I want to make a box joint jig for my table saw and have the 'squares' if you will, a quarter inch. I found a very simple and nice design for my table saw to do this easily. But it showed that you need to have a dado blade in for it to work. I can not do this and wanted to know if there was a design alternative. Otherwise I do have a router table and that would be fine of course too. But there is also a Problem I see that will be in affect. There is only one track. Not two (I have basic equipment, only 16.5) and I think that would not be stable enough for that accurate cut. What design would be recommended? I want to do table saw but can only have one blade in, unless there is a way to do it with a router table with one track. I will be getting a band saw soon but that would take to long and that can be inaccurate...
It's possible using a relatively complex screw advance box joint jig. It's difficult to explain, but there's a great video demonstrating it here.
Basically, you move the workpiece incrementally to make multiple, somewhat precisely spaced cuts for each finger.
Note that you'll want a square cutting table saw blade.
Box joint jigs generally count on being able to cut the slot in a single pass. If you want a 1/4 inch cut, that means you need a 1/4 inch thick cut, which is why a dado blade is used.
Theoretically there could be a jig which registered off the two sides of the cut and let you take multiple passes with a normal blade, but that would be a rather finicky design, I think.
If you can't use a dado blade for whatever reason, another approach would be a finger-joint jig that runs on your router table, using a quarter inch straight bit to make the cut.