Page 35 - Router Boss Manual

Cutting Matched Pin Dovetails

In the dovetail methods we’ve shown so far, the
pattern on the opposite end of the front and back pieces
reverses itself because we’re cartwheeling the pieces.
This is not noticeable with a symmetrical layout, but
there are times when the pattern needs to be the same
on both ends of the pin boards. One practical applica-
tion of this is making lidded boxes. It’s much easier to
cut the joints in the stock first, then cut the lid from the
assembled box.

To avoid a reversing pin pattern, we’ll use a differ-
ent set of settings for each end of the pin boards. How-
ever, we’ll only use one set of settings for the socket
boards because we’ll somersault them end-for-end in-
stead of cartwheeling them. For this procedure, we’ll
also use the white story board inserts instead of the
front scales or digital readout. Using the story boards
is quick and easy, especially if you’re making multiple
copies of the same piece. There are no numbers to write
down or remember; you simply line-up the cursor to a
pencil mark and make the cut.

We’ll make our box from 1/2”- thick stock and the
sides and ends are 4” square. The “body” of our box
will be 3” high and the “lid” 7/8” high (the extra 1/8” is
for the table saw blade kerf when we cut the lid free).
The body will have two pins/sockets and the top will
have one pin/socket at each corner.

Start by labeling the pieces as shown above right,
marking the outside faces of adjoining pieces at one cor-
ner with the letter A and working your way around the
box. The two end pieces (pin boards) should be labeled
A-B and C-D and the two side pieces (socket boards)
should be labeled A-D and B-C.

With the pieces labeled, mark the location of the pin
centers on one end of one of the socket boards. For our
box, we marked the pin centers at 1”, 2” and 3 1/2” on the
A-D board. The layout doesn’t have to be precise, it just
needs to look right.

Mount the A-D board with the labeled face out.
Start with the “A” end pointing up. Mount a centering
bit in the router (or use the laser crosshairs) then use
the power feed handle to position it on the first layout
mark.

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