SHOP-TESTED AND RATED T hrough-dovetail jigs under $350

A THROUGH-DOVETAIL JOINT Through dovetails make a strong and beautiful joint, but who has the time to cut them by hand? We tested 10 -assisted jigs and found winners in three price ranges.

ew things say more about the quality Dovetail jigs have a reputation for being of a project than through-dovetail overpriced and overcomplicated, but is that Tails Fjoinery. Attractive looks aside, the a fair characterization? To find out we joint’s interlocking pins and tails have rounded up 10 jigs capable of producing proven their strength and reliability in join- through dovetails, with prices ranging from Pins ing boards end to end for more than 5,000 $50 to $330. Three jigs (the CMT300, years. Some woodworkers get misty-eyed Craftsman 25455, and Woodline WL-RJT) when they romanticize about cutting dove- require buying accessory equipment to tails with hand , but you can use a make this joint, thus inflating their base router and a commercial to do the job in prices. After running each jig through rigor- a fraction of the time—and typically with ous testing and letting the dust settle, here’s more precision and airtight fit. what we found. woodmagazine.com 77 Despite unique features, jigs fit one of two styles THE UPSIDE OF UPSIDE DOWN Although the 10 jigs we tested achieve the these, the Katie Jig, Keller, and MLCS jigs same end result—tight-fitting through- can be used in a or on a benchtop for dovetail joints—these work-savers certainly handheld routing, or you can use them Bearing-guided bit don’t look the same. You use routers to cut upside down on a router table, as shown the pins and tails by following templates, with the Keller at right. Woodline’s jig con- but that’s where the similarities end. Six of sists of a phenolic and base, and the jigs must be mounted or clamped to a works only on a router table. We prefer using benchtop or workstand. You lock in a work- these jigs on the router table for better visi- piece with the jig’s built-in clamping system, bility and control. then run the router on top of the jig, as Clamping for the latter jigs proves so easy: shown on the previous page. All six feature Just a pair of one-handed clamps safely either cam-clamping bars or threaded knobs secure the workpiece to the jig. When rout- on bars, and proved adequate in our test. ing on the router table, grip the jig body at its The other four jigs consist of templates ends rather than gripping the workpiece. Visibility of the cutter improves and the mounted to either a block or plate, Katie Jig and Keller offer optional clamping chips blow away from you when routing with the workpiece clamped to Half-bthe jig.lind Of do vetailkits, but you can get by without them. tails and pins on a router table.

How do you like your pins and tails spaced? YOU’LL LIKE MOVABLE FINGERS A N Most of the tested jigs use a one-piece tem- Consider, too, how much function you get Spacer plate to space dovetails equally along the for your hard-earned dollars: We like block B O width of the workpiece. But two—the Katie the extra value of jigs that come equipped C P Jig and the Leigh—allow you to arrange the with templates for through dovetails as well template guide fingers to create custom as for half-blind dovetails and box joints, D Q spacing. This same feature also lets you set and some even for sliding dovetails, as E R up perfect half-pins on each end of the joint shown below. The Leigh and Porter-Cable and then space the pins between them models can create all four joints with no S F equally. We like this versatility. One-pieceBox joint need for accessories. Hartville and Rockler Movable Half-blind dovetail fingers G T templates offer no variability unless you jigs cut through and half-blind dovetails. All skip some slots when routing, or reposition other models require optional equipment to H U the jig after cutting. cut joints other than through dovetails. V A N I J W B O X K C P Y D Q L Z Use a spacer for equal positioning of the M adjustable fingers on the Leigh (shown) or E R Katie Jig, or eyeball it for a hand-cut look. Half-blind dovetail Sliding dovetail S F Box joint Half-blind dovetail G T Sliding dovetail Bushings or bearings: Which guide bits the best? BUSHINGS FOLLOW TEMPLATE’S PATH H U Although these jigs can look quite different, tested jigs require guide-bushing changes V each consists of a multiple-fingered template when changing bits. A N I or templates that you guide your router Another thing to be aware of: Some guide J W B O around to shape the pins and tails. Most of bushings might not fit your router. Porter- X the jigs use guide bushings, as shown at Cable-style bushings (included with five of P K C Y right, that mount to your router subbase or the eight jigs that use guide bushings) need L D Q router-table insert, but the Katie Jig and an adapter for routers outfitted for other Z M Keller 1500 rely on bearing-guided bits, as bushing styles such as Bosch. Also, the E R shown top right. With these, you simply run CMT’s bushings require using its optional S FILENAME:175DoveJoints_#100504459.eps F Box joint the bearing along the template fingers. Ease subbase ($40), or you can use your own of setup proves the Date: chief 6-06 advantage with bushings as long as the outer diameters Sliding dovetail Lorna J. Filename: 175dovetail joints G T these jigs because you don’t have to install a match and you shorten their length to fit the Guide Template R LeMoine bushing finger H U guide bushing. The downside: Replacement ‰"-thick template. Craftsman’s bushing for bits can sometimes be difficult to find. cutting pins measures .400", an odd 8-16 size. V I A guide bushing offers the advantage of But it’s made to mount only on Craftsman Backer board J W working with any replacement bit that routers. For other routers you’ll need to buy, X matches the dimensions the jig requires. But from Sears, a universal subbase ($13) or a Only the correct-size guide bushings will K even a slight variance in bushing diameter set of Porter-Cable-style bushings that allow you to rout perfectly matching pins Y can affect the fit of the joint. And five of the includes the odd size. and tails that each template requires. L Z M 78 WOOD magazine March 2007 FILENAME:175DoveJoints_#100504459.eps Date: 6-06 Sliding dovetail Lorna J. Filename: 175dovetail joints R LeMoine 8-16

FILENAME:175DoveJoints_#100504459.eps Date: 6-06 Lorna J. Filename: 175dovetail joints R LeMoine 8-16 It’s not “Dovetails for Idiots,” LINEUP TIP SAVES YOU TIME QUICK AND EASY POSITIONING but help is nearby Some manufacturers create shortcuts for the Centering user by putting tips and helpful markings on mark their templates. Porter-Cable has numerous tips etched into its aluminum template, as shown far right. Craftsman also has molded bit-depth settings on its jig body. The Leigh features color-coded settings to ensure that you’re setting up for the right joint, and it also has a precision scale for accurate and Eliminate the worry of getting perfectly easy adjustments. symmetrical pins and tails by centering your Hartville’s GFK1800 has a centering mark workpiece to the template. on its template, shown near right, that allows Porter-Cable’s templates feature depth you to align your workpiece by simply find- CMT’s color-coded edge guides help you settings for bits, width settings for guide ing its center. No need for edge stops. We line up your workpiece in the jig to correctly bushings, and fine-tuning directions. tried this on other unmarked templates by position the pins and tails. The brown and making our own mark and found it worked violet guides serve as workpiece stops for these you simply position your board’s edge great as well. If you don’t want centered and through dovetails in fi" and ‡" stock, against the stop, put its end against the tem- symmetrical pins and tails, either use a jig respectively, on the jig’s face, as indicated in plate, and lock the . Rockler, Katie with adjustable fingers or design your work- the manual. (The other colored stops work Jig, and Craftsman feature similar styles, pieces to have the desired positioning. for half-blind dovetails and box joints.) With although not color-coded.

Tame tear-out and bit chatter for better results JUST SAY “NO” TO TEAR-OUT Tear-out (see photo right) proved troublesome Although cut quality proved a nonissue, on both workpiece faces with all the jigs and we found that ‹"-shank bits chattered far in all materials unless we sandwiched the more than fi"-shank bits. Leigh’s 8mm bit workpiece between sacrificial backer boards. (equivalent to ˇ") chattered some, but not as (We cut dovetail joints in red , , Baltic much as smaller shanks. Chatter stresses the plywood, and MDF.) Some jigs only bit and creates discomfort and annoyance for have room for a ‹" front board, but we found the user. Porter-Cable includes fi"-shank Note the effect on tear-out when using a backer board on both faces (left) and only that was enough to help eliminate tear-out. bits; they’re optional for CMT and MLCS. one on the back face (right).

MEET THE CONTENDERS

CMT300,CMT300, $$130130 (($250$250 ffullyully CraftsmanCraftsman 225455,5455, $$200200 (($240$240 ffullyully Hartville GFK1800, $250, fully equipped for through dovetails) equipped for through dovetails) equipped for through dovetails 888/268-2487; cmtusa.com 800/549-4505; sears.com 800/345-2396; hartvilletool.com

We found that the color-coded edge stops—which With quick setup and an easy-to-understand This 18" jig’s assembly time took the longest in our help position your workpiece quickly and accu- manual, we cut perfect joints on this jig in practi- test, just over one hour. Similar to older stamped rately—make setup a snap. The backer boards cally no time. The jig body and templates consist steel jigs, this one features better clamping, with needed to prevent tear-out must be ‹" thicker than of high-impact polystyrene. The molded bit stops tubing and cam-action levers, and a the workpiece to keep the bits from cutting into the speed up the setup process, with only a little fine- powder-coated body to resist slippage. The manual jig. It has lots of small parts (edge stops, template tuning needed. It’s one of two jigs that can work on says little about through dovetails, so we learned ) that could easily get lost. The two manu- 1"-thick stock. But the hassle of using two guide by intuition and trial and error. The GFK1800 is als (one with illustrations and one with written bushings (one an odd size) that fit only Craftsman available as a half-blind jig only for $150. Hartville instructions that refer you to the illustrations) routers or the optional subbase detracts from an also has a 12"-long model (GFK1200, $100 base proved awkward; we’d prefer one manual. otherwise quality product. price, plus $145 in through-dovetail accessories). woodmagazine.com 79 Katie Jig KJ12000002, $260, fully Keller 1500 Journeyman, $160, fully Leigh D1600, $330, fully equipped equipped for through dovetails equipped for through dovetails for through dovetails 317/881-8601; katiejig.com 800/995-2456; kellerdovetail.com 800/663-8932; leighjigs.com

It took longer to read the manual than to cut the first Cutting through dovetails doesn’t get much simpler Although it looks complicated, this jig proved easy dovetail with this unit. It came out of the box fully than with this 15" jig. There’s very little setup, and to understand and use, thanks to the best manual assembled, with backer board installed, and we only slight adjustments the first time you use it. in the field and the included DVD. Assembly took completed a joint in only seven minutes, with no You also can cut dovetails for angled joints with 27 minutes, with just another 9 minutes needed to need to adjust for a perfect fit. The edge stops work this jig. Buy the optional small-bit set ($65) to cre- turn out a tight joint. An included reducer allows great at positioning the workpiece, and it required a ate scaled-down through dovetails, or the box-joint you to use the 8mm-shank bits in a fi" collet. Also ¸" Allen wrench (included) to remove the 1" spac- bit set ($32) for traditional box joints—both with available as options are finger-joint templates ers. The optional handles for router-table use seem the same Journeyman template. The only down- ($200) and Leigh’s Isoloc template set ($340) for unnecessary, since you can hold it by its body. side to this jig is it won’t cut half-blinds. hearts, clovers, bears, keys, waves, and ellipses.

THROUGH-DOVETAIL JIGS UNDER $ 350 JOINT THROUGH-DOVETAIL ROUTER BITS CAPACITIES (INCHES) PERFORMANCE CAPABILITY (2) WORKPIECE PINS (12) GRADES (13)

BRAND MODEL JIG STYLE (1) OUT-OF-BOX WITH OPTIONAL ACCESSORIESADDITIONAL ACCESSORIES REQUIREDTEMPLATE MATERIAL (4)ROUTER GUIDING SYSTEMGUIDE (5) BUSHING DIAMETER (FOR TAILS, SHANK SIZE (7) DOVETAIL ANGLE (DEGREES)DOVETAIL BIT SIZE (DxH, INCHES) STRAIGHT BIT SIZE (DxH, INCHES)MINIMUM (8) THICKNESSMAXIMUM (9) THICKNESS (10)MAXIMUM WIDTH (11) MINIMUM SPACING (ONMINIMUM CENTER) WIDTH EASE OF INITIAL SETUPEASE OF CHANGING SETUPEASE OF TUNING FIT OF MANUALJOINT (14) CLARITY EASE OF USE FOR THROUGH DOVETAILS (3) FOR PINS) (INCHES) (6) 25 CMT CMT300 B H B,T D,G,S,T S G fl, Á ‹"** 8 fi x 1 ˇ x 1 ˇ /32 11‡ 1 fi B B+ B C B G,HB,HT AB,B,S,SB,T,TB I L $130 Craftsman 25455 B H B,T D,S PS G fi, .400 ‹" 7fi ¨ x 1 ‹ x 1 › 1 16 1 ¨ B B B B B B,G,HB,HT,T G,S,SB,TB U L $200 Hartville GFK1800 B H,T B A G ‡, fl ‹" 7 ‡ x Œ ‹ x 1 › ‡ 18 1¤ ‡ B B B B B G,HB,HT,SB,T,TB B U 1 $250* Katie Jig KJ12000002 W T B A B N/A ‹" 7 Á x ‡ fl x ‡ ‹ ‡ U 1› Á A A- N/A A A SB,TB B,C,H U 1 $260 Keller 1500 W T B P B N/A ‹" 7 Á x ‡ fl x ‡ ‹* ‡* U 1¤ Á A- A A B A SB,T,TB AB, C U 1 $160 Leigh D1600 B B,H,S,T E Z G Á 8mm* 8 fi x Å ˇ x 1 ¤ Å 16 Œ ‹ B+ A A A A G,HB,R,SB,TB AB,E,V CA 5 $330 MLCS 8712 W T A G fl fi"* 14 ‡ x Œ › x 1 ‹ Œ U 1¤* ‡* B C B+ C A- G,SB,T,TB CH 1 $50

17 17 Porter-Cable 4212 B B,H,S,T A G ‡, fl fi" 7 /32 x ‡ Â x 1 ‹ 1 12 1 /32 A A- A A- A B,G,HB,HT,SB,T,TB CH 1 $160 Rockler 23882 B H,T P G Á ‹" 8 fi x Å ˇ x 1 › ‡ 12 1 fi B B B B B G,HB,HT,SB,T,TB T 1 $140 Woodline WL-RJT W E H,T T H G Á, ˇ ‹" 14 fi x fi ‰ x ‡* ‹ ›** 14 1 fi B A A- B B- E,G,HB,SB,TB AB,E,HT, T U L $180 NOTES: 1. (B) Benchtop 5. (B) Bearing 12. (*) Template also available with 1"-wide tails (W) Workpiece-mounted (G) Guide bushing and pins 2" on center.

2. (B) Box joints 6. (N/A) Uses bearing-guided bits, not guide 13. A Excellent (E) Exotic joints bushings. B Good (H) Half-blind dovetails C Fair (S) Sliding dovetails 7. (*) ‹" bits also available (T) Through dovetails (**) fi" bits also available 14. (N/A) Preset by manufacturer. No front or back adjustments available. 3. (D) Dovetail bit 8. (*) Spiral bit (G) Guide bushing 15. (AB) Alternate bits (S) Straight bit 9. (*) ¤" minimum thickness when using (B) Box-joint template (T) Template optional small bit set (C) Clamp kit (E) Exotic joint templates 4. (A) Aluminum 10. (*) 1" with rabbeted pins (G) Guide bushings (H) High-density polyethylene (**) Manufacturer plans to offer templates (H) Handles for router-table use (P) Phenolic and bits that will machine through dovetails (HB) Half-blind dovetail bit (PS) High-impact polystyrene in ‡" stock. (HT) Half-blind dovetail template (S) Steel (R) Collet reducer (Z) Zinc alloy 11. (U) Unlimited (S) Router subbase

80 WOOD magazine March 2007 MLCS 8712, $50, fully equipped Porter-Cable 4212, $160, fully Rockler 23882, $140, fully for through dovetails equipped for through dovetails equipped for through dovetails 800/533-9298; mlcswoodworking.com 888/848-5175; porter-cable.com 800/279-4441; rockler.com

Similar to the Keller in its design, this jig proved Essentially a revamped half-blind jig, this model This jig includes everything you need to cut half- more difficult to set up and fine-tune, taking three excels at all joints. With so many helpful hints blinds and through dovetails. It features sturdy test cuts to get it right. Nevertheless, once we etched onto the templates and jig body, you almost cam-clamping power and adjusts easily when zeroed it in, it turned out great-fitting joints. The don’t need the manual (which proves very good as fine-tuning the fit of a joint. Rockler’s bits had the instruction sheet could be better illustrated. If you well). It’s one of only two jigs that will machine longest shanks in the test, resulting in the most prefer wider tails and pins, choose MLCS model stock up to 1" thick. Replacements for the unusual- chatter. (Rockler’s Steve Krohmer told us they will 8713 for the same price, or get either model with dimension bits ($16 for the 13 ⁄32" straight bit; $22 be replacing in the first quarter of 2007 their ‹"- ‹"-shank bits. Pretty simple once tuned in, and an for the 17⁄32" dovetail bit) will prove difficult to find shank bits with 8mm shanks, which should reduce unbeatable price. from sources other than the manufacturer. chatter. A reducer for fi" collets will be included.)

THROUGH-DOVETAIL JIGS UNDER $ 350 ACCESSORIES (15)

Woodline WL-RJT, $180 ($207 fully equipped for through dovetails) 800/472-6950; woodline.com

STANDARD OPTIONAL COUNTRY OF ASSEMBLYWARRANTY, (16) YEARS (17)BASE UNIT SELLING PRICE (18) Originally designed to cut decorative (hearts, keys) available. You also get a DVD to help guide you. 25 CMT CMT300 B H B,T D,G,S,T S G fl, Á ‹"** 8 fi x 1 ˇ x 1 ˇ /32 11‡ 1 fi B B+ B C B G,HB,HT AB,B,S,SB,T,TB I L $130 and box joints in small boxes, this jig has grown Two downsides: You have to buy the optional half- Craftsman 25455 B H B,T D,S PS G fi, .400 ‹" 7fi ¨ x 1 ‹ x 1 › 1 16 1 ¨ B B B B B B,G,HB,HT,T G,S,SB,TB U L $200 into a fully functional multi-joint unit. The through blind (for the pins) and through templates, and those limit you to ›"-thick stock. (Woodline’s Hartville GFK1800 B H,T B A G ‡, fl ‹" 7 ‡ x Œ ‹ x 1 › ‡ 18 1¤ ‡ B B B B B G,HB,HT,SB,T,TB B U 1 $250* dovetails we cut with it needed very little fine- tuning. You get a lot of versatility with this jig by Wayne Sutter told us they will have templates and Katie Jig KJ12000002 W T B A B N/A ‹" 7 Á x ‡ fl x ‡ ‹ ‡ U 1› Á A A- N/A A A SB,TB B,C,H U 1 $260 being able to add new templates from the many bits for ‡" stock available by January 2007.) Keller 1500 W T B P B N/A ‹" 7 Á x ‡ fl x ‡ ‹* ‡* U 1¤ Á A- A A B A SB,T,TB AB, C U 1 $160 Leigh D1600 B B,H,S,T E Z G Á 8mm* 8 fi x Å ˇ x 1 ¤ Å 16 Œ ‹ B+ A A A A G,HB,R,SB,TB AB,E,V CA 5 $330 MLCS 8712 W T A G fl fi"* 14 ‡ x Œ › x 1 ‹ Œ U 1¤* ‡* B C B+ C A- G,SB,T,TB CH 1 $50 If it were for our shop, we’d go with a versatile jig

17 17 Porter-Cable 4212 B B,H,S,T A G ‡, fl fi" 7 /32 x ‡ Â x 1 ‹ 1 12 1 /32 A A- A A- A B,G,HB,HT,SB,T,TB CH 1 $160 Before buying one of these jigs, consider templates made it impressively useful for a Rockler 23882 B H,T P G Á ‹" 8 fi x Å ˇ x 1 › ‡ 12 1 fi B B B B B G,HB,HT,SB,T,TB T 1 $140 what you want to do with it. Given that all variety of joints. Woodline WL-RJT W E H,T T H G Á, ˇ ‹" 14 fi x fi ‰ x ‡* ‹ ›** 14 1 fi B A A- B B- E,G,HB,SB,TB AB,E,HT, T U L $180 the jigs create good joints and all but one of The Porter-Cable 4212 follows closely the jigs cost $130 or more, we recommend behind the Leigh in performance—selling (SB) Straight bit (T) Through-dovetail template that you get the most bang for your buck: for $170 less but lacking variable spacing, (TB) Through-dovetail bit Buy a jig that makes more joints than just and earning a Top Value award. Keller’s (V) Vacuum attachment through dovetails. (A separate half-blind 1500 cuts through dovetails simply, quickly, 16. (CA) Canada dovetail jig will cost you another $100 or and accurately, but for the same money (CH) China more.) Also, get a jig that will be just as easy lacks the Porter-Cable’s versatility. (I) Italy to remember and use even if you let it sit idle The MLCS 8712 shares Top Value honors (T) Taiwan (U) United States for a year. with the Porter-Cable. Despite a couple of That kind of versatility, coupled with minor inconveniences and the fact that it 17. (L) Lifetime exceptional performance, is what grabs Top only turns out through dovetails, the 8712 18 (*) Hartville kit #30073TD Tool honors for the Leigh D1600. Although does a respectable job for only $50. ¿ Prices current at time of article production the priciest, nonetheless it executed clean, Written by Bob Hunter with Pat Lowry and do not include shipping, where applicable. snug-fitting dovetails on accommodating Illustrations by Roxanne LeMoine 16" templates. And though we’d prefer bear- ing-guided bits instead of its guide bushings, See more Tool Reviews at: the D1600’s set of standard and optional woodmagazine.com/reviews

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