ProBox Install title

These are some tips and tricks that we have learnt over the years that might be useful when using the ProBox Fin System.

• When starting to route a box hole with the Ryobi panel router, to avoid the router grabbing or kicking and to prevent cutting the jig, use the router like a plunge router. Place the woodworkers base on the router and then set the half-circle of the base down on the jig/board, then with both hands on the handles, slowly allow the bit to rotate down into the board. This technique gives you a lot more control over the router, when compared to trying to drop the router down free hand. If you are using the Trend router this problem is solved by the fact that it is a plunge router and therefore inherently more secure.

• Don’t store your jigs in acetone after they have been used. Acetone will not damage the jig, but it is not necessary to completely clean them very often. Leave the spray adhesive on the jig after it has been used. If it is placed in acetone then the adhesive will need to be applied to the jig every time. Clean off any resin from the inside edge of the jig by twisting the jig, or by using your thumb, fingernail or knife blade to remove any pieces of resin on the jig. Lightly add more spray adhesive before the next use, this saves on clean up time and adhesive.

• For resin reinforcement, cut some 24oz woven roving cloth into 18” squares, then pull out the individual strands, one strand will do one box. You can also get 2 yards of woven roving, then cut it in half and pull out 36” long strands that can then be cut in half to achieve the 18” length needed to wrap a single box.

• When topping off the resin, be sure to pour between the screws first, this helps the resin flow underneath the large tabs. Then pour from the screws out towards the ends of the box, and then from there on towards the single tab on the rail side of the box. Make sure to add enough resin to completely fill the area between the resin dam

and the jig as the resin will soak into the foam a little and settle down. Not enough resin and it can settle down below the level of the glass, leaving a dip around the box.

• Clean the adhesive off the boards before sanding, as this saves sand paper and minimizes the chances of over sanding around the boxes as the tendency is to chase the adhesive gum around the board. A very light coat of WD40 can be used, but any adhesive remover will work as well. Use just enough to release the adhesive, then use a razor blade and cloth to remove the adhesive.

• For a slick shiny finish, after sanding, spray a light coat of clear acrylic on the boxes. A simple mask can be made to prevent over spray from getting onto the rest of the board. This is a little extra work but it looks really clean.

• When routing the center box on a board with a large stringer, it is wise to make shallower passes during the routing process to prevent the router from catching. One trick if you don’t want to be adjusting the depth of the router bit for these cuts, stack two additional jigs on top of the base jig, holding them down with masking tape. Then do the routing of the stringer, then remove one jig and repeat the process until the routing is completed. If you are using the Trend plunge router just make shallower cuts by not plunging all of the way down. Or plunge down through the stringer like a drill, then cleanup horizontally with the router.