| Blanket Chest -- Dovetail Joinery |
From "Wood Works"
episode WWK-103 |
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Materials: 14" wide walnut stock for the sides
Table saw
Safety glasses/goggles
Dovetail jig
Router
Dovetail bit
Straight bit
Large flat hammer
Slow setting (resin-based) glue
Brush
Blue masking tape
Chisel
Belt sander
Plywood panel cut to size
Clamps Note: If you can't find 14" wide lumber for this project, simply plan on gluing two pieces of walnut together; however, be sure to align the grain of the wood to give the finished piece a sense of uniformity. Safety Alert: When using a saw, please be sure to wear safety glasses. - Cut the walnut stock to length.
Note: Now it's time to cut the dovetails from the blanket chest. The dovetail joint (figure A) is the strongest joint known to woodworkers, and in this particular case it adds an artistic touch to the piece. Did you know? The dovetail joint got the name because it's shaped exactly like a dove's tail. Making the Dovetail Joints Note: Traditionally dovetail joints are made by hand, but David Marks, the host of Wood Works, used a dovetail jig, a dovetail bit and a router. - Before making a cut on the actual walnut stock that will be used for the blanket chest, practice on a scrap piece. This could save money in the long run!
- After practicing on scrap wood, go ahead and make the dovetail cuts (figure B) for the long sides of the blanket chest.
- Flip the dovetail jig and setup to cut the pins for the short sides of the blanket chest. For the router, change the dovetail bit to a straight bit.
- Cut with the straight bit (figure C).
- Once the dovetail joints have been created, use a large flat hammer to do a dry fit for the case of the blanket chest. Be sure to double-check that the dovetail joints go together properly.
- Do a layout for the rabbet that will be cut along the bottom of the case for a plywood panel that will be dropped in later. Once the layout is complete, take the case to the router table and cut the rabbet.
- Once the rabbet has been cut, it's time to glue the case together using a slow-setting glue that is resin-based.
Note: It's best to barely tap the dovetail joints together at the four corners in order to leave room to apply the slow-setting glue inside the dovetails. A great tip is to use blue masking tape (figure D) to capture the squeeze-out glue when the case is clamped together. - Once the glue has been applied, hammer the joints tightly into place.
- Because the glue will need approximately 8 to 12 hours to dry, it's best to use a clamp. Be sure to check that the corners are square and the clamps tight before the case is left to dry and set.
- Once the case for the blanket chest has dried, use a chisel to chop the corner perfectly square to accommodate the plywood panel that will be placed in the bottom of the chest.
- After making the corners square, use a belt sander to clean the glue squeeze-out and flush the corners of the case.
- Once the rabbet is squared up and the corners are clean, it's time to glue the plywood panel into the bottom of the case.
- Clamp the plywood to the case (figure E) and let set.
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RESOURCES :
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Author: Albert Jackson
Publisher: Knopf
ISBN: 0679766111
Arts and Crafts Woodworking Projects: 11 New Designs in the Stickley Tradition
Model: 0811726622
Author: Robert E. Belke
In the Craftsman Style: Building Furniture Inspired by the Arts and Crafts Tradition
Author: Editors of Fine Woodworking
Publisher: Taunton Press
ISBN: 1561583987
Order this title from Amazon.com.
Authentic Arts and Crafts Furniture Projects
Model: 1558705686
Author: Popular Woodworking Magazine
176 Woodworking Projects: A Workbench Treasury
Model: 0806965282
Author: Workbench Magazine
To order this title from Amazon, click here.
The Small Wood Shop (The Best of Fine Woodworking)
Author: Helen Albert (Editor)
Publisher: Taunton Press
ISBN: 1561580619
Mastering Woodworking Machines (Fine Woodworking Book)
Author: Mark Duginske
Publisher: Taunton Press
ISBN: 0942391985
David Marks Website
David Marks, DIY's Wood Works host, is a master woodworker. For more information on cut sizes and project details, please contact him via his Website at www.djmarks.com
The Complete Illustrated Guide to Woodworking
Author: Lonnie Bird, Andy Rae and Gary Rogowski
Publisher: Taunton
ISBN: 1561586021
Treasure Chests: The Legacy of Extraordinary Boxes
Model: 1561583626
Author: Lon Schleining
(2001)
The Taunton Press Inc.
Website: www.taunton.com
Boxes and Chests: How To Make and Decorate 15 Traditional Country Projects
Model: 0811725596
Author: Alan Bridgewater and Gill Bridgewater
(February, 1997)
To order this title from Amazon.com, click here.
Stackpole Books
Website: www.stackpolebooks.com
The Complete Dovetail: Handmade Furniture's Signature Joint
Model: 0941936678
Author: Ian Kirby
(2001)
Linden Publishing
Fresno, CA 93721
Fax: 559-233-6933
Woodworking With the Router: Professional Router Techniques and Jigs Any Woodworker Can Use
Model: 0762102276
Author: Bill Hylton
(1999)
Readers Digest
Pleasantville, NY 10570-0235
Popular Woodworking
F & W Publications, Inc.
Website: www.popularwoodworking.com
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