Q: Can you please explain to me how to make finger joints with a router?

A: Leland Stone, DEWALT Expert provides the answer to this question. Finger joints are VERY easy to make with a router -- the key, as with any operation, is an accurate set-up. Let's say you're making 1/2" fingers in 3/4" stock: Dado a fence that's 1/2" wide and 3/4" tall into a piece of plywood. Parallel to this fence dado a miter gauge slot. Next to the fence, drill a one-inch diameter hole. This board is now an auxillary top for your router table, and it's placed with the hole centered over the router collet. WITH THE POWER DISCONNECTED chuck a half-inch straight bit in the collet, raising the router until the end of the bit is 3/4" above the surface of the auxillary table. Adjust the auxillary table until the fence is 1/2" from the cutter, clamp the auxillary table in place, and run trial cuts to check your set-up; use the miter gauge from your table saw, which rides in the slot and guides the workpiece through the cut. When the set-up is perfect, run half of your box pieces, using a very sharp bit or a backer board to prevent tear-out on the rear of the joint. As each notch is cut, move it onto the fence -- this automatically ensures consistent spacing. The other half of the box pieces are run exactly the same way, EXCEPT that the fence is adjusted (by moving or by adding a shim for the initial cut) so there's zero clearance between it and the cutter. You have to alternate "fingers" so there's a "finger-gap-finger-gap...." on one board and "gap-finger-gap-finger...." on the other board. Lace your own fingers together in front of you and you'll get the idea...plus the derivation of the joint's name! With a little bit of tinkering, you are sure to figure out a way of building a reusable and adjustable jig for this job.

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