DIY Biscuit Joiner XL

When a standard biscuit joint doesn't cut it, you need the Biscuit Joiner XL. The strongest biscuit joint in the world.

The good old biscuit joiner. Great for joining up boards, panel glueup, and more. But sometimes little biscuits just aren’t strong enough. I’ve decided to take matters into my own hands, by making the biscuit jointer XL.

P.S. If you haven't caught on yet; yes, this is an April Fool's day joke :P

All you need for this project is a plunge cut saw, and some plywood. I’ve got this little scrap piece, that’s the perfect size.

The rest will be cut from a sheet of 3/4-inch baltic birch plywood.

There was a little bump in the sheet of plywood I’m using.

Just going to knock it down with a block plane.

Now I’ll just surface everything for this project to 220 grit.

A hand sanding block is used on the edges.

I set a flag stop at the mitre saw and batch out all the cuts.

The part which lays on the stock will be beveled. This is how you make a 45° bevel cut when you don’t have a table saw.

This piece will have holes drilled to accept the rods on the saw.

Okay, I attached that to the saw, but small problem: there’s a little bump here. Shouldn’t have drilled those holes right in the center.

Easy fix for a router with a flush trim cutter.

Now I’ll drill and tap two more holes so machine screws can secure this part to the saw.

Just in case this project isn't controversial enough, I’ll use a domino joiner to join these parts up.

Dry fit is good.

Now the more relaxing part of this project… the glue up!

Clampy, clamp, clamp.

Hmm, maybe one more clamp.

Just going to cut some reinforcement triangles here, for the edges.

Some more glue, and I’ll take these in with a pin nailer so they stay in place.

Scraping off the squeeze-out.

The final piece will be this knob, so it’s easier to hold the tool against a workpiece.

So more or less, this is how it’s going to work, and the height is adjustable.

I set the height with setup blocks. Great!

Now here’s big two-by-six I need to join.

Finally, I present to you this Biscuit Joiner XL.

I suppose this part is pretty self-explanatory, although I’ll probably go back and make these slots a little bit wider.

Yeah, I’ll make a few more cuts until the slots are 1/4-inch thick. Readjusting the position.

I repeat this until all excess material is clear.

Now I need my biscuits. I’ll trace out the blade diameter onto 1/4-inch plywood, and then cut it out. The blade packaging came in real handy for this!

There you go: strongest biscuit joint in the world.

HIGH FIVE for reading!

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