Rob CosmanbT E C H N I Q U E B O O K

A11 rights resewed. No part of this book may be reproducedor transmitted in any form or by any means, electronic ormechanical, including photocopyng, recording, or by anyrnJormahon storage and refrleval system. Mthoul wnttenpermission ftom Rob Cosman.

02008 AvsRlcAN Cnarrsl,nN Punucenous

Box 3260, Grand Bay, New Brunswic( Canada E5K 4V51-877-967-5966

rsBN 978-0,9809412-0-3

Visit wr.rw.robcosman. com

Photography by Kim HilchieBook design by John Hoffrnann

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TABLE OF CONTENTS

Hand-Cut Dovetaih www.I0Dc0sman.c0m ROB(OSMAN 3

4 DEDICATION

5 PREFACE

6 SECTION 1 TOOLS FOR THE TRADE

12 SECTION 2 STOCK PREPARATION

15 SECTION 3 THE MARKING GAUGE

21 SECTION 4 LAY OUT

28 SECTION 5 DOVETAIL SAWING

33 SECTION 6 THE FRET sAW

36 SECTION 7 SPLITTING KNIFE LINES

40 SECTION B CHISELING

45 SECTION 9 TRANSCRIBING THE TAILS

50 SECTION 1O SAWTNG PINS

55 SECTION 1 1 CHISELING THE PIN WASTE

51 SECTION 12 PRE-ASSEMBLY CHECK

53 SECTION 13 ASSEMBLY

59 SECTION 14 TROUBLESHOOTINGTheTail BoardThe Pin BoardThe Joint

I owe my most humbie gatitude to the giver of all talent. Often as I cut into wood I am hum-bled at the beauty that is ours to enjoy.

My success in this field is largely the result of an encouraging and loving wife, Kimberley hasalways been supportive of my endeavors and the first to jump in and help. This book wasmade possible by the many hours she put forth. In addition to helping me she has raised andeducated our ten children.Truly a remarkable womary wife and mother.

I also owe a debt of gratitude to both Kim's and my parents that among many things taughtus the value of hard work. Into the lives of the fortunate enter very special people. For me thiswas Dr. Dale Nish. Early rn my career Dale recognized my ability and provided me with everyopportunity to expand my experience and develop my skll. He opened doors that would nothave otherwise been opened. Dale has spent his career discovering talent and giving thoseindividuals the opportunity to display it to the woodworking world. I would also like to thankthe many woodworking students/friends that I have had the pleasure to meet, teach andbe{riend around the world. Finally my childrery a most cherished blessing in my life.

Family First!Rob Cosman

I

4 ] ROBIOSMAN www.robcosman.com Hand-Cut Dovetails

PREFACE

Hand-(ut Dovetails www.r0DC0sman.c0m ROB COSMAN 5

I have been working wood since my early childhood. On my mothers side my grand{ather andgreat grandfather were both carpenters. I knew them both and had the opportunity to workwith"Gramp". My father was an industrial arts teacher fumed carpenter so woodworking wasdefinitely in my blood. During my boyhood I was always building something, from boats togun handles and Irom go-carts to wooden bowls. Not onlywas I fascinated with wood but myquest for perfection nearly drove my father crazy.

During my early years of professional furniture building I worked hard to master the art ofdovetailing. As a student and teachlng assistant at BYU, I used my access to the wood shop topractice cutting a row of dovetails each moming before class, Once I mastered the process mynext quest was speed. I had the incredible opportunity to spend some time with masters LikeTage Frid and Alan Peters. Their input to my career was both priceless and inspiring. It isbecause of this I now feel it both an honor and a duty to pass on what I know and help keepthe tradition alive. To this end I have produced three dovetail videos, written this book andcontinue to travel the world teaching those wanting to learn. Saw cut to saw cut joinery is mymotto, straight from the saw and without a test fit. \A,hi1e some scom, hundreds have gone onto do it and do it extremely we1l.

I continue to build fuiniture for my ever-expanding family and with no end in sight I amthrilled at the prospect.To teach and work wood for a living is both an honor and prMlege.

L SECTTON1 TOOLS FOR THE TRADE

Ater teaching hr-rtrclrecls of iolks in ser,eral countries hoi,t to hant-l cltt dovctails, I havc fonndthe use of impropel tools quite common.To do the iob rvell the tools need to be sharp andproperly suited for the task. On a dovetail sar'r,, that covers evcrything froni the handle to

ihc number oi teeth. This first section is desigred to inform you on i,r,hat to look for rnrhenchoosing or r.naking vor-rr dovetail too1s. \'\thile not promoting an-v spccific brand, the betterqr-ralitv tools rvil1 olien come with lnost if not a1l of the character.rstics sr-Lggestcd belon'l As vor-rgain experience yorl mav want to fine tr.ure 1,.our too1s, I have oiten done this and I note thosechanges in the tcxt.

A pistol grip registers inthe hand the sanre rvaveach time it is picked LLp.This allorvs the user todcvelop a fecl for verticalsarving, a blg help rvhensawing pins.

. A thin blade (.018-.020)removes lcss rvood ai-rdis easrer to push.

. Thc set of the teeth(s1i ght or,rtrvarcl bendingof eacli tooth) shoLrld bein the range of.001 kt.003 per side to help theblade track propcrlv(cut straight).

. Dovetailing is primarilvripplng r,t oocl vs. crosscLrtting, hcnce the tecthshould be filed rip (cut-l ing f . rce r r f l , ru l l l ps lpqndicu . r - tn lcr r$h o i b l ;dr) .

. PPI or points (tccth) perinch shoukl be in tbe14-16 range, too manvteeth (20+) sklvs thesarving lvhile too fervteeth (-12) rnakcs thesan r'lifficr-rlt to start.

DO\TTAIL SAW

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. Barrel hme qarseq rrp

usually ready to use outof the box.

. Thc crrft ino vrhppl nn' ' . ' ' - ' . - ' . t ]

this gauge is easier tosharyen than the pin ontraditional gauges.

. The micrometer adjust-mcni el]nurq fnr rrpnr

precise settings.. Rar re l onr ropq c rn hp

rolled instead of pushed/pulled for precise markingor on difficult surfaces- . . ^ L ^ ^ ^ - ^ - - ^ - , , ^ l ^ ^D U l r r d ) d r r d r r u v v c u 6 c ,

. Sawing the buik of thewaste betureen tails^ - , 1 - ; - ^ ; - ^ ^ - ; ^ - + L ^ -dl tu Pl1 tJ rJ gdJltrl u ld r l

chiseling, especially withnaffow or London styietails & pins.

. Frpl q:urq r:n rqp \/pn/- * " - ' " ' ' ' - J

fine blades that wil1fit anaffow dovetail saw kerf.

. Frpt qaurq urith riqid' ' ' . ' . ' ' t r ' *

lremeq end urin o nr r I

tension adjustments a11owfor a very taunt blade thatresists bowing during use.

. To exceed the limitationof a 3" throat, the bladecan be twisted about 30dpmpps a t thp c lamnino* ' l r ' ' ' " * . . ' . ' ' , - , ' . r ' . . t )

nnintq Thiq Lppnc lhp

frame above the joint ona horizontal cut.

"M*iu;;.':::. .:I€r"t

FRET SAW

Hand-(ut Dovetails www.r0Dc05man.c0m ROB COSMAN

. Dividers are a moreaccrlrate mcthod oi tr:ans-ierrine ciinrensious.

. Six-inch dniders are acomiortable sizc iorjoint lavor-rL.

. Scrcit h'pe acljr-rstmentsarc better than fi-ictionh'pe for prc.rrentingaccidental mo\renrent.

. A goocl nrarking kniic1 '1 . . ' . J - 1o he , ' , " t ' i , , r [ . tb l t h rhold ancl accuratc to Lrse.

. Tlie blaclc needs tct bc thinenough kr pass in thedorretail kerf r.ct r-igidenough to pre1,g1l1 ataat-sivc flexirre rlurins nse.

. If thc blacle is too sharpthc mark left in cnd eraincan bc cliilicult to scc,dul l ing the bladc makest l r , n ' . r rk r r t t l c t , t r t . l r ' .1> :e tto sec.

. The blacle shoLLld bc rvidect'totjsh at the tip to allcnvthe user to fccl jt registcragainst tlie tail.

MARKING KNIFE

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. A six jnch sqnat-c ts larireenor-rgh to be accuratcvet small ancl conrrenientto rlse.

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COMBINANON SQUARE

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. This marker allows theangled face and thesquare end to be markedurifh nnp cpl-tinq

. Dovetail angles varywithhard and soft wood" 1:7rake (8 degrees) for hard-wood and 1:6 rake (10degrees) for soft wood.

;:.',..fiA round mallet does notrequire directionai hittinglike ihe hammer t1pe.The mallet should be lightenough to be comfortableyet hear,y enough toallow gravity to do mostof the work.

i :)i. " : r . ,

, ' " i, 1 n E l -

. A steel hammer allowsthe user to"feel"or readwhat is happening witheach strike.

. For assembLing smallboxes and most drawerdovetails, a 12-ouncehammer is sufficient.

!| Hand-CutDovetails www.rob(osman.com ROB COSMAN 9

www.r0br05man.(om Hand-(ut Dovetai ls

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. A spatula is invaluablcfor east' ancl accurateplaccnrent oi e1ue.

. Stecl blarles arc morcdr-nable bLrt plastic blacli.sarc casler to ctean.

. Chisels ncecl to bc conr-ti l table kt use, l ight anrllvell balancecl.

. The bettcr ihe stcel andsharpcr the chiscl thelonser the eclgc rctenturn.

. The sidc slopc on bevclcdged chisels nccds tcrextcnd lron the chisclback kr the top, alloningior clear-ance l hcn cliopplne bthveen tai1s.

. Uslng an insicle rabbet isan cfiectirrc tvav to r-eier-cncc. the tailboartl to thepln boarcl u4ren h-atrsferring d(r'ctails. Sec page 18.

. Thc skew,block planc r,r'ithits fence ancl skciverl bladerurakes thc srtroothcst ci-rton cross grair-t,

. The shor-r lcler plane canalso cb tht lob thoughsorlctjnres nctt r1-lte asclean or as convrrt ient.

CLUING SPATT]'I-A

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CHISELS

SKE\'V BLOCK PLANE

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SHOONNG BOARD

. Shooting boards aredesigred to enable theluser to casjlv plane tlicend of a rnork piece atright aneles to its taccanci 1ts edge.

. ;\ good nraterial forshooting boarcls isI,icdir-r nr densih' fiber'board (NlDF), it is stablc,inexpci'islve and has along tvearing srLriacc.

. There is no spcciflc size,ho\t'ever this shootineboarrl is 28" br, 17' and ismade for both rlght andleft hand nsc.

. Thc base is 28 bv 17 bvr/r", the top is 28 bv 11bt"/," and the front cleatis 17 br '1 / i ' bv1," .

. The top'/," piecc has ashallor,r, rabbet ('/ru" bv'/r") cr-rt along the edgc iorthe plane to ridc against.

. Thc top, bottom and cleatafe ghled ancl scr-en edtogethel; it is bcst toclamp the unit ilat nfiilethc glr-re sets.

. The shootine boardr,r,orks best if the iencc ispositioned 6-8" in fionrthe cnd.

. Thc icnce should be aclr-u-a ble harc'hvoocl andsecr-rred lvith ghre andscreivs, this one is 10r/:"br'1 '/, ' br'1 '/. ' .

. Thc icnce must be sqr-rar-eto thc leference siclc oithe shooting board(tvhere the planc rides)and helcl back'/ '" h.omtouclring the planc in use

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www. ro b cosm a n. comHand (ut Dovetails

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ROB (Ost\4AN 1l

SECTION 2 STOCK PREPARATION

TIPS

Often overlooked" one of the keys to a successful joint is to have accurately milled stock.Your boards should have the inside face hand planed flat, smooth and paral1e1 to the outside.The edges should be planed straighf square and para1le1 to each other. The end where thejoint will be cut needs to be square to the long edges and the face. The end also needs to besmooth to better show the knife layout marks.

It is a good idea to practice with the same woods you use for building.The most commonplace for dovetails is in drawer construction and slnce the drawer fronts are thicker than thesides, throughout this book you will see 13/16" stock demonstrated for the pin board (simulatingthe drawer front) and 1i2" stock demonstrated for the tail board (simulating the drawer side).

Using contrasting woods is another he1pful tip. In finished woodwork it is a great way toshow off the dovetailed corner as the drawer gets opened. Dark pins against light tails caneven make a so-so joint look a lot better. \.A/hen you fust start cutting dovetails a bit of successcan go a long way in encouraging you to persevere.

. Place your hand on thewidest part of the sideand be careful not to tipthe p1ane.

. Use the long sole of theplane to straighten theboard's edge.

. Use the shooting boardto keep the boards edgeand plane square toeach other.

. Do the same to theonnocite edoe- r r ' " _ - - ' * o - '

'-\

PLANINGA CF{AMFER

SHOONNC ENDGRNN

. Planc a small chanrier tcrprerrent splintcring of theback etlge.

. Plane thc chamfer bvhn l , l i r , ' t l rp h , r r r , i ru r r r :" - ' ' ' ' ' t l

irom lire left sicle of thelence.

. Position thc boar-cl lviththe chamfered sidcagainst the lence.

. Kccping the board tight tcrtl.re fencc, thc plane tightto the rebatccl cclge anclthc boarcl ied urto p1ane,cut nntil thc chanrier"almost clisappears.

. Rcpeat these steps rviththe tailboarcl.

. The inside iacc oi thc pinand tail boarcls nrust beplancd bciorc thc jointis cut.

. IrLanc b rcniorre the millnrarks anc'l to leave thesr.rriace flat, snrooth andfinishcd.

,W" '

PLANINGTHE INSIDE FACE

Apleceof18 br , 11 b) , r / : ' n rd i l r j thabot to tu f ro l tc lea ta t ' ida ' / , ' topbackc lca tmakcs a g-eat plirning board for wofking on short and small prieces.

www.robcosman.comHand'(ut Dovetai ls ROB CO5MAN 1 3

I

SECTION 3 THE MARKING GAUGE

Hand-Cut Dovetails www.robcosman.com ROB CO5MAN 15

TOOLTIPS

. When cutting dovetails the marking gauge is second only to the dovetail saw in importance.,, It needs to leave a clean 1ine, square to the good side of the scribe and angled on the waste

side. The gauge creates part of the finished joint so the better the mark the better the joint.

, Because of the shape of the cutter, it pulls on the gauge as it is dragged through the wood.For ease in making fine adjustments, some have a one-hand operated micrometer.' These are equipped with two locking screws that hold the gauge firm1y in place.

The cutters on the banel t)?e gauges are very easy to sharpery a bit of face honing on a finestone is a1l that is needed. Also look for a gauge that is well-balanced and comfortable to use.The sharper the mark the better the chisel wiil hold in the line as you get ready to chop.

. Set the marking gaugeto the thickness of thepin board.

. Scribe the pin boardthickness on all foursurfaces of the tailboardIt is easier to pull thegauge than push it.

. The hvo edges are moreeasily done by holding thegauge against the end ofthe board and rolling thecutter side to side.

. Make this mark as deepas the gauge will allow

. Set the marking gaugeabout'/r" less than thethickness of the tailboard.

SCRTBINGTAILBOARD $* t**;:i

ROLLT}IE EDGE

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. Scribe just the hvo facesof the pin board.

SCKBEPINBOARD U I

The following process will help align the tailboard to the pin board when transcribingthe tails.

. Make the plane a rebatinglnnl hrr rpmmrin o the ci, la

nlafp ln pvnnqp ihp p,' lopr - * . ' . " . , ' r " " ' . ' . ' ' * t r .of the blade.

. Adjust the blade to projectirrql hprunnd fhp cdoe nfl - " ' " ' J " " - . ' ' ' ' * b ' ' '

the tool and para11e1 to thesnlp Spt i l fnr a l iolrt crt

Hand-(ut Dovetails wwurobcosman.com

. Clamp the tailboard,inside face up and projecting jr-rst off the edgeof the bench.

. Adjust the fence so thepoint of the blade is cui-ting on the scribe line.

. Balance fhe tool so iistarts, cuts and ends onthe same plane.

. Theshavingneedstobeuniform in width, lenghand thickness.

. A couple of light passesare usually better thanone heavy one.

. A shoulder or rabbetplane can do the job withthe aid of a fence.

. Check your results with astr"aight edge and a back-lighf it should be lowerand parallel to the insideface of the tailboard.

. If it is out of parallel,depending on thecondition, either repairit or start with a newtailboard.

Hand-Cut Dovetails www.r0Dc0sman.(0m ROBCOSMAN 19

www.r0bcosman.c0m Hand-Cut Dovetails

SECTION 4 LAY OUT

TOOLTIPS

The fewer steps and tools ln layout the better. Reduce the steps - reduce the riskof errors.

Combined with a good steel rule, dividers are the most accurate method forfransferrinp dimensions.. ^ - ^ . " . ' ' ' ' ' . t ]

Use a fine ballpoint pen for layout - it is easier to see, the ljne width doesn't change- - l : + / ^ ^ l - , , ^ - , ^ L ^ * l4rru rL J drvvoyD DItdlPl

A precise joint starts with a precise layout.

. Secure the iailboardr rn r ioh f in lhc r r iqe rco e* r . ' t ] ' . . ' ' .

square or bubble 1eve1 toensure it is plumb.

. Keep the end of the tal1-board low in the vise toprevent sawing chatter.

. Seftin o thp urnrL niono" " " "b * ' '

plumb helps developthe ability to sawnprncnd ier r la r

Hand-(ut Dovetails www.robcosman.com

. These narrorv pindovetails arc simple tol ; r r n r r l h r i : h i l t n r o h

" " " . - . b "

to cut for beginners.

. Mark the half pins byrp fp lcnc ino nnp lpo n f lhp

" " - ' - b . - " '

f i r r i r lo r r t tho e , loo nF th . .

tailboard and making amark rvith the other.

. For nroqi ; rnnl icr t ions- _ f r _ _ - - - - -

'/r" will work.. Do both sides ar.rd sa\re th€

sclnrg lu lar .,ut frre otl,olcomefs of the project.

. Use a second pair ofdrviders for the ncxt step.

. Divlde the distanccbetleen thc '/rpin marksby the desired numberof talls, leave a shallor'vnrer lz r l o . r rh i r rn r l inn

See top of page 67.

LONDON DO\ETA]LS

1/2 PINLAYOUT

LONDONLAYOUT

www.robcosman.com Hand (ut Dovetails

DO\ETA]L MARKER i,

\\'IDE PIN SAMPLE

Hand-fut Dovetails

. Use the doveiail markerto lay or"rt thc joint.

. Rcfcrence both anglesfrom the same mark.

. Wide pins offel morcroom to rvork ar.rd lvill bethp qrrhic.cf .f ih{. rPct r )f" '

! 4 l ' "

this book.. Th lev n r l r r r idc r n ins l l rp' ' ' - - ' t - " ' " . ' ' -

divider setting has krinclude thc rvidth ot onetail and one pin.

. Balance thc'/:pins, makethem r,vide enough tor o q i c l q n l ; r i n q h r l n n l

so wide as to be out ofnronnriinn io ihe iointT " T ' - ' ' ' " ' ' _ ' ' _ l ' ' _ ' - '

. '/*" is a good size to startwith thor-Lgh sor'ne finetuningwill cone withprachcc.

. Tdcr l ih 'hnth rA ni rq r rnfh' ! l ! ' - J ' - _ _ ' T _ _ _

- "

a shallolv mark.. Save this dir,ider setting

for ihe other comers.

www.robcosman.com

LA\{NG OUT 1/2 PINS

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ROB(OSMAN 23

. Start the second pair ofdivrders on the '/: pinmark.

. Wthout leaving anymarks adjust the diviclersuntil you can step off thedesired number of tailsand land on the opposite'/' piu.

. Open the cljviders a smallamount to begin cxperi-menting with pin widths.

START ON 1/2 PIN

. Start on thc 1/' pin andwalk across the joint.

. Notc horv far beyond theopposite '/: pin the dividerleg lands. This wili r:ltimately reprcsent thewidth of the inside pins.

. Opening the dlviders willincrease the pin widthand closing the dividcrswill shrink the pin width.

. Don't press hard cnoughto leave marks until thedesired setting is found.

STARTINC INTHE ]/2 PIN

www.robcosman.com Hand-(ut Doverails

. With the desired stetting,L L ^ l / - ̂ ; , - ^ - J

) L d r L u r r L r r t r / 2 P I r d r r u

step across the jointleaving shallow marksa I each i r rnc l ion Spe lnn

of page 67.

. At the opposite edgedont leave a markhpvnnd lhp An in l i { r thp" ' J " - ' * . ' ' '

divider out and siart from+L; . r / - - ; - . - ,1 . ^ ,^ l l , L . -1 ,L I L r J / / P l r r

A l r U V V A A U A L \

leaving a second mark ateach junction.

. T Jnon cnmnlptinn rrol. - r . - " ' . - - " r , - ' - . - " J " . ^qhnrld havp vnr rr 1/, nr'n

l " - ' ' ' Y '* ^ - l - - ^ - l - ^ ; - - ^ f ^ ^ . . ^ lr L r 4 r ^ D d r r u P d l r J u r c L ] u d r

^ ; - * ^ - 1 . ^ ^ ^ . ^ - - + L ^P [ t l r t d r N J d L L U J J t l t g

board.

DMDERLAYOUTl

Hand-[ut Dovetails www.robcosman.com ROB (O5MAN 25

. Se t e f inp ha l lnn in l non" - ' r " - " ' r - "in thelhpin mark andslide the dovetail markeragainst it using the desiredslope, 1:7 for hardwood1:6 for sofh'vood.

. Start the pen at the scribeline and draw up.

. This prevents accidentallydrawing below the scribeline, something thatcould lead to sawingbelow the 1ine.

. Angle the pen into thegauge to get an exactplacement.

. The most critical tailboardcut is the perpendicularacross the end, the Lineand saw cut must besquare.

SQUAR]NGTHE END MARK

Hand-(ut Dovetails www.r0DCosman.c0m ROBCO5MAN 27

I

SECTION 5 DOVETAIL SAWING---

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TOOLTIPS

Practice so you can assemble your ioint from the saw. The purpose of a dovetail saw is tocut a clean straight kerf that can be giued. Intentionally leaving material to be pared later iscounter-productive and non traditional, dovetails were meant to be assembled saw cut to sawcut.Your saw needs to be up to the task, good tools equal good work.

The peqpendicular cut on the pins is critical. For the joint to work the sides of each pin mustbe straight and plumb. This is where gravif can he1p. A pistol grip saw handle registers in yourhand the same way each time you pick it up with a bit of practice you wili be able to sawvertically without watching a line. Remember to always plumb the work piece in the vise!

You should hold your dovetail saw like you would cradle a baby's hand. Holding tootight is a common enor made by beginners. Held lightly a properly set saw will cut straightand leave a smooth kerf.

. Hold the sawwithyourindex finger pointingdown the blade.

. Your grip should be similarto the pressure used tocradle a baby's hand.

. Holding on to the saw tootightiy prevents it fromsawing straight andcauses a ragged kerf.

28 Hand-CutDovetaih I

ROB COSMAN wwwI0DCosman.c0m

TTII-,MB & FNGERPINCH

. J Jsp fho hnftnm nrrrfpr' f * * - . ' '

nf rrnrrr inrler f inopr :n,-]. " ' . { r ' ' * ' . *

th r r r rh to n inch ihp pnd

of the board to form ananchor for the saw.

. Pinching with the bottomquarter keeps the contactpoint with the saw abovethe teeth.

. Press the saw laterallyagainst your finger andthr rmh to nrerrpnf i l

T ' - ' . ' ' . ' "]1,^* ^ l , l - r ; -^ -- - .^. ,1 1 v l r r ) N 1 1 L U 1 5 d D ] V U

begin the cut.

. T lqp r ro r r r anehnr i r ro d io i iq" " ' J " " . " ' . ' ' . " ' ' - . t ] " ' D . . "

to press the saw intonncit inn hacir . lo the l ino

. This cut should be next tothe line but shor-rld notremove it.

ROBCOsMAN 29

LATERAL PRESSTRE

Hand-Cut Dovetails www.robcosman.com

. j-;. - t €!:;s.. ?th,nCq!FEFWTrylFJ

. Start the cut by tilting thesaw forward and takingabout 80% of its weightoff the wood.

. Continuing to press later-ally against your fingertipswill increase your sawstarting controf use alight touch.

. fu you cut along the line,focus on where the sawmeets the wood andmake the necessarycoreclons.

. After establishing ashallow kerf pause fora second.

. \A,4th this part of the taskdone, take a breath, aimthe saw aiong the angledmark and head for thebottom.

. Don't attempt mid cutconections, its better tohave the kerf straighteven if the angle isslightly off.

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STOP ONTT{E SCREE

M.REPETTTTVE CUTS

. Saw right to the scribelinel

. Stopping on the lineestablishes your cornersand saves a lot of time.

. Saw all of the sameangles before changingyour body position and1'our bench 1amp.

. This saves tlme andyou will benefit fromthe repetition.

. To saw the other side ofthe tail pull your thumbout of I'our line of sightand use just your indexfinger to anchor the saw

$iiti

ht'

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t | 'N{u

Hand-(ut Dovetails www.robco5man.com ROB (OsMAN

. Finish the saw cuts.

SECTION 5 NOTES JfJ]C-l

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3 2 ; ROB COSMAN www.r0D(0sman.c0m Hand-CutDovetails f

SECTION 6 THE FRET SAW

TOOLTIPS

A good fret saw will have a rigid frame and a tensioning system that allows for a verytaunt blade. The better saws have two tensioning mechanisms, one on the frame to take upmost of the slack and a finer adjustment on the end of the blade clamp. \A4th nanow bladesmore tension is required to prevent severe bowing during use.

Go slow until you get accustomed to how the saw performs. The nanow blade doesnot provide tracking like a dovetail saw so you have to steer the cut as weli as push and pu1lme saw

Taping the handle with adhesive sport tape will improve your grip and make the saweasier to control. The nalrower (3 ") th,roat saws are easier to balance on a horizontal cut.

. Install the fret blade tocut on the pull stroke andput it under substantialtension.

. Use a pair of pJiers or sidecutters to twist the bladeabout 30 degrees at thee]emninq nn in fq

. This keeps the sawsframe above the joint onhorizontal cuts.

Hand-(ut Dovetails www.I0D(0sman.c0m

. Having twisted the bladeyou wili need to tilt thesaw siightly before youdrop it dov,n the kerf.

. Come offthe bottomabout 'Ar" before you starlsawing.This keeps you asafe distance from thescribe line.

. Saw as close to the scribeas you can. Although fastcutting this saw can befficult to control, slowdov,n until practiceenables you to sawaccurately.

. Slowdownasyouapproach the end of thecut to prevent scaffng+ L ^ ^ l i ^ ^ ^ - + + ^ i lrrrs 4urdlsrrr r@.

www.r0DC0sman.c0m Hand-Cut Dovetails

I

SECTION 7 SPLITTING KNIFE LINES

TOOLTIPS

tF

aJJJJJJJJJeJJJJJtl

A ballpoint pen works best for drawing the tails. However with the precise work of sawingthe pins to fit, a knife line is better suited.The knife line gives a very definite dividingpoinf splitting a pen or pencil line can be very subjective.

V\hen you are transferring the tails to the pin board, concenhate on keeping the knife tightto the part being copied. Pushing too hard into the part being marked will cause the knife towander as it searches for the path of least resistance. A slightly duiled knife is easier to use andIeaves a wider and easier to see'\,/" .

When sawing against a knife mark on the pins, aim to take half of the knife "V" out withthe saw kerf while leaving the other half of the"V"with the pin.

. Think of the scribe line asa"V"shaped groove.

. Proper sawing leaves onehalf of the'T"with the tailor pin while the other halJis sawn away.

Jf,f,f,efeteq-j

35 Hand-(utDovetails e

ROB COSMAN www.roD(osman,c0m

. Set the iailboard level andlow in the vise to preventsawing chatter.

. Use a bubble level if youcant"eyeball"it.

. Use your digits to anchorthe saw as it starts to cuton the waste side of thescribe.

. If your grip is sufficientlyl ; ^ L r ^ - + L ^ ^ ^ , , , - + ^ v ! - + ^1161tL i 4 ) t r rC DdVV J(AILJ rU

cut it will slide over to thescribed shoulder.

. This technique gives thecrr l r rn evrat qlrr l tnq

reference point.. This is the reason for

er r t t ino dppn rmth thp

marking gauge.See page 16.

. Split the scribe line byLppn ino he l f fhp"V" in

the kerf.. Strive to get a perfect$

vertlcal cut.. Slowdormatthebottom

to avoid scarring the sideof the tail.

HALFWAYDOW\]

Hand-Cut Dovetails www.r0DC0sman.(0m ROB COSI\4AN 37

. Sawing an angled comerwith a saw that cuts asquare bottom leaves a bitof waste to be removedwith a chisel.

. Check )our cuts for excesswaste. Anything abovethe scribe line needs tobe pared.

. If there is material to beremoved" start with thechisel on the markinggauge line and under cutthe surface in the middleof the board.

. Th iq i c pnd mein cn i i

does not reduce valuableglue surface.

. A nanow chisel a11owsgreater control by reduc-ing the pressure requiredto cut.

. With the middle removedyou now have smallerareas ro pare.

. Keep the chisel referencednn fhe qlrop l inp" " ' ^ ' - b* *b" - " " '

Hand-(ut Dovetails www.I0DCosman.c0m

SECTION B CHISELING

TOOLTIPS

--r;

IThe chisel is probably the simplest of common woodworking tools, however for it to performit must be properly prepared and sharpened. The back df the chisel must be made andmaintained dead flat. To do this the sharpening stones have to be kept flat. This means flatteningthe stones before each use and every minute or so during heavy use. The closer the chisel

"back. is to being dead flat the sharper you can make it ani the b"etter it will perform.you cancheck flatness by inspecting an image reflection on the chisel back. No distortlon - it,s flat.Distoriion - it's not flat. If there is distortion you need to reflatten the chisel starting on yourcoarsest stone.

Your drisels should to be comfortable to use. Top-healy chisels can be awkward and tiresomesince you often hold the chisel near the tip to bener gLude it. Modify them if necessary, I havecut handles in halJ to lighten them up especia,lly on the smaller sizes.

The bevel angle can dramatically change a chisels performance. whiie 25 degrees iscornmon for bench chisels you may find a steeper angle is needed for mortise chise"ls (30) anda more acute angle often works best for soft woods. I have a few chisels ground at 17 degeesfor chopping light woods that easily crush.

U11tttUr|tOCI1l1a,t

It

. Use a sacrificial board toprotect your bench topand your chisels.

. Set the tailboard insideface up, start chiseling onthe inside and finish fromthe face side.

IiIItIII

40 www.I0Dcosman.(0m

rtjROB COSMAN Hand-Cut Dovetaik

CHISEL PERPENDICULAR

ffi'r'..;:;

CHOP FL{LF\\AY

EXCESS \\ASTE

. Positiun thc tailLroartland chisel so vou carlsec plrlm0.

. Keep the chiscl plunrbor-pcrpenclcr.rlar asvou chopr.

. Chop the scribe lurc krthc midpoint betl cclreach ta i l .

. Note; somc noocls nrarcrush beforc thel cr-rt.]f so, rtr.r mav neecl anarrorv chiscl n,ith anaclrte cLLttlng anglc(17-18 dcgces)

. Flip the tailboartl ovcr.andinspect the scribc hnc.

. Too n'r-rch n'aste increastsplessLLre un thc chiselbevel thr.eateniue kr pushit bcroncl the scribe linc.

tl ir i

Hand (ut Dovetai ls www.robcosman.com

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ROB (O5MAN 41

M|ri#

CORNER INSPECTION .6:;:$

. If the sar'v cut was tal<ento the scribe line, thecorner is established andthe job is done.Sec page 31.

Corners like tliis dramatica1lv increasc the time rttakes to cut a dovctail.

. \\brking front to back,skell a narror'v chisel tocrit the corncrs clean andremove thc ilebris.

. Use the straight edge ofthe chisel to check forh , , m , r c h a h , - o o n t h o t r i l c

the surfacc mr-Lst be flat orslightlv r-rndcrcut.

i \

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iu ' \ IFryrq;d

CORNER INSPECTION

3l*,*,.,-CLEANING CORNER

Hand-Cut Dor/etails www.robcosman.com ROB COSMAN 43

. Start on the inside faceof the joint with the tail-board secure in the vise.

. \'Vith the guiding handanchored against the tail-board" finnly grasp thechisel close to thecutting edge.

. Set the chisel edge justinside the joint to startthe cut.

. Pare to the centel, flip theboard and repeat fiom theother side. Ease off as youapproach the center.

N0TE:Hff m:';:ffi:lT.i''1:ilffi ::.''*zeappLiedrorceSECTION B NOTES

www.IoDCosman.c0m Hand-Cut Dovetails

SECTION 9 TRANSCRIBING THE TAILS

TOOLTIPS

This is a critlcal process, perfectly executed tails are of no use if the transfer to the pinboard is not accurate. Cuttine a shallow rabbet on the underside end of the tailboard canneatly align the fr,vo boards. Ir needs to be 1/32" deep, smooth and parallel to the face ofthe iailboard.

Finding a good marking knife is difficult. It needs to be thin to fit betlveen London dovetails,flexible to bend slightly when pressed and wide at the tip to register against the tail.You- . . h " ' . l n m r L a ^ " m n 6 l i f t r n n p l n c r r i fl r l d y r r d v q t u l l r d N s u r r

" u u " )

Try to resist pressing the knife hard into the end grain of the pin board. Doing so willmake the knife difficult to control as it tries to follow the path of least reslstance. For thisreason it is better dull than sharp, when dull the mark is easier to see and the blade easierto steer.

. Secure the pin board inthe vise, face out and thetop flush with the plane.

PIN BOARD INVISE

Hand-Cut Dovetails www.robcosman.com ROB CO5MAN 45

. Push the plane back iromthe pin board to create abridge.

. Use the rabbet to registerthe tailboard into poiitionwith the pin board.

. Pulled into place the hr,zoboards are lined up andjust need to be flushedon the edge.

wwwrobcosman.comHand-(ut Dovetails

*

I

. With drawers and boxesthere is a"bottom hous-ing" groove on each piecethat needs to be aligned.

. Use the dovetail markeror any flat surface to flushthe edge of each board.

Use your opposite handto prevent the tail boardfrom moving as you scribethe tails in the pln board.

. Approach the side of thetail with the markingknife at 10-20 degreesand bend it to 1ay flat.

. This pressure keeps thekn i fp t ioh t tn thp te i l ec i t- " ' " ' L ]b -

"

iq draoop,l lhnr tho en,.l' " - . * t r t r ' *

grain of the pin board.. Don't push dornn so hard

that it becomes difficultto keep the knife tight tothe tail.

Hand-(ut Dovetails www.robcosman.com

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. U:e a bendr lamp tocheck for stray knifemarks before removingthe taiiboar"d

. Make anv correctionsnow and note them witha mark as soon as theboard is removed.

. Bv angling the benchlamp to shine across thepin boarcf shadows willmake the knife rnarksmore visible.

. liy,to avoid highlightingwur chalk or penciJ, thebare marks are best.

. C-hamjer the inside edgeoi each tail.

. Start the chisel'/,u,' fromthe end.

. For greater control andsafely. choke up on thecntsel.

ROB CO5MANwww.robcosman.com

Hand-Cut Dovetails

CFIAMFERTT{E EDGE

I

. The chamfer needs to rundov,n the"side"of the tailtn eeco eccemhkr enrj

fac i l i fe tp oLr ino-"--'- ' .. ' ' lr '*, ' 'b'

. Clip the shavings at thescribe line.

Hand-Cut Dovetails www.robcosman.com

SECTION 1O SAWING PINS

TIPS

Practice so you can saw with,confidence. Always attempt to spiit the line, don,t be temptedto saw away from the line and have to pare to fit.

Precise sawing. is a lot easier if you are relaxed. After laying out the joint take a few deepbreaths, look off in the distance to give your eyes a quick rert Ina th.n i.sume vour work.

There is no substitute for good light. A werl-positioned bench lamp will go a long way tohelping you make accurate saw cuts.

. Make sure the pin boardis low in the vise andstanding plumb.

PLTIMB LINES

MARKINGWASTE

Hand-(ut Dovetails

. Use a dovetail markeron its side (or a square)ln rJreur nomon,- l in ' l " t

lines from the scribe lineto the knife marks in theend gain.

. Minimize mistakes bvclearly marklng the wastel

. Pinch wiih your forefingerand thumb to provide anrnnhor Fnr q t r r t ino lhp

saw cut.

www.robcosman.rom ROB COSMAN 5l

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THLII4B AND FINGER POSITION

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. Press the saw against1,our fingers and positionit to spiit ihe line.

. lhke 80% of its weightoit the wood as 1'or-r tiltthe saw forward to startthe cut at the back of thepin board.

. To do this properly the"V"shaped knife line hasio be split.

. One half of the"V"stayswith the pin while theother is wasted in thesaw kerf.

SAWTILTED

. Once the kerf is estab-iished along the top,finish the cr,rt by salr,rngto the scribe line.

. Ar option is to establishthe top kerf then pausebriefly before aiming thesal to finish the cut.

SAWTNGACROSSTHE BOARD

52 ROB COsI\,1AN www.rob(osman.comHand-(ut Dovetails

. Follow the line to thebottom.

. Complete the cut bysawing to the scribe line.

. Vertical saw cuts are ihemost critical. Practice andgravity will make thissecond nafure.

Hand-Cut Dovetails www.r00c0sman.c0m

. Th crr^r nn lhp onnncifp

side of the pin your+ L , . - L L ^ - + ^ ^ , , 1 1 1 . . ^ - 1 .L r L U r r L U L L d J t U P U I U d L N

ln oYn^co lhe l ino \Tnur

the index finger anchorsthe saw.

. Use the fret saw to cutas close to the line aspossible.

. Rioht s idp nf lpf t n in" ' ' " r " '

shows some of the"V"rpmein ino lp f t q ido n f

r iqh i n in showq the"V"_-o_ __ r ___qn l i t :n , l thp r ioh t c ido

nf thp rioht nin qhnurq all' -

" ' ' l j b "

thp " \ / " rpm: in in o'- ' ' , ' , . '*, ' *"b'

. Llard ninq ininino qnFtpr. ' " ' - r . . . " / " - ' . ' . t r " ' ' . . '

tails will allow for somecnmnrpqqinn nf thc 6horq

. Hard pins loining hardi : i lq rl loruq fnr rrpnr l i tt lo. " . ' ' . - l ' - . . ' '

cnmnrpqqinn rrnrr nood

+ ^ ^ , - 1 i . . . + ̂ - ^ ^ - . 1 ; - ^ 1 . .LV auJuJL dl lvrurrLF)ry.

*

FINGER &THUMB POSITION FOR OPPOSM SIDE

ROB (O5MAN www.r00c0sman.(0m Hand-(ut Dovetails

SECTION 1O NOTES

SECTION 1 1 CHISELING THE PIN WASTE

TOOLTIPS

The chisel work done on the pin board is usually more diffioilt than that done on the taij-board.You will find chopping end grain is easier with a narrow chisel than with a wide.The reduced effort needed to cut with the narrow tool means the user has better control.youmay also find the narrow chisel cuts cleaner with less fracturhg of the wood as compared tothe wider chisel. In most cases i would use a 1/2" rather than i3l4',.

Effective chisel work requires a sharp chisel that has a dead flat back. The chisel back isthe.jig.that_guides the tool.You need to keep the chisel vertical as you start to work in thescribe llne- Ifyou start fiom a vertical position the tool will begin to under cut as you near thecenter of the board. This ensures there will not be a bump in tlie center that has to be removedwith another step.

Yorr can.speed up the dovetail process by becoming more efficient with each procedure.i'Ahen.chopping the pin waste, practice angling the chisel to follow the side of the pin.This eliminates or at least reduces the amount of paring to be done in the corner pnorto assemblv

. Place the pinboard on asacrificial board to protectyour bench top.

. Dcvclop a comiortablcand accnlatc nrcthod iorplacing the cliisel edge,

. It hclps to anchor rroLu-pricling hand on thenork piece before settingthc chiscl.

. Keep the chisel verticalrvhile chopping alongthc scribc.

. Practice kr reduce thenumber of requiredmallet strikes,

. First strrke seats the chisel,second and third tal<e itto ihe nrid polnt.

. Flip thc pin board over tcrfinish chiseling from thelace side.

. To pr-s,cnt thc chisclflom nioving past thcscribe line r-rse a preliminan'chop to Lctt'tol'cexcess hraste.

. Less waste equals lesslater.al pressurc on thcbevel oi the chiscl.

EXCESS T,VASTE

www.robcosman.com ROB iOSMAN 57

----T

. Place the chisel tight tothe side of the pin.

. After seating the chiselwith a light strike angle itto chop dor.nn the side ofthe pin.

. If you can learn to chiselalong the side of the pinyou will save considerabletime in the fina1 clean up.

CHISELANGLED ,

CLEAN CORNERS

,t:,;ffi,n,fl. ,

www.r0DC05man.c0m Hand-(ut Dovetails

. Secure the pin board(face out) in the viseto free up both handsfor paring.

. T/q eecipr ln nere onl

glain with a narow chisel.It requires less effort topush thru the wood andthus gives you greatercontrol.

. One hand pushes whilethe other anchors andfirm1y grips the chiselto provide controllingback pressure.

. Seat the chisel handle intoyourhandto applythecontrolled power neededfn nerp pnd qein. " r * . " " . . * t r . * . .

Hand-Cut Dovetaih www.robcosman.com ROBCO5MAN 59

www.r0bc0sman.c0m Hand-Cut Dovetails

SECTION 12 PRE-ASSEMBLY CHECK

TIPS

2'*h%'

."**$

I dont dry fit my joints and I discourage my students from doing the same. Anything learnedfrom a dry fit can just as easily be discovered during a careful preassembly check. Dryfitting causes a couple of problems; it prevents you from developing the confidence in yourlayout and execution. The crutch of a dry fit lessens the need to prefect your technique. Thesecond problem is the risk of compressing fibers and damagng crisp edges. The joint wiil fitbest the first time.

Be patient and take the time to make conections before you apply the glue.The excitementof seeing the joint together often gets the best of us. If it isn't conect before it's assembled itwon't be conect after.

Sometimes being too patient can be equally bad. Too much fettling is often more detrimentalthan not enough. Precise layout is the key. Being able to trust and work to your marks willensue a good fit.

. Use a small square tocheck for flat between thepins, a bump will preventthe joint ftom seating.

. ff the square rocks, youwill need to pare awaythe high spot.See page 44.

Hand-Cut Dovetails www.robcosman.com ROBCOSMAN 61

SECTION 13 ASSEMBLY

T/PS

I

fr

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4J

The assembly is the final make or break of the dovetail joint. once you apply the glue theprocess must move forward in an orderly fashion. The wood wiil im.eiiatelv b.nln r.,g9-r_o,r?,-ok*e from the,glue and what srarts our as a rubricant w,in;";; d" #

"pi"r,i..11,"-.th.

sequence thought out and any needed tools close by. on bigger joints it helps tonave an enra pan ot hands.

secure the pin board finnly in the vise so it does not move as you pound the joint together.At this stage you need everything to work smoothly.

If,something goes wrong and the joint needs to be taken apart, instead of beating i! uset

heaf guo 91 blgw dryer to soften the glue.you may find it easier to use two guns, one ro

heat the inside while the other is heating the outside.Yellow and white glues wiflsoften attemperahres easily reached with a blow dryer

. Use a spahrla or palletknife to glue the longgain sides of the pins.

. A thin even film worksbest, don't glue theend grain.

. Appl"v a thin fihr on thel r i l c ohr ino hn lh n inc e r r r l. * " . , , t r ' * ' ' ' btails ensures a good ioint.

. If vou assemble quicklythe gh,re will lubricatethe joint and help it gotogether.

. Yon can put a dab of glueon the '/r pin end grainsurfaces.

It is safest to use handpressLlre to start the joint.

. Use a fullwidth-poundingblock to evenly close thejoint.

. Pound thru the endq:in for ihp hpqt iunqfpr

of force.

TAILAND PINALIGNED

BLOCK & IIAMMER

aft+F+)

F+F+F+F+F+

www.r00c05man.(0m Hand-(ut Dovetails

ALX4OST CLOSED

PROLIDTNLS

. Kt 'cp tht 'assembll t tvenbr adjLrst ine thelc r.oLrhit r l i th lhe hanrnrr.r.

Sctfing tht nraikingg.rlige r/r lt'ss lhan thctailboarrl allorvs thc jorntto scat bctbr-e the blocl<touches thc prns. Scepauc 1(r

. Clitck ior sqr-iar.e on thejnsit lc oi the jolnt.

. Usc hand pressllfc k)makr. ant crtrrt-.cli ons.

. It's best to re-seat thejoint after makingadjushrents.

. \Mpe off anv cxcessglue before planing thejoint flush.

. Plane the edges flush.

-t*d$g

RESE,,%ry

www.rob(osman.com Hand-[ut Dovetails

InF]NISHED

ftrT

. If rou press the dividerstoo clecp dunng thc 1ayout they mal'be difficultto eliminate 1ater.

. A tight titting shor_rlderjoint shorvs well. This isrvorth the cxlra practicc

. Hopefullv you're com-pletelrr satisfi ed rvith_vour finished joint. Ifnot take a look at somcrepair methods in thell'or-rbleshooting sectionI

I

Hand-(ut Dovetails www.robcosman.corn ROB (O5l\IAN

SECTION 13 NOTES

Hand-Cut Dovetails

SECTION 1 4 TROUBLESHOOTING

IIPS

Bepatient and check each stage before advancing to the next. Most repairs are easier tomake before the joint is assembled. Remember that Jach step builds on th'e accuraq, of theprwious one.

You have to know when to repair and when to start over. In most cases its best to start overif there is any chance th9 lePair will detract from the piece. Repalrs can be time consuming ina three-tail comer it could easily take more time to repair than to redo.

Part of being a good craftsperson is to make invisible repairs. If your repal is palnfullyobvious it is better to start over than to have to explain or apo'logize r*u.rt

'

. This is one of the mostcommon sawing enors.

. The top of the pin ismarked from the bottomof the tail but whenassembled the top of thepin comes to rest at thetop of the tail.

. If not sar.tm perpendicularthe transfer of tails to pinswiil result in a compound-ed error.

Hand-Cut Dovetails www.r0DC0sman.(0m ROBCOSMAN 69

. To make this repair youhave to resaw the sideof the tail.

. Pinch the end of theboard firmly with thebottom ofyour fingerand ihumb.

. Press the saw laterall,vagainst 1'our fingertiPsto prevent the saw frombeing influenced by theerrant saw kerf.

. The lateral pressureagainst the anchoringfingers is the key tostarting this correction.

. On ; norm.rl sarr cttt cachside of the kerf touchesthe blade and forces it tocr-rt straight.

. In this repair most of oneside of the kerf is missing,

. Lateral pressure from theopposite finger tips isneeded to press the sawagainst the right sideof the kerf to guide itthror,rgh the entire cui.

. The finished cut, on theline and perpendicularacross the end.

REPAIRMTH NEW KERF

4lr4p+Jdtt?4471n?+

ROB (O5I\4AN www.robcosman.com Hand-(ut Dovetails

CHISEL CtilDE h*-

PARE REPAJR

\\

. If tl-re waste bctr,veen thetails has already beenrcmoved the previousprocess will prove toodifficult.

. For this repair you willneed a sharp chiscl, ablock with a square edgethat is at least 3/.' thick anda rigd ciamp.

. Place the tailboard on asacrificial board on thebench with thc rvide orf l r rpd onpr ino f rc ino r rn' ' ! ^ ! ^ ' r - ' L ] " b ' * - l ] b

" T '

. Clamp the block with thesquare edge flush withthe side of the tail nccdine squared.

. Thc clamp needs to bet iqht pnnrroh fo rrrorrr.nf' - ' _ ' _ ' " " - " _ ' r ' _ ' '

anv movement.

. You will need a sharpchisel with a flat back todo this properly.

. \Mih vorrr f inc 'ers k, .o)' ' . . o - . " , - . - - T

the chisel lir:mly againstthe bbck.

. S l : r i n r r inov i fh fhp. - " . - ' t * , ' " b

corner of the chisel usinga sr'veeping motion.

. Do this to get a clean cut,cn inc s l r . r io l r f dour r r n r5 . - , ' ' b " ' - - ' b " '

ncrnprd ic r r l : r lo lheT ' T ' " "_ ' ^ ' ' ^_ ' " . - '_

fibcrs may calrse themb roil or tcar.

. It is best to lvork in liomthe outside cdgcs tonr r ) foa t fhc Dpr i r rp lp rT _ " _ _ "

! 4 T ! 4 ' '

trom splintering.

b-

Hand-[ut 0ovetai ls www.robcosman.com ROBIO5MAN 71

. Now the side of the tail isperpendicular as shownby the pen line.

. To finish the job, trim thewaste at the base.

. This is not a seriousproblem unless the angleis so far off it takes awayfrom the joint.

. This is easier to repairbefore the waste isremoved.

. Start this repair withthe saw just inside theexisting kerf.

. Angle the saw to matchthe pen Line and use yourfinser iinq tn hnld i+---'o-- *r "

. Wth a light touc[ sawslowly so the teeth cancut into the side andestablish a new kerf.

. The teeth are cuttingonone side only and willhave a tendency to slidetowards the existing kerfifyou saw too fast orapply too much pressure.

. The wood on the left sidenf the kerf eannni nrnrridp" - " ' T ' " * '

as much support to theblade as the right sidebecause of the first kerf.

. For this reason you willneed to keep lateralnrpqqr r rp rn r i lh r rn r r r f inoorr ' . " " " ' . ' ' ' " . - 1 " * ' . ' ' . t r ' 'i i nq :c ' : ins i ihp lp f t q idp. ' T " * a * ' ' ' " '

of the saw

O n i h o l i n p ; n d r p r d v

to go.

. Th rpnair ihis errant qaru

Ler f ru i l l rpar r i rp chans ins. ' ' 1 " , . ' ' ' ' " ' ' t r ' , l r

the size of the pin.. I\hile it will be noticeable

i l rp in in f can s t i l l hp np : l_ " ' I " _ " '

and tight.

Hand-(ut Dovetails

1i-GqniFry-.

www.robcosman.com

KERF 1/2WAY

ROB COsMAN 73

I. Use the dovetail maker to

redraw the lines startlngwhere the last kerf meetsthe scribe line.

. Start this saw cut as younormally would, use yourfinger and thumb toanchor the saw.

. It will behave as normaluntil you get near thebottom where the supporton the left side of the kerfwilldiminish.

. Slow down and use alight touch at the bottomof the cut to prevent thesaw from falling to the leftas the srrppor t d imin ishes.

. To keep the saw trackinguse your finger tips topress the blade againstthe right side of the kerf.

RE-DRAWTHELINE

NEARINGTHE BOTTOM

ROB (O5MAN www.robcosman.com Hand-(ut Dovetails

l

\A,EDGE FALLS AWAY

SAMNG BELOWTHE SCRIBE

. Erren n.ithor-rt keli sr-rppoltat the bottom of the cutvoll can still finish clcanand strarsht.

. Salr,ing belor'1,the scdbelinc looks sloppr.anclnhi le one or hvo can beovcrlookecl, nore thanthat lvi1l neecl to berepairccl or-redonc.

. This rcpalr can onlr,berlone bciore the plirsare crit.

. Set thc nrarking gar-rge tojr-rst beloiv the ilccpestl<erf.

. ( . . r , t u l h ) ( r i b ( ' J n r \ \ l i l t ,all aror-rncl the tailboarcl.

. Reurember to clo all thepieccs that are atTcctccl bi'this clirnensional change.

. Chisel the ngr, scribe 1ine.

NEW SCREE LINE

www rob(osma n.com

\

. A mispiaced chisel markl h r t in lp rnrn lq : q t r : ioh i" ' " ' - - * r ' " ! ! " ' - ' t l b " '

line will sholv.

. Th is rcnr i r c :n on l r r hp' " ' r ' - - " - ' . - - . . J " -

done before the pinsare cut.

. Ifl'ou can afford to losethe tailboard length thengauge a new scdbe linethat goes just belowthe void.

. Be snre to change thelength of the othertailboard.

. Sawing below theshor:lder line is acommon mistake.

. If lpft vnr uri l l h:rrp r oan' ' ' - ' ' ' * ' ' . . b " T

on fhe pdop o f thp in in t" _ " " ! + ' - !

v ' ' , \ - ' _ '

that is very visible.

II

CHOPPING BELOWTFIE SCREE

NEW SCR]BE LINE

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Hand-(ut Dovetails

t

. Set the markine gaueefor the lolcst part of thesaw cut.

. \'Vith the rvaste aheaclvremovecl there is notmuch surface area tcrregister the heacl ofthe gauge.

. \Alrth the head of thegauge held firmh' aeainstthe end of the tailboardmake sever-al iight passesbv rolling tlre cutter acrossthe edge.

. IV i rh r i lhpp l hn , ' o r roa' T - b ' " b -

vou ma-v be able to finishthe shouldcr by slicing allr r n r r n d l h e p r ] o p : r r , l. * | r ' * ' ' ' '

working tor'varr1 themrdillc.

. The option is to mark thcn o r i n r o l o r r r r r l r r r r , . l h n

shor-rlder r,r'rth a chisel.

SCREETHE PERIMETER

wwwrobcosman.com ROB TOSMAN 77

. \Atth the board secured inthe vise, set the chisel onthe scribe line.

. Under cut the middie ofthe shoulder leaving aqtrin nn oifhor ci,, le

. These narow strips areeasy to pare with a chisel.

. Be careful to follow theoutside scribe 1ine.

Inspect the pin boardafter transfering the tai1s.If several of your marksare misplaced lt may bebetter to start over.Plane the end grain toremove the marks, scribea new line and re-do thetail transfer.

PARET}IE EDGES

78 ROB COSMAN www.rob(osman.(om Hand-(ut Dovetails

. After transcribing the tailsand before you lift thetailboard, check with abench lamp for anyerrant knife marks.

. Re-do any suspect tailsand note the inconectmarks.

. As soon as the tailboardis removed use a pen toidentify the correct mark.

. This repair is easier tomake before the pinwaste is removed.

. The pin cuts have tobe plumb for the jointto work.

. Slopingkerfs create awedge at the top orbottom of the piry onecauses a gap the othera split.

. This repair uses the saw to trim the sideof the pin.

. IMth sufficient lateral pressure the teethcan cut on one side without siiding outof position.

. Start this procedure with the blade in theenant kerf and with your thumb pressingtne saw teeth against the side ofthe pin.

. You will have to support most of the iaia/sweight so the teeth can establish a,,shelf,and not merely scrape the side of the pin.

. Slowly saw this"shelf"down the side ofthe pin until the fuli width of the blade iscutting wood.

. At this point the saw will start to trackby itself and you can flnish the cut to thescribe line.

Hand-Cut Dovetails www.r0bc05man.c0m

. It\4th a plumb pin thejointwillwork.

. This mistake is normallyfatal and the jolnt shouldbe re-done.

. If it must be saved, thebest way is to saw thru thejoint once it is assembled.See page 83.

. The extent ofthe undercut will determine thewidth of the saw kerfneeded to make the repair

. A saw cut on the wrongside of the line is easierto fix after the joint istogether. More than a fewof these would be reasonto start over.

. This repair is done bysawing thru the joint toestabLish an even widthkerf. See page 83.

www.r0Dc05man.c0m Hand-Cut Dovetails

. The best way to makethis repair is to pareacross the graln.

. Paring across the grain iseasier if the fibers are flrstsevered at the base.

. Having been severed thewood fibers wlll fal1 awayas they are cut making iteasier to control the chisel.

. Use a sharp chisel that iswider than the pin is ta1l.

. Anchoryourforwardhand against the woodand squeeze the chisel toprovide controlling back-pressure.

Hand-Cut Dovetalls www.robcosman.com ROBCOSMAN 8I

. Aq \n r npr r lhp h :c l n f

lhp n in ra ise ihp ch iqp l to' - ' - r - " /qLprlr lhp tnn anrnpr'"r -" '- ' .- ' '

. This will avoid breakingoff the corner at the endof the cut.

. For better control it iseasier to take several light- , . + - r L - - ^ - ^ l ^ ^ ^ - - ,! u t J L t t a l t u r t c l t c d v y .

. Work toward the knifemark until the side of thepin is straight and plumb.

. Although it appears easyto place the chisel in theknife mark and pare, thegraln is often running the\,!TOng way.

. The risk is that the woodfibers will break andr rndormino tho n in" ' ' r ' "

ACLEANPIN

-ionx sTRFACE

ISAMNGTHROUGHTTIE GAP

. This is the result of thegrain running against thedirection of the cut.

. Ifthe grain is runninginthe right direction the cutis easy and finishes clean.

. It is easier to repair a gapthat is uniform in width.

. If the gap is narrowerthan the kerf of l.oursaw, simply cut througirthe loint scribe line toscribe iine.

Hand-(ut Dovetails www.robcosman.com

. A wider gap will need awider kerf fiom a largersaw, adjust accordingly.

. Thp qnr rerp edoc n{ a^ " ' " ' 1 * * ' - - . . b ' " ' *

scraper does a good jobof deepening the cornerswhere the saw couldn'reach.

. A sharp or wedged shapecould easily split the wood

. Select a piece of woodthat closely matches theeroe ln ha reneiro, l

. If you're lucly you wl1lfind an off cut from thesame board.

www.robcosman.com Hand-(ut Dovetails

. Saw a filler strip, a bitthicker than the gap.

. I use my opposite middlefinger to press the smallstrip against the blade tosupport it while being cut.

. Determine the shape andsize of the filler strip fromthe actual gap.

. Rather than try to drivethe filler strip all the wayto the bottom of the gap,I trim the inside comerto ensure a tight fit.

Hand-Cut Dovetails www.r0DC05man.c0m

l

. On a flat metal surface,nnrrnd thp fi l lpr ctrin fnr " ' ' - . ' ' 'compress it.

. Tap lightly so \.ou won'tsplit the wood.

. Thp mnish r rp in lhp o l r rp' ' . ' . ' t r ' * '

w i l l h r inq i t hack in q ize' '_-- -____-and nicelrr fill the gap.

. Check if the strip willfit.

. A l i t t lp pr f r : nnrrndinqr " ' ' " " ' t )wili make it easier tonoqii inn i lrp fi l lpr qtrin inr ' " ^ - ' " - . . " ' ' ' - " ' - ' r , ' '

the gap.

. Or r fh in rpnr i rq uzero , l n r

other coated paper does agood job of spreadingglue in the gap.

. Work it forth and back toget good coverage.

POLND TO COMPRESS THE FILLER

L

CHECKTF{E FII

www.rob(osman.com Hand-(ut Dovetails

. Dont pre-glue the strip,the moisture will causeit to swell before it isin place.

. Set the filler strip in placeand tap it as necessary

. You can wait for the glueto dry or trim itwhile thewood is soft and pliable.

. Use several passes withfhp enrncr nf r chem

chisel to shear off theevnpcc f i l ler ctr in

. The repair is well camou-flaged and if is hard to seethe long grain butt joint irthe walnut.

I A FEW STROKES WTrlrTliE PL-ANE

Hand-Cut Dovetails www.robcosman.com

ABOTIT TT]E ATIII]OR

f) O0 COSV,IN has been woodworking lor mosf of his life.I \ \Aft i le earning a B. Sc. rn Induslr ialTechnoJoglrfurnifureDesign at BrighamYoung University, he was Dr. Dale L. Nish'steaching assistant. Rob has also worked with many of the world'sbest master craftsmen - includingAlan Peters, Sam Maloof,Tage Frid, Monroe Robinsory and Peter Korn.

Rob frequently travels to demonstr"ate woodworking techniques,and has taueht hand tool skills to hundreds of students. He hasoperated a custom woodshop since 1989, where he designs andbuilds made-to-order furniture with an emphasis on using handtools. Rob and his wife Km live in New Brunswick with theirten children.

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