27 – Machine-Cut Dovetails

Video - September 3, 2007

Most of you know by now that my schedule has been a little packed lately due to a long series of commissions. I promised you that once they were over, I would be able to focus nearly all of my efforts on The Wood Whisperer. And now its time to deliver. I am finally on the last of that series of projects and will be done within the next 7-10 days. This particular episode represents a taste of whats to come. With some new editing software, a new camera, and a little more knowledge and experience on my part, we are able to offer higher quality videos and higher quality content. The new format of the show represents what we would like to think of as “Season 2”. I hope you enjoy it.

I would have to say the most commonly requested episode so far has been dovetails. Handcut, machine cut, through or half blind……..you guys love your dovetails! Well, I have held off for a while because I wanted to make sure I did the process justice. This particular episode is a glimpse into the world of machine-cut through dovetails. Even though the episode is 30 minutes long, I feel like I just barely scratched the surface. The devil is in the details! And each jig differs in those little details. Fortunately, there are some common elements to all these jigs that make this episode useful to anyone, regardless of what jig you use. I happened to use what I consider to be the best jig on the market: the Leigh D4R.

No matter what jig you use or even if you cut them by hand, there’s no denying the “cool factor” surrounding dovetails. If you haven’t made them yet, they are easier than they look and it is certainly worth your time to learn the process. So watch the video and find out what it sounds like, when dovetails cry……….

***Error note*** Thanks to Steve and Brian in the comments section for bringing this to my attention. During the filming of the podcasts, I was using “props” for my cuts and consequently was not as careful with my organization as I should have been. Now you see why I use props. lol. I accidentally reversed the pins and tails. My rule is to cut the tails in the sides and the pins in the fronts and backs. I did the opposite in the video. I guess thats what happens when you are focused on filming and getting the right shot, instead of making proper dovetails. So don’t get confused. As long as you remember the rule (and you don’t try to make a show out of everything you do), you should be fine.

Products Used

Leigh D4R
camp=1789&amp
creative=390957&amp
creativeASIN=B001ANMD7Y&amp
linkCode=as2&amp
tag=thewoodwhispe-20

Discussion

Darryl September 3, 2007 5:14 pm

Marc,
I like the changes you’ve made to the show. The new intro is great, the tool tips are nice as well as the other graphical items tossed in there.

I’d also like to thank you for showing the “real” version of the liegh jig. I’ve got the previous model (the D4) and I do like it (though I need to practice more) but it was nice to see you showing the details such as the test board. No other woodworking show seems to show that part and it truly is a critical step.

Thanks again, you and Nicole are doing a fantastic job!
Darryl

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Jeff September 3, 2007 5:33 pm

Marc,

Nice work on the dovetails podcast. Its nice to have you back doing podcasts for us again. Are the handcut dovetails next!

Great work by both you and Nicole,

Jeff

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steve September 3, 2007 5:36 pm

Is it just me, or did you cut the pins and tails on the wrong pieces for that case? The wenge should have pins, not tails.

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PrettyMuchIRock/Taylor September 3, 2007 5:47 pm

You guys have a pool? Great video, thank you.

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thewoodwhisperer September 3, 2007 6:26 pm

Thanks for the kind words guys. Hand cuts are not next, but we will do a show on them eventually.

Taylor- yes. ;) I dont recommend living in Arizona without one.

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Brian September 4, 2007 2:58 am

Just like Steve, I can’t help but wonder why you cut tails on the wenge fronts – at least that what it looks like?

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Mitchell September 4, 2007 4:21 am

Iâ

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Ronaldo September 4, 2007 5:29 am

Boy, your beard grows back really fast ;)

Thanks for the videos and keep up the great job!

-Ron

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muddler mike September 4, 2007 6:31 am

wow, Marc – really demystifying the process for us newbies. I love the new changes to the format – it’s looking so well produced that I’m ready to hear it being bootlegged by DiY….lawsuits pending, of course. :)

Mike

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Jack Frost September 4, 2007 7:11 am

Great podcast. I watch alot of woodworking shows and noone, even Norm, ever shows all the set up that goes into makikng dovetail joints. Thanks for the demo.

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Kirch September 4, 2007 7:16 am

Marc & Nicole:

Outstanding work on the dovetail podcast! The closeup camera work to show the scoring cuts and plunge cuts was especially good. I love the out-takes.

How long does it take to produce a 30 minute segment like that? I am not sure everyone has an appreciation for the amount of work involved.

Kirch

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thewoodwhisperer September 4, 2007 7:28 am

lol now thats a classic. After a second comment I figured I needed to go back and review the details again you guys are absolutely right. I did reverse my pieces. Is this a “do as I say and not as I do” situation? lol.

Oh well. Just remember, pins on the fronts/backs and tails on the sides. Damn good thing those were just “props” for the show. ;) Incidentally, I made an error note in the actual show notes.

Kirch- It does take quite a while. The filming was done over the course of 2-3 days, but it wasn’t the only thing I was working on. So lets say 1 day of filming. The editing took me about 2 days. Now the reason for that is because I am using new editing software and I am still getting comfortable and experimenting with different graphics. But eventually the editing will get faster.

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Brian September 4, 2007 8:11 am

We all have bad days

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thewoodwhisperer September 4, 2007 8:15 am

Oh Im not ready to call that a bad day just yet. Making that mistake on a customer’s project…….now THATS a bad day. ;)

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Andy September 4, 2007 9:18 am

Episode #27 was great. Thought the Leigh dovetail jig was too complicated, not so after your video.

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terrysintown September 4, 2007 9:49 am

Hey Marc very good dove tail video.
I would like to say one thing about a comment you made during the opening. â

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thewoodwhisperer September 4, 2007 10:32 am

Hey Terry. I think you misunderstood the point I was making. The louvered doors were something the customer wanted. I didnt necessarily like the way they looked. But that had absolutely nothing to do with “quality”. The doors were finely crafted and they suited the customer’s taste. There is a big difference between the concepts of style/taste/aesthetics…………..and quality. Let me give you an analogy. You are a painter and the customer wants a certain wall painted pink. You think pink is ugly, but the customer insists they want it pink. So you paint the wall pink. Your responsibility then is to paint that wall with the best techniques you know how, regardless of the color.

So with woodworking, if you have certain quality standards, than I believe you should always strive for those standards even if the customer would be satisfied with less. And of course, to survive in this business, you occasionally need to compromise those standards to bring a piece down to a price the customer is looking for. But when this happens, I make sure the customer is fully aware of what they are getting……and more importantly, what they are NOT getting.

And if I do ask what you guys think about something, I am fully prepared to take criticism, good and bad. I may not always like it, but I don’t think I have ever responded unreasonably to criticism.

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Brad Nailor September 4, 2007 10:57 am

Cool video Marc. I have been wanting to buy one of those dovetail jigs, it’s great to see the ins and outs of how to use one. One of the things I learned in working in a production woodshop is always mill setup pieces when preparing your materials..they are indispensable! Another thing is, no matter what your personal tastes are you have to give the customer 100% of the quality that youâ

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Larry Moyers September 4, 2007 11:23 am

Great demo on dovetails. Since I have the Leigh systems, I plan to use your video to refresh its setup….. Thank you

Suggestion… since you reversed the pin and tail setup, please consider redoing this video… your presentation is a terrific training reference for those who infrequently use a dovetail system.

Thanks Larry

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thewoodwhisperer September 4, 2007 11:35 am

Larry. Remake the video? lol. I was lucky to get the video out the first time.

The good thing is that most people would not have even picked up on the error if I didnt announce it. In the video, When I said I was cutting pins, I was actually cutting pins. When I said I was cutting tails, I was actually cutting tails. The mistake is only visible when I am doing the test fit and you see me fitting a piece of wenge with tails, to a piece of maple with pins. The actual process and setup and spoken advice is all accurate. Just pretend you are color blind and there will be no confusion. :)

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Gracious1 September 4, 2007 12:03 pm

Marc,

Thanks for giving me dovetail fever. I was watching your podcast at 3a.m. last night(up with a sick kid) and I came thisclose to running out to the garage to run a few pieces through my D4 to see if I could minimize tearout, get them snugger, get some test pieces in the kitchen so my wife would make me breakfast, give me a back rub, etc….

Didnt realize the effect dovetails had on the significant others! Thanks for the additional non-woodworking insite and wish me luck!

Also, yet again, kudo’s for the continued evolution of TWW to you and Nicole!

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terrysintown September 4, 2007 12:10 pm

Hey again Marc

Not to turn this into a debate but rather a discussion, I do understand where you are coming from although you kind of lost me at the pink wall. All Iâ

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Brian September 4, 2007 12:13 pm

Marc, I realise it will be PITA but I would pull this video and re-edit the corrections else it will come back to haunt you. I agree with others who have commented on it as an excellent educational resource but as it stands it will confuse those who are new to this game – especially as you go to the trouble of explaining why the tails and pins go where they do.

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thewoodwhisperer September 4, 2007 1:18 pm

Hey Terry. Of course we are still buds. I guess everybody has a different philosophy. I consider the door style an aesthetic issue, not a quality issue. I believe that something can look like crap, yet be well constructed. Alot of the artistic furniture I see is exceptionally ugly, but I have to marvel at the skill involved in building the piece. So I suppose we, as woodworkers, need to decide where to draw our personal “line”. From my experience, if every piece I build has to conform to my own taste and my own likes and dislikes, I would never make any money. When a customer commissions me to build a pre-designed piece, I am not in much of a position to change their design. Yes, it takes the art out of it, but I wasn’t hired for my artistic vision in this case. I was hired for my technical skill. And I think that’s where we differ. That sounds like a job you would have turned down. For me, it was a no-brainer. The money was good and I need to eat.
This customer’s design essentially revolved around these doors. The doors were a distinct part of his vision. Telling him his doors dont look right to me would be roughly equivalent to telling him I dont like his hair cut. I have to know where to draw the line between an opinion, and a necessary design suggestion.

And on a second note concerning the video, right now its just not feasible to redo the video. This video is by no means a step by step how-to on machine dovetails. No one should be able to take this video alone and go cut some dovetails. It was really meant to cover the basic concepts and provide tips and tricks that you might not otherwise see. With a written correction, this comment thread, and a user’s manual, I have faith that even beginners will understand and not be hindered by the error. Perhaps when my schedule frees up I will go back and reshoot those scenes. Hell, maybe I will just shoot a correction announcement and insert that into the video. :) In fact, I think that’s just what I will do.

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Mitchell September 4, 2007 1:20 pm

Wow! Tough crowd, Marc, especially the cyberspace hecklers.

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Frank September 4, 2007 3:38 pm

You said it Mitchellâ

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Shannon September 4, 2007 4:12 pm

Great show!! I have a leigh jig and learned a few tips from you that I plan to incorperate in my shop.
You mentioned in your show that you can use any wax applied to the tools. The problem is that the wax must be silicone free (many waxes contain silicone). The silicone can interfere with finishes down the road. I personally use pure carnuba wax. It is a little spendy, but when you think of the $$$ we have spent on our tools, I feel it is well worth the extra cost.
Keep up the great work. I look forward to future episodes.
Shannon

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Kendall September 4, 2007 5:23 pm

Awesome Job Marc! Thanks for always encouraging me to be a better woodworker.

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runningwood September 4, 2007 5:55 pm

Marc, great podcast again, but one other thing that was a little confusing to a newbie. The video seemed to skip the step describing how you determine spacing for each individual pin/dovetail. You showed where the end pieces fit but then it skipped to …. now it is set up and you were tightening screws. Is each one evenly spaced, does it matter or is it something you just eyeball ? Not a criticism , just a question.

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Damn Hippie September 4, 2007 6:25 pm

Hey Marc, thank you so much for the step-by-step on the machine-cut through dovetail process. Once again, and as always, you’ve delivered a high quality podcast with both solid information and a good sense of humor.

As for the snafu with the tails on the fronts, I think you deserve a little slack. I think it looked kinda cool. What would stop you from putting a dowel vertically through the tails and pins, to support the “mistake”?

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thewoodwhisperer September 4, 2007 6:44 pm

Hey Runningwood. The awesome part about that jig, and other jigs as well, is that the spacing doesn’t matter. Whatever looks good to you. But as always, consult the users manual for your particular jig just to be sure of the spacing situation.

Hey You Damn Hippie. :) You certainly could dowel the dovetails if you wanted to. But truthfully I dont think all is lost if you assemble a drawer backwards like that. Honestly, a nice tight fitting joint and a little glue will go a long way. There is still lots of long grain to long grain glue surface and I think you would still have to break the joint completely to get them apart. So although its not the “proper” way to do it, I dont know that I would trash a whole project if you realized at the end that the pins and tails were reversed.

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Jeff September 4, 2007 7:04 pm

Marc, I guess know you know why Norm never got more specific than the basics! As usual I did learn some tricks of the trade that will make my dovetails better and easier but I think that cutting dovetails with a router is one of those things that you need to do yourself with your jig and your manuel.
On a different subject I am now completely caught up with the T Chisel rough cut show thanks to your link. He is quite a character and a craftsman.what Are your thoughts on Tommy and his bombe secretary?

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Paul Comi September 4, 2007 8:24 pm

Good podcast on the Leigh jig. You almost have me wanting one :-)

I say almost because, like you I started off with the Rockler jig and hated it, learned to cut dovetails by hand, and then recently bought a Keller jig for functional dovetails. I may eventually get a D4R if I find myself having to make a lot of multiples of drawers like for a gang run of dressers for someone (and can absorb it into the job).

At first I thought the Keller was the poorman’s dovetail jig, but in reality, its super efficient and produces excellent functional dovetails with the absolute minimum of set up. I use mine in conjunction with the router table and its definately the get r done dovetail jig.

ps The power went out in my area of Los Angeles on Saturday and it was 106 outside. I can’t fathom what its like to live in Arizona with the heat you have to deal with.

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Brad_Nailor September 4, 2007 8:37 pm

Forgot to say..the video quality is excellent….the new camera is really working for ya. The dovetail type details look like Sketchup to me…wow…Getting fancy! Next maybe some animations?

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Dean Knight September 4, 2007 9:04 pm

Grest piece on the dovetail jig. I do a few things differently than you showed but that is the beauty of this machine. It will allow different procedures for those of us that wish to use them. You almost can not do it wrong if you read the book, you only need to pick the way you like best. One factor is Marc’s use of two routers and the setup involved. I use one router and reset my router. you did a good job Marc despite some of the comments and I sure appreciate it. Dean Knight

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Drew Armstrong September 4, 2007 10:13 pm

Marc & Nicole… Awesome video… the new equipment and software has made a perceptable difference. Thanks for the T-shirt… now offer a grey one so i wont ruin the next one I order first time out… white and me should not be allowed together… How about grey or navy blue…

Drew

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Jeff September 5, 2007 6:00 am

I think some here need to cut the man some slack! At the beginning of the podcast did you see the caption that said “this podcast will replace the owner manual”? Neither did I because it wasnt there! Also, if you pull up the DIY Network, you won’t find the WoodWhisperer because they are not shooting the podcasts! These podcasts are being done by Marc and Nicole on their own dime. They are not being directly paid by someone to shoot these.

As far as the pins and tails being backwords, who says that is wrong. I recently had a commission where the customer wanted the drawers of their cabinet built witht the tails pointing out! It actually looks nice and the customer is happy. Besides, if you cut the pins and tails correctly and glue them together, you WILL NOT pull them apart. So who’s to say what is backwards?

I wonder how much crap the rest of us would catch if we put our projects on a website and had them critiqued by every tablesaw owner in the world? I don’t think I would enjoy my work being disected grain by grain.

Have a great day,

Jeff

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Chris September 5, 2007 10:22 am

Marc,

great show, great podcast!
Just an expansion on a comment you made in the intro to your dovetail podcast. The old Chinese certainly knew and occasionally used dovetails. Dovetails were one of the simpler joints and as far as I know were rarely used as structural elements in fine furniture. Of course there are few notable exceptions such as this one:
http://www.wkfinetools.com/tUs.....tail11.asp

Keep up the good work!

Chris

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Paul F September 5, 2007 12:08 pm

Fantasic work on the new season! I really enjoyed the new video on the D4R, as I purchased one just one month ago. Any words of wisdom on using plywood in the jig for drawers? Your tips on tape and backer board really helped, but I found I had to put a board on the front side as well. Also, I pre-cut my dadoes for the drawer bottoms, but my pin placement must be slightly off, because my joints did not line up when attaching the sides and front. Maybe I would be better to cut those after?

Thanks again for the great work,
Paul

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Hank September 5, 2007 3:09 pm

Mark-
WOW – I mean WOW!!!!
I am not sure there was EVER that many comments from listeners?

Here is my two cents – DO NOT REDO the video!!!! (Yea I saw that you already said you wouldn’t) – but here is the thing. What many of us like about your site and specifically the pod casts – is the fact that you are DOING this (whatever technique or project etc.) and the reality is we do things wrong – that is life! That is life in the shop – you have to pay attention, you have to block out those things from work or what ever and as you point out sometimes it is not easy and that is when we make mental mistakes that as in this case are not easily fixable! But if I were in your shoes, I probably would have played up the fact of the mistake as a training point of “Measure twice, cut once” (In this case stop, look and make sure of your pin and tail boards!) (Sorry Nicole – skip to the next sentence!) Because noone wants to screw up their chance for a good tail!

Thanks again Mark for a GREAT pod cast and learning opportunity!

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techie September 5, 2007 4:55 pm

Finally, a podcast where Marc is using the venerable OF 1400 EQ. Nice to see German engineering used in such a nice setting (cutting dovetails of course). I like how the ease and control of the fine micro-adjust were demonstrated cuZ i am gonna use the same router to make my own dovetails.

The video is a great inpiration.

thanks again

Marc

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NoTalentRookie September 5, 2007 6:24 pm

You could have taken the easy way out and explained that this particular drawer is not narrow side to side, and deep front to back, but wide side to side and shallow front to back. Oh…..and those color differences……thats a design element. Yeah….thats the ticket…a design element! ;-)

I ain’t nowhere near ready for dovetails yet…but I sure enjoyed the video. Keep up the good work.

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Doug Varney September 6, 2007 11:46 am

The mistake you made on the dovetails, and the wonderful way you handled it shows that you are trying to TEACH us not just make a presentation. Great job. I learned a ton.

Thx

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Mike in St. Paul September 7, 2007 6:47 pm

I’ve said it before, and I’ll say it again…

Marc, the reason I love this site so much is because you are a kick-butt woodworker and craftsman, but you are also human and YOU AREN’T AFRAID TO ADMIT IT! No offense to Norm Abram or any other big-time woodworker, but you never see them screw up (yet you know they do).

I learn more from you from what you do right and wrong than all the rest combined. Being human helps us see common errors and realize that when we screw up, we are learning from our experience and that is okay.

THANK YOU for providing yet another awesome podcast. You are the BEST! And a few new bloopers never hurt either! :-)

Thanks,

Mike in St. Paul

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John September 8, 2007 1:17 pm

Hi,

Been there, done that. I call them fancy fingerjoints.

Keep up the good work!

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Vic September 8, 2007 11:13 pm

I know, I know. I’m extremely late viewing your latest podcast. MY BAD! But, I’m
kinda glad I didn’t watch until now, because I usually only see the comments made before mine. The comments on this podcast truly show your impact in this new realm of woodworking education. If your podcast were not interesting, informative, and very highly watched, you would not be receiving the highly emotional and varied responses. After I figure out if I can ever master my Woodrat, I might think about a Leigh jig. Thanks again for always entertaining me and thanks to all you regulars who love woodworking and TWW enough to have strong opinions, which are also very entertaining.

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wilbur September 11, 2007 5:28 pm

Hi Marc,

Excellent job on the episode! I really like the widescreen format.

Two questions about this episode:

1. One of the best features about Festool routers, I’m told, is the dust collection. It looks like you didn’t hook up the dust collection while routing out the tails and pins. Is there a reason for this?

2. From a production standpoint, how long does it take for you to finish a dovetailed drawer using the Leigh jig, including setting up the jig, doing your test cuts, and cutting out the dovetails with your “good” boards?

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thewoodwhisperer September 11, 2007 6:03 pm

Hey Wilbur. The Festool dust collection is indeed the best in the business, but on a dovetail jig, it is off little use. The dust collect of all routers is above the base. The vacuum sucks the chips up as the bit creates them. On a dovetail jig, the bit is below the base, the jigs fingers, and is housed by a guide bushing. There is virtually no way the suction can reach the bit. So on a dovetail jig, the only effective dust collection will occur below the router. I believe Leigh just came out with a vacuum attachment that does just that.

As for the production time, I have never really timed it. But I would say I could have a set of dovetails cut in about 30-45 minutes.

Hope that answers your questions.

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Norm Musur September 12, 2007 1:28 pm

Marc: Saw one of your videos for the first time yesterday. I really appreciate your approach of candor, humor and youth to a somewhat stodgy industry. I will try to support you financially so you can keep it going. Thanks.

Norm Musur

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Dean Knight September 12, 2007 1:44 pm

Marc, yes Leigh did come out with a vacuum device as you said. The other factor that has Leigh in business is the quality and repeatability. If all of us could cut them by hand and have them 1/2 as nice we would cut them by hand. To most of us the time is not the factor it is the quality. I wany my dovetails to look like yours or Norms (God bless Norm) and there is only one way I can do that and that is to use a Leigh jig.
Dean

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J. Mason September 12, 2007 5:11 pm

One item re:dovetail jigs. The Leigh is probably #1 on the gold standard but there is a jig out there called the Stotts which you make yourself. Granted it only makes through dovetails but for about $40 fee you can get the template and build it as long as you want and it cuts a pretty good eyeball dovetail for much less than the Leigh. Once you make the jig, it does not take 30-40 minutes to dovetail all four sides of the drawer, if you can remember to keep them in proper order.

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TJ September 13, 2007 6:45 pm

Marc & Nicole,

I’m still trying to find those vitamins you take :)

What a great show and how refreshing it is to see a professional boost his audience’s self-confidence by NOT editing out the real world experience.

Keep the good work!

Thanks,

TJ

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Greg September 13, 2007 7:02 pm

Thought this presentation was awesome. I also enjoyed the bloopers.

Do you think you will eventually get to the setiing up of the jointer?

Please keep up the great job.

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Vic September 15, 2007 7:43 am

Greg, check out Video Podcast No. 6. “This Jointer’s Jumping”.

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thewoodwhisperer September 15, 2007 10:30 am

Thanks Greg and thanks Vic for pointing him to Episode 6. Eventually I will do a full episode on the setup of the jointer. Kinda like I did for the bandsaw. Now that I have finished all the commissions I was working on, I can really focus on determining a filming schedule. So the best I can say right now is……”soon”. :)

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Don September 17, 2007 10:29 am

Hi Marc,

I understand you cut the pins and tails in the wrong boards by accident. I do on occasion cut them this way intentionally when I want to show them off. Visually the tails are much more interesting to view I think. In order to overcome the loss of the lock offered by a properly cut dovetail I dowel the joint.

Once everything is cut I dry fit everything to assure fit then glue up the drawer as normal. Once the glue is dry, from the bottom I drill a 3/16â

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Grant in North branch September 18, 2007 7:29 pm

Another great show Marc(but I still miss your old intro music)!

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thewoodwhisperer September 18, 2007 7:39 pm

Thanks Grant. Want me to send you a copy of the song on CD? :)

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Grant in North branch September 18, 2007 7:49 pm

Excellent!
I don’t mean to take anything away from your new stuff; it’s just that the old intro was so identifiable.

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thewoodwhisperer September 18, 2007 10:41 pm

Well, unfortunately the song is identifiable with several other internet shows as well. Its a royalty-free track from Apple and is quite popular. I decided for the sake of originality to go with a less known royalty-free track. I also don’t think the other song would have been an appropriate fit for the new intro.

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Grant in Nortgh Branch September 19, 2007 4:00 pm

Marc. You are quite right.
I am over it; but I do hope to hear more of your funky, jazz, fusion stuff in the future. (-:

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CAM September 19, 2007 5:49 pm

Marc, I was wondering what software application you are using for your podcast editing. I’ve been playing with iMovieHD, which has some limits but the ease of use has been a real time saver for my limited videos.

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thewoodwhisperer September 19, 2007 5:59 pm

I will definitely jam it out again in the future Grant. No worries there. :)

CAM, I am currently using Final Cut Express. You can find out more about my setup on the About page: http://www.thewoodwhisperer.com/about

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John September 29, 2007 9:25 am

Man, you can grow a beard in between 20 second segments!!!!! Impressive

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Flash Jorden October 2, 2007 6:45 am

Great videos! I was turned onto your site by one of my fellow radio controlled model airplane enthusiests. The title of the episode was great, although you missed your chance to use a “sample” from Prince’s song. Probably better you didn’t, legal reasons and all. It was a good of you to go back and add the correction piece in the middle (although it does sound like someone lets a fart rip about 1/2 way through it. LOL) of the video. It helps folks like me keep things straight. And I will echo those folks who also say that it is good to show your mistakes (and the out-takes) in the video. Keep up the good work. I’m definitely adding your site to my favorites list.

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Grant Davis October 15, 2007 4:47 pm

Mark,
I really like watching your videos, but I wanted to point out that you were particular to show that you put on your respirator when you made your first cut. However when you made your test cuts setting up your jig I noticed that you were not wearing it. Care to explain?

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thewoodwhisperer October 16, 2007 11:12 am

Hey Grant. Is that something that really requires explanation?? My guess would be that I either forgot or I was just in a rush. In general, I recommend wearing a respirator anytime you are cutting or sanding wood.

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Jeremy (Bama5150) October 16, 2007 4:21 pm

Maybe his producer should remind him to wear his respirator? Or his camera man, lighting guy, director, video editor or that guy who holds his cue cards?
I guess we can give him a little credit for pulling it all off as well as he does. I’m just glad he still inspired to keep putting out these videos.

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Steve November 12, 2007 7:54 am

I want to ditto the comments of Hank and others and encourage you to leave the video alone. Your example of how distractions can cause errors, well there you go. I tell my students that I make my biggest mistakes when I’m in a hurry or tired. If you edit it all to death people get the wrong idea about how much time it takes to actually make this happen.

Unfortunately for me I have one of those blue router jigs still in the box that I bought on sale to do cabinet drawers for our new kitchen. I’m going to give it a go, if it’s too frustrating I’m heading back to my standard rabbeted and pinned drawer joints like you showed on your first example. They are very strong, look good and easy to make.

Steve

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William December 2, 2007 6:04 pm

I just learned about the WoodWhisperer site from a friend the other day. The intro for this episode is great. I think your mistake, along with the inserted “corrective,” has far greater teaching value than a cleaned up, perfected “studio cut.” You can see exactly where and how you got things reversed. That alone makes it a keeper. I remember telling an experience woodworker of a similar mistake. His reply was, “You never learn anything by getting it right. Now you’ll never do that again.” Your video goof will imprint the difference between pin and tail boards much more deeply than you intended and will remind me to mind my pins and tails along with my “i”s and “o”s. Keep up the good work, and don’t let the armchair cybercritics discourage you. Awesome video!

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Benjamin Portnoy December 11, 2007 8:34 pm

Wonderful episode!!! I just recently completed a “poker box” after seeing this and used through dovetails on it. The piece came out quite nice, I used cherry for the front & back and walnut for the sides. The colors of the wood really looked nice using the dovetails. Thanks!!

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Shannon in Maryland January 14, 2008 7:12 pm

Marc,
Great episode. You have inspired me to upgrade from my Rockler to a Leigh jig. I especially like the pink feather boa in the background. I imagine this keeps the dust out of your shirt. Also, I knew I liked your style, but now I am convinced after I saw you drink Fat Tire beer!

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keith November 30, 2008 6:09 pm

Sorry … very late in getting hooked on your podcasts. Very impressed with your work. Had a quick question on the D4R stand you were using. I have an older D4 and hate clamping it to the benchtop. Was the stand you were using a custom stand, or is that available somewhere? I didn’t find it on Leigh’s website.

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thewoodwhisperer November 30, 2008 9:01 pm

Hey Keith. better late than never. :)

The stand is actually made from parts that are sold by Rockler. They basically sell fancy angle iron that you can made into any size stand you want. I then just put a piece of ply on the top and glued some dowels to the surface. Pretty simple but its not something that Leigh sells.

Hope that helps.

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keith December 3, 2008 5:25 pm

Cool idea. You should sell it to Leigh (or Rockler). :)

Thanks!

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Trevor Vernon April 30, 2009 1:02 am

I’m so glad I stumbled onto your site Marc in the UK most people (who have SKY TV) think woodwork means Norm & while I’m not about to knock him ‘cos he’s great at what he does I’ve got to say you are really in the ZONE man Thanks for taking the time, you got my support. By the way I have a Leigh D4 & have made exactly the same mistake, I now use your inside/outside marking system(why didn’t I think of that?)I also have a dovetail jig that looks exactly ike the first one you showed but in the UK it’s marketed by Trend if anyone is interested?? Keep up the good work!!

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Jeff T March 6, 2010 9:56 am

Hey Marc
Not to pile on, but you made another error in technique. At one point you bent down and routed at face level, something you should never do. Leigh’s manual warns about it as well. Great show, thanks for taking it on.

Jeff

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- thewoodwhisperer March 6, 2010 10:00 am
  
  haha well I wouldn’t call that an error so much as a calculated risk. I find it very difficult NOT to watch what’s going on and when I am trying to approach the wood gently to avoid tearout. I agree its not ideal, but with good eye protection, I find it no more dangerous than anything else I do in the shop involving spinning blade and wood.
  
  Reply
Ross November 6, 2012 11:50 pm

Just gotta ask, on your first demo drawer with the steel dowels you say you decided to dress it up with the little strip of wenge. I’ve dressed up joints like that too, but generally because I cut the depth wrong and had a little gap. :)

So was that wenge piece a deliberate design choice, or was it a happy accident?

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Thomas De Luna December 10, 2012 2:04 am

This video helps a lot since I am getting into building boxes with dovetail joints. I have given it my first try and I think I am making it seem more difficult as it should. I have had tearout and this helped me solve that. The other is deciding how to cut the other side so the pieces will fit together. I am still trying! Thanks for your help!

Thomas

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Brandon December 28, 2012 5:44 pm

I love demonstration videos like this. I was hoping to see a comparison of various jigs in use, but I realize that would be a very time consuming process. My wife for me the Rockler jig several years ago and it has just been removed from the box. She got me a new porter cable hand held router for Christmas, so I think I will put the two together and test it em out. At the beginning of the video you said that you had issues with an older Rockler jig. I’m curious if you have tried the newer version, if it has improved, and if the issues you had in the past have been corrected? Also, any tips for the Rockler jig?

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- thewoodwhisperer December 28, 2012 6:09 pm
  
  No experience with the new one unfortunately.
  
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Jack O May 17, 2014 6:32 pm

Marc,

While I realize that this video is years old I have to ask if you have used the Leigh VSR vacuum and router support attachment? I just got one and the improvements with the dust and chip collection using my Festool CT22 and the added support for the router are quite impressive.

Keep up the good work,

Jack O’Connor

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Vince November 21, 2014 4:53 pm

Love the B & W scene but I have to admit that THE best part is how you were moving nothing around on the grill with the tongs (I have been told I don’t have a “normal” sense of humor). Always sound advice/instruction and a quirky delivery. Keep up the great work.

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Peter Johns June 11, 2015 6:25 pm

Excellent video and introduction to the D4 jig. Many thanks Marc, this is a valuable resource for us amateur woodworkers. I have just got a 2nd hand D4, have read the manual, and now looking forward to applying these tips and tricks. Particularly like the one about the way to minimise tearout and the process for doing each tail – climb, RH side, then LH side

Keep up your great work

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Jack Prince January 22, 2018 11:59 am

I just purchased my first dove tail jig after much research and selected the D4R Pro. I opened the box and checked everything out. Found that the fingers definitely needed some exercise to move freely. Read and reread the instructions. Looked at a bunch of videos and decided to have ago at it. First mistake was thinking, I’m good and will just cut four pieces to start with making a box. No need for a 5th practice piece as I’ll just set it on the numbers and be good. Didn’t quite work out for me. Lot of gaps and didn’t have the direction down for loosening and tightening the joint. But hey, got lots of practice and realized its probably best to make the joint on the tighter side and creep up on the smooth snug fit. So that is exactly where I am at now but before trying it again, I wanted to check out any other videos out there for a final prep and just spotted your video. Whats another 32 minutes. I wanted the benefit of all the tricks. With all the info fresh in my head, I watched your video and found it spot on. Especially liked the demo on preventing tear out which I had a little of during my first cuts and minimized by gently letting the router bit make small cuts. All in all I think I have the steps down and ready for my second attempt. And will of course use a test board. Although you made this video 10 plus years ago your on camera instruction holds up very nicely. Well Done!

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27 – Machine-Cut Dovetails

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