the line here, too. Once about half of that face kerf is about an inch deep, you can rotate the beam and saw so that you get a 1 inch kerf in that face. Keep going all the way around the beam. If you do this correctly, your kerf will be right on the pencil line all the way around. What is kewl here, your saw will now follow the kerf and stay in the cut quite accurately. I'll add that as you get to a corner of the board, if you want, go ahead and saw down deeper on the corner. If you have many boards, Tom's jig will be faster. But if you have one or two, hand sawing is faster. Plus you will have picked up a skill that you can use the rest of your life.

[@andrewbrown8148]

Cool demo, Tom~! I've had this situation a few times and it didn't occur to me to use a router in this fashion. Great idea~! I think I have an upcoming project where this will come in very handy. Thanks for sharing it~!

[@EpicWoodworking]

My pleasure, Glad it was helpful! 👍

[@edu_carceller]

Great idea and as usual, a lot of fun to watch your videos. It occurred to me, if the post is not too long, you could measure the portion that rises above the bench and vise to be 1/2" short of the jig's height. Then the jig can rest on the bench and vise while you clamp it. You could also clamp a scrap of wood to the post at the right distance from the top and rest the jig on it, clamp the jig and remove the scrap of wood.

[@kennyg6482]

I made the same jig several years ago to cut 6x6's to length and used it as a guide for a circular saw. Made good straight cuts and smooth.

[@normancarnahan4893]

Excellent demonstration, Tom!

[@EpicWoodworking]

Thanks Norm! 😎

[@daveengstrom9250]

That's a pretty slick trick, sonny.

[@EpicWoodworking]

Thanks!! 👍😎

[@ShrednESP]

Looking forward to the workbench build.

[@EpicWoodworking]

Yes, me too, thanks! 😎

[@henrysara7716]

Indeed, very helpful jig.

[@richardpatsel9628]

Simple jig, great video. Love the way you share and teach.😎

[@EpicWoodworking]

Thank you Richard, that means a lot to me! 👍😎

[@sateeshum394]

We used those boxes for long time to make cross profile reference routing on square posts . Especially stair rails ..clamping is good idea for sure ..

[@michaelnorman5640]

Mabey Florida it’s always sunny most of the time lol thanks for sharing another great video! Mabey Jacksonville

[@EpicWoodworking]

Thank you, could use me some more sun this time of year around here! 😎

[@misiacs3346]

Great ideas! Thanks!

[@Smedleydog1]

Line the inside of the box with a quarter or half inch ply about one half inch lower than the outside box to create a slight step. That way you won't have to cut into the box to get the corners.

[@user-ce7on9ts9t]

très bon outil , bravo et merci

[@PaganWizard]

I love this jig!!!!! To make clamping a bit easier, maybe you could try using opposing wedges to lock the box in place.

[@EpicWoodworking]

Yes, great idea! That would definitely make it faster to lock in once you got the wedges sized properly.👍😎

[@grandmajosephine383]

I've used a slight variation of this to square up the top a large stump for an anvil.

[@TerryPullen]

Great jig. An angled jig would work for angles other than 90.

[@EpicWoodworking]

Yes, I don’t see why not, great idea! 👍

[@walterrider9600]

thank you

[@johndeggendorf7826]

Simple genius. ✊🍷🎩🎩🎩🙏

[@nore8141]

I think making a wooden peg/ screw and insert it in to replace the clamps. Overall it’s a great idea 💡, thanks 🙏 ❤

[@sfwoodwork2992]

it should have an inner sleeve that stops short of the edge so the router bit stays clear of the box.

[@EpicWoodworking]

Yes, I was thinking that too, but don’t mind skimming the inside if it’s a once or twice jig. But you are right about that, thanks! 👍😎

[@user-bk2kg9qz1t]

Good idea and good jig but you can cut it with tablsaw

[@EpicWoodworking]

Yes, you are right, but this was for special situations where the material is too large or it’s not possible for some reason. Hope that makes sense 👍

[@Shadowhawk27]

I would personally add a 1/4 inch solid wood piece on the inside otherwise you will chew the top of you box with running the router bit right to the edge of your post, and adding 2x t nuts on 2 sides of the box, threaded rod with pads on the end to stop marring of the wood your trying to square up

[@RYwoodview]

Very nice jig for absolutely squaring large stock. But when does stock that size have to be so perfectly square?

[@EpicWoodworking]

Haha, the million dollar question 🤔. Check out some of the other responses and you may see some applications…especially the one where the post was already set in concrete and needed extending. Thanks for watching! 👍😎

[@normancarnahan4893]

The, again, why not do the best? It’s the Epic way! 😊

[@RYwoodview]

@@normancarnahan4893 Very true!

[@patricksalter5412]

I made a similar jig for cutting 4x4 fence posts. It would allow to use a skilsaw to make all the fence posts the same elevation.

[@37south47]

Having trouble getting something square and true? Well let’s start by building a box jig that’s square and true lol

[@aaronquick]

Why don’t you add a rabbit around the inside top edge, maybe 3/4” 25:58 or 1” deep, so as to give your router bit room to cut the entire top of post, since it’s “a lot more effort” for router bit to cut into the long grain edge of wood. Also, you could install threaded inserts into two sides of jig and include threaded tightening knobs to clamp the post in place for routing.

[@EpicWoodworking]

Yes, great idea Aaron! It’s always quick and dirty when initially working a concept, and refinements like that are where the improvements by experience come in over time. Then you also have to decide how much you’re going to use something like this and if it’s worth making much better. Thanks for the ideas! 👍😎

[@JohnColgan.]

18:40 So it doesn't really need 4 sides, 2 sides works just as well

[@kamleo1685]

The main requirement is that the top of the sides of the jig be in the same plane. A parallelogram would also work.

[@b0y9ggz]

And the dad jokes continue!! Yeah!

[@user-ce7on9ts9t]

Pourquoi ne pas utiliser une fraise avec roulement cela éviterai de couper le gabarit .

[@jjw2909]

Put the 4x4 in the enter and add 4 pieces of wood and you won’t cut into the box

[@EpicWoodworking]

Yes, great idea! Check out the other comments, a number of variations on this approach 👍😎

[@su-mu]

23:08

[@tonywawryka7493]

All that too square ends of wood

[@HappyRecords-un2hs]

99

[@thomaspogorzelski4299]

Sorry but that is the silliest project I ever seen you do

[@EpicWoodworking]

Yes, I think I would have to agree. I was working on something else all day and this was a little side jig I messed with. I actually said to myself before the camera started, “this is going to bomb”, and two days later it’s got 50K views…I don’t understand 🤔😎

[@thomaspogorzelski4299]

@@EpicWoodworking I guess you can never tell what people need to see.....

[@EpicWoodworking]

I was surprised by the appreciation in the comments and the practical applications people drew from that apparently simple and/or silly project. There is one who needed to accurately square the top end of a post that was already cemented into the ground, so to him it was seen as quite a valuable technique. So I agree, you never know 😎

[@andypalmer5145]

The ultimate squaring jig, 26 minutes long. Kept waiting and watching and waiting. Unfortunately you got me with you "clickbait" title. Thought I might see something useful. Thanks

[@EpicWoodworking]

Sorry Andy, I wasn’t trying to fool you or waste your time. This is recorded live as part of our Thursday night livestream, and as I said in the video I am working out this jig for a specific purpose, the upcoming workbench course. I do have lots of other content involved with squaring things up that are more conventional and you might find useful, like this one: kzbin.info/www/bejne/aJ2YdXmieLd6gdEsi=wMmyWhFwOj2__vLU

[@davidlowery245]

I like the jig, but just wondering. Could you cut a shallow rabbet around the inside top of the box maybe an inch deep before putting the box together so you wouldn’t be cutting into the side of the box?

[@dave_ecclectic]

Thats why you jump to the end of vids that don't show it at the beginning. After all, do you actually need to watch someone build something you can easily build or do you only need the idea.

[@EpicWoodworking]

@@davidlowery245 Sure Dave, thats a good variation on the jig. I also thought of adding spacer panels to the inside of the box so you could first make a clean perimeter trim cut before cleaning g up the middle. I don’t mind hitting the side walls of the jig a little given it’s fast and easy to make and it doesn’t really hurt the jig’s effectiveness, but I agree it would be a little cleaner 😎👍

[@SamStGeorge]

I used thd dislike because you talk tooooooo much. We are not hanging out. If you have something to say, say it straightforward. I am sorry

[@EpicWoodworking]

I’m always trying to put my best out there and say it as clearly as I can. These are recorded as a livestream every Thursday night, with no script, so they are more conversational. And you’re right, I do talk more than I would for an edited type video. But you don’t have to be sorry, that’s the way you feel, I don’t expect to please everyone. 👍