After admiring the double and double-double dovetail joints that are capable with the Incra and other jigs, I started thinking, “Why not try this by hand?” So this box is my first experiment with handcut double dovetails. It took me some time to figure out the joinery process, but once I realized a few things about this type of joint, it seemed do-able. It was quite challenging but also a ton of fun. It also does take some degree of patience and precision…which I’m still working on.
In this blog, I’m focusing on the sides of the box, but here’s a few pictures of the nearly completed box -
Materials.
For this box’s sides I used three types of primary contrasting woods, although there is no real reason to do so. Two contrasting woods would work just as well. The woods I chose are:
Honduras Rosewood – front and back. Quite hard and brittle. Chopping pins was a slow process with many trips back to “Mr. Tormek” to regrind/hone. But it’s beauty made up for it.
Caribbean Rosewood – sides. This wood is very close grained, although very hard, it’s not quite as hard as the Honduras variety, and not as brittle. Has some “florescence” when changing the viewing angle.
Birdseye Maple – inlay (the first dovetails). It’s really pointless to use birdseye in this application, but it’s what I had handy at the time. Regular hard maple would probably work better, maybe even holly.
Construction Keys.
The things I found key when constructing a box like this are:
1) Each side of the box receives a rabbet cut on the inside of each end.
2) The width of the rabbet equals the width of the side to be joined into it.
3) The depth of the rabbet equals the thickness of the initial (or “inlaid”) dovetail – maple in this case.
4) You actually build the box frame (sides) twice, cutting the box apart leaving the first set of dovetails, then cutting dovetails within dovetails.
5) When doing so it’s imperative that all the dovetails use precisely the same angle…all the time. To the degree they are not, the inlaid lines (maple in this case) will not be a consistent width, thus detracting from the overall appearance. You can see some of that in my try here.
The picture below shows the rabbet joint cut on each end of each side – 
I set the rabbet depth at 1/8” and cut it on my router table. The decision on the depth of this rabbet made here initially is what “sets” the width of the inlaid dovetail for the entire project. In future boxes using this joinery, I’ll strive to go narrower, (maybe 1/16”) but for the first time this seemed a little risky.
Below is a top-view picture of the pieces in relation to each other once they become integral to the box. In the center is the second of two of my practice joints I tried before starting the box.
The close-up below shows in more detail. From this picture the steps I next took were:
1) cutting tails in the maple (note the sacrificial maple receives no rabbet joint)
2) cutting pins in the Honduras rosewood (the front/back pieces)
The Tails.
Most often I cut my tails first, pins second. The photos series below shows the tail cutting process in the maple -
I don’t normally do this, but for this project I used a small block of wood cut precisely at the dovetail angle for hardwood (1:8) and used this as a “guide block” to rest my saw against for all tails in the box, so they would all be as consistent as possible. This seems like cheating in a way, but it’s critical that both sets of dovetails are all consistent. Again, this is necessary to have an appealing “inlay line” in the maple once I’ve cut the second set of dovetails in the Caribbean rosewood.
These pictures are kind of blurry, but hopefully give the idea – 
Below all the saw cuts are made – 
Here you can see the relationship of the shoulder in the maple to the rabbet in the rosewood – 
In the picture below I’ve made a cut nearly through the waste, but I stop short of going through and finish coming in from the other side. This prevents any chance of the fret saw blade cutting into one of the tails.
Ready for pins – 
The Pins.
The next series of photos shows how I mark and cut the pins in the Honduras rosewood. These will accept the maple dovetails. Note again that the maple is sacrificial, meaning it will be cut off once glued into the Honduras rosewood pins – 
Below shows how I mark the pins. When I’m doing this for real, my free hand is applying downward pressure on the maple to prevent it from slipping during the marking. The first picture shows squaring everything up prior to marking. Notice that I like to use a light under the pieces when positioning the tails for marking the pins…so that the gap between the maple shoulders and the edge of the rosewood can be easily seen and closed very precisely.
For this project I’m using a x-acto knife. I have marking knives, and I was a little hesitant to try this, but it worked out fine.
Here I’m marking the full thickness of the maple (plus 1/64”) on the rosewood so the pins will be a little proud after glue up – 
In this picture I’m cutting out the waste between the pins using a fret saw. Again, at the point of this picture I stop cutting and feed the fret saw down the left side of the waste to finish the cut. 
Notice how the pins look in combination with the rabbet initially cut into the rosewood. This is a key to the maple “inlaid” dovetail being visible from the outside of the box sides. Below is a picture of the finished pins -
The next two pictures show trimming the inside edges of the pins/tails. Rob Cosman shows this techique in his video series and this helps remove some of the friction when fitting the joinery -
These shavings are then cut off cleanly using the chisel.
On this project I took this idea one step further and did a small amount of filing on the back of the sides of the pins/tails, to further relieve friction when fitting the joinery together. This photo below is blurry, but I think you can get the idea. Note that I’m angling the file to purposefully avoid having the file come in contact with the front side of the rosewood pin. I also will only do this at the base of the pin…never at the end where it will show once assembled – 
The Completed Joint.
If you look closely you can see the pins/tails are slightly proud of the side surfaces – 
Even though it’s really hard to “destroy” something I’ve just finished…here I’m cutting the box apart right after getting all the initial corners completed and glued. Notice the remaining maple revealed by the initial rabbet cut into the rosewood – 
Below, I’m re-squaring the rosewood to prepare them for the second set of dovetails – 
This picture shows the relationship of the Honduras rosewood, to the Caribbean rosewood – 
The amount of maple remaining on the inside face of the rosewood is the same thickness that needs to remain in the walls of the maple dovetail, thus determining the size of the Caribbean rosewood tails. Here I’m rechecking this width (after sanding) and will transfer that into the marking of the tails – 
Unfortunately this turned out blurry, but this is how I transferred this width to mark the tails in the Caribbean rosewood – 
In this picture below you can see how the maple and Caribbean rosewood pins will overlay each other, once cutting and assembly is complete:
This series of pictures show the second set of pins being cut:
At last! The second set of pins/tails are complete!
This picture below shows the groove cut in the sides to accept the base…it also clearly shows my “screw-up” in cutting the groove on both upper and lower sides of one of the sides. My “cover-up” was deciding to place a ¼’ strip of hickory inlay around the inside of the top of the box…whooops! -
This picture shows the hickory base (and inlay) being fitted. The tongue and groove were done on my router table -
Here’s a partial “dry-fit” and I’m ready for glue up. I actually did completely dry fit each corner separately once, but did not do this for all four corners simultaneously, fearing I’d never get them back apart without loosening the joinery fit – 
The carcass portion of the box is complete. Here’s a picture of the clamping and end result – 
And here’s one after sanding the pins/tails clean… – 
I’m currently just starting to apply the finish to this box. The top is 6/4 stock cebil with a contrasting maple stripe that runs across the top, “joining” into the maple in the double dovetail. I’ll post this as a project once I get the finish completed. Thus far I’ve put on one oil coat, but I’m torn between a natural wood look and a multilayered poly/oil blend series of top coats that will end up filling in all grain pores. Any suggestions on the completing finish are welcome.
Even though this blog ended up quite lengthy, I hope you’ve enjoyed it.
-- Martin, Kansas
46 comments so far
davidtheboxmaker
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372 posts in 683 days
posted 493 days ago
Wow!
What a combination of determination, skill and patience.
That is one fantastic piece of work.
I realised that the double dovetail could theoretically be made by hand, but never thought that I’d see it done.
Scott Bryan
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20040 posts in 700 days
posted 493 days ago
Martin,
This is a nice blog and a wonderful looking box. I truly admire your patience and perseverance in building this piece. I have trouble enough with just single dovetails and would never fathom trying to pull off a double.
You documented the process well too.
Thanks for the post. I found it informative and clearly demonstrated the process involved in the construction effort.
Well done.
-- With God's help all things are possible- even woodworking. Woodworking is not just a hobby, it is an (expletive deleted) expensive hobby.
TheGov
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18 posts in 531 days
posted 493 days ago
really nice technique
-- What can i say i'm just doing what i love.
trifern
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7890 posts in 645 days
posted 493 days ago
Very cool stuff. I admire your patience and attention to detail. Thanks for the great tutorial.
-- My favorite piece is my last one, my best piece is my next one.
gizmodyne
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1659 posts in 968 days
posted 492 days ago
Wow. I never knew how that was accomplished. Great post.
-- -John "Do I have to keep typing a smiley? Just assume it's a joke." www.flickr.com/photos/gizmodyne
SteveKorz
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2030 posts in 592 days
posted 492 days ago
I stand applauding your craftsmanship, Sir. Very well done, thank you for the post!
-- As iron sharpens iron, so one man sharpens another. (Proverbs 27:17) †
John's Woodshop
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117 posts in 894 days
posted 492 days ago
Man oh Man!
You have got some serious skills. Thanks for the tutorial. Great job!
John
-- John -- Racine, WI -- Woodworking..."It's not just a Hobby, it's an Adventure"
lew
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4405 posts in 633 days
posted 492 days ago
This explains soooo much for me. Thank You!!!
I wish I had your skill and patience.
Lew
PurpLev
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2675 posts in 526 days
posted 492 days ago
that looks awesome! definitely takes lots of patience, and precision – nicely done!
-- When in doubt - There is no doubt - Go the safer route.
Douglas Bordner
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3415 posts in 942 days
posted 492 days ago
Wow, Martin. I couldn’t imagine doing these without the Incra. Great job.
-- "Bordnerizing" perfectly good lumber for over a decade.
Greg Wurst
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713 posts in 710 days
posted 492 days ago
Looks great, but that was a lot of work! I wish I had the time to try those kind of things.
-- You're a unique and special person, just like everyone else.
Lee A. Jesberger
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3709 posts in 857 days
posted 492 days ago
Hi Martin;
This is some spectacular workmanship.
I’ll bet your on some kind of medication, or should be! lol
(I am too).
Great photos as well!
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
Praki
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139 posts in 875 days
posted 492 days ago
Inspiring and very educational. I will attempt this someday :)
Thank You!
-- Praki, Aspiring Woodworker
Damian Penney
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1022 posts in 869 days
posted 492 days ago
Woah :) Seriously cool, well done! Now lets see if you can do a triple….
-- I am always doing that which I can not do, in order that I may learn how to do it. - Pablo Picasso
Ampeater
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196 posts in 625 days
posted 492 days ago
I just added it to my “favorites” list. I want to make one of those after I have practiced for about two years.
-- "A goal without a plan is a wish."
bfd
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413 posts in 685 days
posted 492 days ago
Just added this to my favorites as well…You are 90% Highly Skilled Craftsman & 10% Crazy! I am blown away by this blog. As someone who hand cuts dovetails (humble half blind and simple through dovetails) I can totally appreciate what went into this. Thank you for this blog. I also added your walnut coffee table to my favorites.
-- Brian, Folsom, CA http://www.brianfullerdesigns.com
mot
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4901 posts in 914 days
posted 492 days ago
A well documented and beautiful project. You obviously have the patience and skillset to create tremendous handcut joinery. Thanks for taking the time to document and post this.
-- You can discover more about a person in an hour of play than in a year of conversation. (Plato)
Chip
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1058 posts in 970 days
posted 492 days ago
Wonderful craftsmanship and wonderful that you took the time to show us how you did it. Terrific and thank you.
-- Better to say nothing and be thought the fool... then to speak and erase all doubt.
Dorje
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1768 posts in 875 days
posted 492 days ago
Wow. That’s bold!
-- Dorje (pronounced "door-jay"), Seattle, WA
Woodhacker
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1145 posts in 601 days
posted 491 days ago
Goodness! Thanks to each of you for your comments and encouragement! This was such a fun and satisfying project…I guess because it presented new challenges.
Lee – you’re on to me. I know under HIPAA rules I don’t have to divulge personal medical information, but my current medication is 200 mg of rosewood sawdust 4 times daily at meals and bedtime.
Damian – Hmmmm a triple dovetail…I might have to increase that dosage to 300mg…but that would be pretty cool (the project not the “medication”). Also, I’ve never used a houndstooth dovetails in a project yet, but during this project I’ve been wondering if it’s possible to do a double houndstooth. Regardless of which of those I end up doing first, I’m pretty sure BFD has those percentages he mentions above reversed. :)
Thanks again for your encouragement.
-- Martin, Kansas
John Fry
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73 posts in 578 days
posted 491 days ago
Your hand cut double dove tails, or inlaid dove tails as they are also known, are very impressive. That is some exacting hand tool work. I’ve done several sets of inlaid DT’s and I am in absolute awe of your precision….........But, Man-O-Man!! I think I will just keep using my Leigh D4 for this process. ;-)
-- John, Chisel and Bit Custom Crafted Furniture, www.chiselandbit.com
Al Navas
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289 posts in 753 days
posted 491 days ago
Martin,
You have done a TERRIFIC job on these inlaid / double dovetails! Now, please understand where I come from: I have never made dovetails by hand (I might try them in the future…); I have made them only with a D4 jig, and I can make the inlaid type on the D4, too. But you have shown us that it can be done, and done beautifully, by hand as well.
Well done!
-- Al Navas, St Joseph, MO, http://sandal-woodsblog.com
EdC
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454 posts in 718 days
posted 491 days ago
Martin,
Thank you for putting so much effort into documenting the process you did a fantastic job of of a very difficult job!!
You also did a wonderfull job on making this box. I had thought of trying this idea, after seeing it done on a Leigh router jig. Seen as I do not own a router jig my alternative would be by the old fashined method. You have made my thought process alot easier for me down the road.
-- Ed - Milan, IN
Bob #2
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2987 posts in 899 days
posted 491 days ago
What a great talent! Everything is so crisp.
Thanks for taking the time to show us all the steps and your technique.
Bob
-- A mind, like a home, is furnished by its owner
Dave T
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89 posts in 498 days
posted 491 days ago
WOW, that is beautiful
rickbuddy
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15 posts in 642 days
posted 490 days ago
OMG!!!
Martin, people like you with so much creativity and talent blow me away. That box is awesome.
-- Rick Snail, Omaha, NE --The only stupid question is one that isn't asked.
NICUTO
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26 posts in 494 days
posted 484 days ago
those look awesome!!!!!! i really like your idea with the coping saw to cut out alot of the waste. great job!
-- Nick, Maine; www.nwbwoodworks.com
mohkev
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7 posts in 485 days
posted 484 days ago
Beautiful work. Thanks for the step by step shots of the process. Really helps me out to see it that way.
-- -Mohkev
Joe Lyddon
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470 posts in 930 days
posted 483 days ago
Woodhacker, Martin,
You’re no Woodhacker!
That is the BEST procedure I have ever seen on Handcutting Double Cut Dovetails!
I FINALLY can understand how it’s done!!
I Thank tou very much for your wonderful documentation of your procedure & skills.
Martin, I have a website where I save things that really interest me… Can I get your permission to post your work to my website?
www.woodworkstuff.net
Thank you.
-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: http://www.WoodworkStuff.net ... My Small Gallery: http://www.ncwoodworker.net/pp/showgallery.php?ppuser=1389&cat=500"
Al Navas
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289 posts in 753 days
posted 483 days ago
Martin,
I am SO impressed, I have posted a little something at my blog, to let everyone know about the wonderful job you did with these hand-cut inlaid dovetails!
KUDOS, Martin!!!
-- Al Navas, St Joseph, MO, http://sandal-woodsblog.com
Chris
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1452 posts in 869 days
posted 483 days ago
Wow, great how to…. Very informative. Was it fun to figure this out?
-- Chris
Joe Lyddon
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470 posts in 930 days
posted 479 days ago
Martin,
Thank you for giving permission to add this to my website!
I finished it today!
http://www.woodworkstuff.net/MeckAHandcutDBLDT.html
Hope you like it…
Look down in the Joinery Section…
http://www.woodworkstuff.net/woodidxjigs.html
-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: http://www.WoodworkStuff.net ... My Small Gallery: http://www.ncwoodworker.net/pp/showgallery.php?ppuser=1389&cat=500"
sIKE
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1093 posts in 632 days
posted 479 days ago
Man that looks nice, hadn’t seen it done by hand before!
-- //FC - Round Rock, TX - "Experience is what you get just after you need it"
GaryK
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9496 posts in 866 days
posted 479 days ago
Great dovetailing job and also a great blog on how you did it!
-- Gary, East TX -- The longest journey begins with a single step.
Joe Brumley
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63 posts in 660 days
posted 466 days ago
Awesome! I agree with everyone else, you are a true craftsman. Nice work! And don’t worry about working on your patience and precision too much. I think qualifies you for a phd. in both.
-- Joe, Indiana, http://www.crookedshack.com
Partridge
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219 posts in 834 days
posted 463 days ago
this looks fun and frustrating all at same time.
nice work.
-- Do it right the first time. Becuase fixing it is a wast of time.
clem
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5 posts in 541 days
posted 455 days ago
really a great job
clem from delaware
-- clem de,woodworkerclem.com
flomp
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25 posts in 525 days
posted 422 days ago
military precision im impressed
lowbike1
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17 posts in 439 days
posted 419 days ago
Wow, thats very impressive, thanks for posting pics of all the steps!
Texasgaloot
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467 posts in 578 days
posted 372 days ago
Martin, I appreciate the way you think outside the box…
I’ve been hand cutting dovetails for years, and have never tried a double. It never occurred to me to try a double. I might even go for a triple… too much coffee…
Tremendous precision. Well done!
-- There's no tool like an old tool...
Blake
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2715 posts in 752 days
posted 372 days ago
Um, WOW! and, er, uh… WOW!
-- Check out my new website! http://www.blakeweberwoodworking.com
haltman
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9 posts in 380 days
posted 361 days ago
Wow really interesesting job! Thank you for shareing!
-- ciao h.
grumpycarp
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232 posts in 624 days
posted 361 days ago
Consider the lillies of the field (guilded) . . .
And I recently whined that making an end grain cutting board was doing everything twice . . .
Beautiful, thanks for the blog.
deucefour
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80 posts in 132 days
posted 58 days ago
Thank you for sharing, very nice work.
-- "I gotta have more cowbell"--------Bruce Dickinson
patron
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2244 posts in 219 days
posted 58 days ago
truly inspirational !
and thank you for the step by step instructions / pictures .
you are one serious craftsman ,
well done !
-- david ,new mexico ,allheart
Rob Drown
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324 posts in 711 days
posted 54 days ago
It has been said a bunch but, WOW. Amazing and beautiful. It is really more attractive than the machine cut ones because of the tiny variations make you realize this was done by some very skilled hands. Thank you for sharing!!!
-- Sharp tools and thin whispy shavings make woodworking a joy.