The through dovetail joint is the foundation of my wooden tool chest
build. Strong and attractive the dovetail is the traditional joint of choice for joining boards at right angles. Here is how I went about setting out and cutting my dovetails using hand tools and with some practice you can too. As always make sure you take all necessary safety precautions and follow all the safety instructions provided with your tools.
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Step 1: Terminology
Just to keep things easy I have labelled the key areas of the through dovetail joint.
Step 2: Tools
These are the tools I used. Mallet, Bevel Edge Chisels, Marking Gauge, Cutting Gauge, Dovetail Saw, Dividers, Marking Knife, Hard Pencil, Dovetail Square (or adjustable bevel), Try Square, Ruler, Smoothing Plane, Coping Saw
Step 3: Face Side, Face Edge
Make sure your material is cut to an accurate dead length, apply face side faced edge marks and reference the corners.
Step 4: Baseline
Set your cutting gauge to create the base line. Set it to the exact thickness of the timber to be joined. In this case the timber is of equal thickness. If the thickness of the stock varies apply the thickness of the tail board to the pin board and pin board to the tail board. For best results use the timber to set your gauge. Don’t be too aggressive with the gauge. We just want to create a nice edge for a chisel to pare from later.
Step 5: Half Pins
Dovetail joints start with a half pin located on the outside of the joints. Typically on fine work this would be 6mm > 9mm on larger work like a tool chest 10mm > 18mm would be acceptable. Set your marking gauge to the half pin size of your choice and mark the half pins onto the tail boards.