Patent ID: 7931059
Filing Date: 2011-04-26
Classification: B27F

Abstract:
1. A method for making a dovetail joint, comprising: providing a work piece comprised of a rectangular board having a top end, an opposite bottom end, a left side, an opposite right side, a front surface and an opposite rear surface; marking the workpiece top with desired locations for tails and pins; aligning a generally rectangular board with the workpiece top markings and marking the rectangular board with identical workpiece markings; forming a plurality of parallel grooves corresponding to said workpiece top markings across one surface of said rectangular board; cutting said grooved board, transversely to the grooves, into two boards, thereby forming two identical indexing boards; clamping the work piece into a vice with the work piece end initially to be worked on horizontally positioned as the top end; clamping one indexing board to the workpiece so that the indexing board non-grooved surface is positioned against a workpiece rear surface, said indexing board oriented so that the grooves are positioned vertically with the indexing board positioned flush with the workpiece top; identification marking a workpiece left side and an indexing board end adjacent the workpiece left side; aligning a rectangular backup board against a workpiece front surface; providing a jig having a support base, two perpendicular clamping bars and a tail guide insert with a downwardly protruding indexing tab, said tail guide insert attached between said clamping bars; mounting the jig on the top of the workpiece wherein the jig support base has a front surface abutting the indexing board grooved surface, the clamping bars hold the indexing board, workpiece and front backup board together, and the tail insert indexing tab engages the left most indexing board groove; configuring a router having a follower collar with a dovetail bit; placing the router on the clamping bars with the follower collar positioned between the clamping bars; turning the router on and moving the router toward the tail insert cutting through the backup board, through the workpiece top forming a tail, into the indexing board non-grooved surface until the follower collar is stopped by the tail insert; turning off and removing the router from the jig; moving and resetting the jig one indexing board groove to the right; repeating the above router and jig movement operations through the right most indexing board groove; removing the jig, indexing board and front backup board from the workpiece; rotating the workpiece so that the workpiece bottom end is the new top end, and the original workpiece left side is now the workpiece right side; clamping the indexing board to the workpiece new top so that the indexing board non-grooved surface is positioned against the workpiece rear surface, said indexing board oriented so that the grooves are positioned vertically with the indexing board positioned flush with the workpiece top, and the identification marked workpiece side and indexing board end are aligned; mounting the jig on the new top of the workpiece wherein the jig support base has a front surface abutting the indexing board grooved surface, the clamping bars hold the indexing board, workpiece and front backup board together, and the tail insert indexing tab engages the left most indexing board groove; placing the router on the clamping bars with the follower collar positioned between the clamping bars; turning the router on and moving the router toward the tail insert cutting through the backup board, through the workpiece top forming a tail, into the indexing board non-grooved surface until the follower collar is stopped by the tail insert; turning off and removing the router from the jig; moving and resetting the jig one indexing board groove to the right; repeating the above router and jig movement operations through the right most indexing board groove; removing the jig, indexing board and front backup board from the workpiece; replacing the router dovetail bit with a straight bit; clamping a new work piece into a vice with the work piece end initially to be worked on horizontally positioned as the top end; clamping the second indexing board to the workpiece so that the indexing board non-grooved surface is positioned against a workpiece rear surface, said indexing board oriented so that the grooves are positioned vertically with the indexing board positioned flush with the workpiece top; identification marking a workpiece left side and an indexing board end adjacent the workpiece left side; aligning a rectangular backup board against a workpiece front surface; providing a jig having a support base, two perpendicular clamping bars and a pin insert having a horizontal, V-shaped element protruding forwardly and terminating in a forward, vertical apex, said pin insert having a downwardly protruding indexing tab, said pin insert attached between said clamping bars; mounting the jig on the top of the workpiece wherein the jig support base has a front surface abutting the indexing board grooved surface, the clamping bars hold the indexing board, workpiece and front backup board together, and the pin insert indexing tab engages the left most indexing board groove; configuring a router having a follower collar with a straight bit; placing the router on the clamping bars with the follower collar positioned between the clamping bars; turning the router on and moving the router toward the pin insert cutting through the backup board, guiding said straight bit on each side of the pin insert V-shaped element through the workpiece top forming a pin, into the indexing board non-grooved surface; turning off and removing the router from the jig; moving and resetting the jig one indexing board groove to the right; repeating the above router and jig movement operations through the right most indexing board groove; removing the jig, indexing board and front backup board from the workpiece; rotating the workpiece so that the workpiece bottom end is the new top end, and the original workpiece left side is now the workpiece right side; clamping the indexing board to the workpiece new top so that the indexing board non-grooved surface is positioned against the workpiece rear surface, said indexing board oriented so that the grooves are positioned vertically with the indexing board positioned flush with the workpiece top, and the identification marked workpiece side and indexing board end are aligned; mounting the jig on the new top of the workpiece wherein the jig support base has a front surface abutting the indexing board grooved surface, the clamping bars hold the indexing board, workpiece and front backup board together, and the pin insert indexing tab engages the left most indexing board groove; placing the router on the clamping bars with the follower collar positioned between the clamping bars; forming a pin, into the indexing board non-grooved turning the router on and moving the router toward the pin insert cutting through the backup board, guiding said straight bit on each side of the pin insert V-shaped element through the workpiece top surface; turning off and removing the router from the jig; moving and resetting the jig one indexing board groove to the right; repeating the above router and jig movement operations through the right most indexing board groove; removing the jig, indexing board and front backup board from the workpiece; clamping the pin workpiece into a vice with a workpiece end having pins horizontally positioned as the top end; sandwiching the pin workpiece between two rectangular boards aligned along a line at the junction of pin and board; removing the pin insert from the jig; clamping the jig over the workpiece top and rectangular boards; aligning a jig left clamping bar interior edge at a right edge of a pin adjacent an area of unwanted material to be removed; aligning a jig right clamping bar interior edge at a left edge of a pin adjacent an area of unwanted material to be removed; placing the router on the clamping bars with the follower collar positioned between the clamping bars; turning the router on and manipulating the router between clamping bars eliminating unwanted material; turning off and removing the router from the jig; moving and resetting the jig to new area of unwanted material; repeating the above router and jig operations until all of the unwanted material between pins on one workpiece end is removed; rotating the pin workpiece so that the workpiece bottom end is the new top end, and the original workpiece left side is now the workpiece right side; repeating the above jig and router operations until all unwanted material is removed; and joining a pin workpiece end with a tail workpiece end.