JOINT MAKING OPERATIONS
6. The Middle Sections
The method for making middle sections for both pin and tail
boards are the same. And, as with the double dovetail, either
vertical or sliding methods for cutting these pieces may be
selected.
Note: Wall thickness dimensions given on plan pages are
approximate. To insure that the top and bottom wall
sections end up precisely the same thickness as the side
wall sections, it is suggested that you first make test cuts
using scrap pieces.
a.
VERTICAL METHOD
(1) Select a workpiece for pin middle sections and a
workpiece for tail middle sections. They should be of
equal widths and thicknesses as their respective mating
pin and tail boards. They should also be long enough to
clamp to the Vertical Push Fixture for vertical cuts.
(2) Clamp the pin middle section workpiece to the VPF and
perform the assigned series of cuts which will mate it to
the pin workpiece.
(3) Fit together to the pin board and glue in place. Allow to
dry.
(4) Clamp the tail middle section workpiece to the VPF and
perform the assigned series of cuts which will mate it to
the tail workpiece.
(5) Fit together to the tail board and glue in place. Allow to
dry.
(6) On both pin and tail workpieces, place a mark on the
middle section part of the workpiece which will extend its
length by the
wall thickness. On a table saw, cut off the
middle section to the mark.
(7) Clamp the longer pin piece to the VPF and perform the
series of cuts which will mate to the tail middle section.
(8) Completed pin and tail workpieces can now be fitted
together and glued. Final sanding should be kept
minimal to maintain appearance of joint.
b.
SLIDING METHOD
(1) Select suitable workpieces for the two middle sections.
The boards should be several inches long and same
width as your tail and pin workpieces, but of thicker
stock. Plane each to a dimension that is greater than the
depth of your dovetail cut by the
wall thickness amount
found on the respective full-size plan page. As in the
previous method, test cuts will determine the precise
thickness required to achieve uniform wall thickness.
(2) Perform the assigned series of sliding cuts to the pin
middle section which will mate with the pin board. Be
sure to use a rubber-soled push block for all sliding cuts.
Note: When making the pin middle section, it is necessary to
make an open cut on the outside edge farthest from the
fence. As the board is pushed forward it can become
pinched between the fence and the bit, causing a
dangerous situation. The best way to perform this cut is
by making several small side by side passes starting
from the outer edge of the board.
(3) Perform the assigned series of sliding cuts to the tail
middle section which will mate with the tail board.
(4) Using a support board (ideally, a mating piece cut by
following the short template lines which would mate to
each board), on a table saw slice sections about
1
/
32”
wider than their respective mating board thickness.
(5) Glue each sliced center section to its respective mating
workpiece. Allow to dry and belt sand smooth.
(6) Clamp the longer pin board to the VPF and perform the
series of cuts which will mate to a completed tail
workpiece.
(7) Clamp the longer tail board to the VPF and perform
the series of cuts which will mate to the completed
pin workpiece.
(8) Completed pin and tail workpieces can now be fitted
together and glued. Finishing sanding should be light to
maintain good appearance of joint.
QUICK REVIEW
Double-Double Box Joints
Router Table Top
21
Tail Board
Tail Board
Middle Section
Workpiece
Middle Section
Workpiece
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
Tail
Middle Section