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Making boxes with dovetailed splines without a Kehoe jig #1: Dovetail spline jig and splines

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Blog entry by Toolz posted 1535 days ago 4736 reads 3 times favorited 9 comments Add to Favorites Watch
no previous part Part 1 of Making boxes with dovetailed splines without a Kehoe jig series Part 2: Box progress today »

The first thing I did was to make a simple jig for cutting the dovetail in the mitered box sides to receive the splines
Dovetail Spline Jig 1

Dovetail Spline Jig 2

Dovetail Spline Jig bottom

I tried cutting the splines on my router table with a 1/2” 14 degree dovetail bit I used to cut the dovetail slots in the box side. Too many problems for me doing this plus it was a scary experience even using a “small parts jig” to hold the pieces. After re-reading the responses to my questions posted here yesterday http://lumberjocks.com/topics/17947

I set the blade on my table saw to 14 degrees, cut off one slice, flipped the board so what was the top was now the bottom, marked 1/2” adjusted the fence and cut a spline 1/2” wide. I tested it and wonder of wonders it fit! I then set up my Rockler thin stock ripping guide to make repeatable cuts
Rockler thin rip jig
Now all I had to do was flip the stock, slide it up to the ripping guide and readjust the fence and lock it down.

Here are photos of dry fitting the splines before cutting them to slightly over long and gluing them in.

Box with splines dry fit

Test fitting splines

Many thans to all who responded to my questions about doing this. I’ll post pics of the completed boxes when they are done.

-- Larry "Work like a Captain but Play like a Pirate!"



9 comments so far

View CharlesNeil's profile

CharlesNeil

1127 posts in 2504 days


#1 posted 1535 days ago

am i mistaken or is the grain in your splines going in the same direction as the grain in the box / if so you want a long grain, not an end grain

View Toolz's profile

Toolz

1003 posts in 2376 days


#2 posted 1535 days ago

Charles, blame it on crappy picture taking. I did cut them so long grain runs the same direction. I took the pictures before I cleaned up the splines a bit.

-- Larry "Work like a Captain but Play like a Pirate!"

View CharlesNeil's profile

CharlesNeil

1127 posts in 2504 days


#3 posted 1534 days ago

got ya… just checking on ya :)

View Dan Lyke's profile

Dan Lyke

1472 posts in 2759 days


#4 posted 1534 days ago

Nice! And well done with the table saw, I’m not sure I’d have trusted it to get that angle right. Now I need to do this with the spline cut on the router table and take pictures of that method, for those of us without tablesaws.

-- Dan Lyke, Petaluma California, http://www.flutterby.net/User:DanLyke

View Toolz's profile

Toolz

1003 posts in 2376 days


#5 posted 1534 days ago

Dan: Looking forward to the pics of your router table method! I used a Wixie digital angle thingie (the square one) zeroed it out on the saw table, raised the blade attached the Wixie and tilted until the Wixie read 14 degree. The Wixie is pretty darn accurate. I learned about here on Lumberjocks.

Charles: you can check on me anytime my friend…. just don’t get too disappointed when I screw things up..I do that a lot. :-)

-- Larry "Work like a Captain but Play like a Pirate!"

View Dan Lyke's profile

Dan Lyke

1472 posts in 2759 days


#6 posted 1534 days ago

Thanks for the heads-up on the Wixie. I’ve been using a framing speed square for bigger angles, not for blade angles, and I got pretty close on the joints for my plate frame where the error was accumulated 12x, but more accuracy for such things is better.

-- Dan Lyke, Petaluma California, http://www.flutterby.net/User:DanLyke

View CharlesNeil's profile

CharlesNeil

1127 posts in 2504 days


#7 posted 1534 days ago

Toolz, he he he me too, the best definition of experience I ever heard is “mistake + mistake+ mistake ” , I got LOTS of experience and continue to gain more on a daily basis :)

View majeagle1's profile

majeagle1

1416 posts in 2130 days


#8 posted 1534 days ago

Great blog, this is something I have been wanting to try on some of my boxes…....
I will remember the wixie as well and maybe try the TS method…..... the router table method can be a little tricky/scary on something that narrow/small.

Can’t wait to see the finished product…......... thanks for sharing your methods !

-- Gene, Majestic Eagle Woodworks, http://majesticeagleww.etsy.com/, http://www.flickr.com/photos/majesticeagle/

View Toolz's profile

Toolz

1003 posts in 2376 days


#9 posted 1534 days ago

Oops, Wixie is misspelled it should be Wixey

-- Larry "Work like a Captain but Play like a Pirate!"

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