Solving Design Problems

As I worked on the design, I began to think about what I didn't like about the dovetail jigs I've used before. The main problem I've had with other jigs is the system for holding the workpieces tight to the jig. (If the wood shifts even slightly, the joint won't fit together correctly.) On most jigs the workpieces are held with metal bars. The bars are tightened down with wing nuts or knobs. But you just can't tighten them enough to keep the wood from moving around as you rout. And, on some of...

Hope Chest Hardware

Woodsmith is offering two hardware kits for the hope chest. One has carved cherry pulls, the other solid brass pulls. kit 58a. Hope Chest Kit Wood Pulls 34.95 includes 1 pair Solid Cherry Hardwood Pulls, 2 x 5 , see photo below. These pulls are hand carved in the Amana Colonies in Iowa. 1 pair Solid Brass Hinges, IV2 long, 2 open width, with screws. 1 pair Lid Supports, one right-hand, one left-hand, brass plated, with brass screws. 1 Chest Lock, key, strike plate, and keyhole escutcheon. 1...

Front And Back

Next, work can begin on the front B and back C panels. Again, these panels are edge-glued from 4 4 stock, and planed to a uniform thickness. cut to size. The length of both panels is the same 35Vs , but the width varies ' dadoes, vis deep on inside face of both end panels edge glue two end panels from 4 4 stock ll l il ll router table fence since a drawer fits under the front panel B . First, cut the back panel C to a width of 17, see Fig. 3. Next, cut the front panel B 6Vh less in width than...

Hope Chest

You can order the hardware for the hope chest from Woodsmith as a kit see box below , or from the following source the woodworkers' store, 21801 Industrial Boulevard, Rogers, MN 55374 612-428-2199 Catalog 2.00. Note The design of some of this hardware is slightly different from that in the photos and in the Woodsmith kit. Desk Butt Hinges 1 pair , solid brass, IV2 long x 2 wide, Order No. D1238. Lid Supports 1 pair , brass plated, 6V2 long, Order No. D1205. Chest Lock, includes key and...

Final Assembly

After the stop blocks are made, you can assemble all the pieces, see Fig. 19. To start, screw the stop blocks down with sheet metal screws into the pre-drilled holes so the shoulder of each stop block is 6Vs from the center of the jig. This may have to be adjusted later, see page 20. Then add the springs, bars, and cams. And finally, the template is held tightly to the studs with washers and wing nuts. DRILL A SERIES OF y,6 HOLES TO CREATE SLOT DRILL A SERIES OF y,6 HOLES TO CREATE SLOT SCREW...

Fitting Dovetail Joints

How tight should a dovetail joint be A good fit shouldn't be so loose that you can push the pieces together with your hands. It should take some light tapping to get them together. PLACE HARDWOOD BLOCK OVER ENTIRE JOINT WHEN TAPPING PIECES TOGETHER PLACE HARDWOOD BLOCK OVER ENTIRE JOINT WHEN TAPPING PIECES TOGETHER However, even with light tapping, it's best to apply even pressure across the whole joint to prevent the pins from splitting out. I place a block of hardwood over all the pins on the...

Pressure Bars And Cams

Build Your Own Dovetail Jig

When all four of the threaded inserts were screwed in place, I began work on the pressure bars and cams. These pieces are cut from three blanks that measure 2 wide and 17 long, see Fig. 3. Note These blanks can be built up from two pieces of 4 4 stock or one piece of 8 4 stock just so they're about 1W to 1 thick. pressure bars. To make the two pressure bars C , cut two of the blanks square 1 x 1 and to a finished length of 15. Then drill -dia. holes 1 from each end to accept the eye bolts, see...

Drawers

Clamp Pad For Dovetails

After the molding strips are in place, the only thing left is to make the drawers. cut the pieces. Begin by cutting the drawer fronts U, Y, CC from 4 4 stock so they're Va less in both width and length than the openings in the cabinet. This is W less in length than the distance between the drawer guides L, N . You can cut them slightly longer and sand them after assembly, refer to page 23. Next, cut the drawer backs V, Z, DD from Vi' stock the same size as the fronts. Then cut the drawer sides...

The Base Frame

Once the case was complete, I began work on the base. The base consists of a scroll-cut kickboard frame with a molding strip glued on top of it, refer to Fig. 8. kickboard frame. To make the kickboard frame, cut the front back pieces G , and two sides H from 4 4 stock to a width of 4 , see Fig. 6. Then miter both ends of the front back pieces so the length of each piece from long point to long point is I1 longer than the width of the assembled case. Next miter the side pieces so they're IVz...

Routing The Pieces

To prevent chipout, start by making a light scoring 3 Next, loosen the front pressure bar and reposition the drawer side so the top end is perfectly level with the top of the drawer front. 6 Mount Vie guide bushing onto the router. Then raise bit Vt from router base as a starting point. It may have to be adjusted slightly later. pass from right to left, see Step 7. Then gently move the router in and out of the fingers, moving from left to right, see Step 8. You...

Woodsmith

Editor Design Director Managing Editor Assistant Editor Project Designer Technical Illustrators Computer Operations Administrative Assts. David Kreyling Cary Christensen Rod Stoakes Chris Glowacki Sandy Baum, Mgr. Jackie Stroud Pat Koob Lisa Thompson WOODSMITH ISSN 0164-4114 is published bimonthly February, April, June, August, October, December by Woodsmith Publishing Co., 2200 Grand Ave., Des Moines, IA 50312. Woodsmith is a registered trademark of Copyright 1988 by Woodsmith Publishing...

Sanding The Joint Smooth

The perfect dovetail joint should fit together tight, flush, and there shouldn't be a lot of excess glue squeeze-out. That's the ideal. But in reality, there may be some finishing work to do on a dovetail joint after assembly. In fact, since I know the joint won't be perfect, I plan the fit of the joint so it has to be sanded down exactly smooth. The only question here is Should the joint be cut so the pins stick up a little from the surface, or so the ends of the sockets stick up a little...

Gluing Dovetail Joints

How much glue should be applied to a dovetail joint And where should you put it on the pins or in the sockets tight joint. If the joint fits tightly, you don't need much glue. I usually squirt one dot of yellow glue on the back side of each pin. Then when the pin seats in the socket, the glue sort of squishes its way around the pin and the socket. loose joint. If the joint is a little loose you may need to brush the glue all the way around the pins and also in the sockets. I usually use a small...

Dovetails StepByStep

Drawer Front Jig

Cutting tight dovetail joints with a router and template is easy but it requires a little planning ahead. It's best to plan the dimensions of the cabinet opening ahead of time to accommodate drawers that are joined with router-cut dovetails. That is, the width height of the drawer front has to be a multiple of . This produces a joint that's symmetrical both on the top and bottom edges, see the photo. Once the width of the drawer fronts is determined, cut the drawer's side and back pieces to the...