|Value of sliding dovetail construction|
|The final steps|
We all know that finishing flat components is faster, involves less waste, and allows nearly anyone in the finish area to produce a higher-quality finish than can be achieved when trying to finish a fully assembled piece. The problem in the past has been that making interlocking sliding dovetail joints has required great skill achievable only by the best of craftsmen.
Within the last couple decades, innovation — launched first by the German company Festool and now being introduced by most major tool manufacturers — is bringing the ability to produce interlocking sliding dovetail joints to even the least experienced of your workforce. The key is guided rail routing and special work tables that make it easy to hold work pieces flat without moving.
A “T” shaped track on these new style guide rails holds a plunge router against both in- and out-thrusts, while keeping it on a perfectly straight line. Once the intended line of cut is established, it is easy and fast to align the guide rail, set the intended depth of cut for the female dovetail groove and make that part of the joint perfectly, time after time. The guide rail does all the work and the router can be moved in either direction with equal ease and equal result. There is little skill required on the part of the operator.
Note that this is very different from asking your operators to hold a router against a traditional fence or guide as they move the router along the intended line of cut. If the router is moved in the direction that has the router bit pulling the router towards the fence, and if the work piece is straight-grained, stable and free of imperfections, most of the time a reasonable dovetail groove can be cut. The problem using these traditional-type fences or guides comes when the work piece has figured, uneven or wild grain (often some of the most spectacular solid woods), or when the cut must be made in the opposite direction where the router bit tries to pull the router away from the fence or guide. Most of the time, the groove will not be perfectly straight and the work piece is ruined. Not a good situation in any production operation.
What these modern guide rails do is hold the router firmly against both in- and out-thrusts so the guide rail, not the operator, ensures a quality outcome, no matter which direction the router is moved relative to the direction the bit turns.
Here is where that really becomes important: Let’s say you want to produce a chest of drawers that has inset drawer faces and dust panels between each drawer bank. You need some way to locate those dust panels so they are exactly aligned side-to-side and in exactly the correct location up and down the chest so the inset drawers will fit properly. The easy and accurate way to do this, and add significant visual value to the piece at the same time, is to clamp each side component inside face up with the front edges touching and properly aligned onto a flat reference surface — one of those special work tables mentioned earlier. Now lay out the center lines for each of the dust panels along the back edges of the two side components.
Place a new style guide rail aligned with the first centerline, clamp the guide rail in place, mount a dovetail bit in a plunge router, and set the desired cut depth. The operator simply moves the router along the guide rail to produce the female dovetail groove in both cabinet sides at the same time. Those grooves must line up properly since they were cut at the same time in both sides. Leave the two sides clamped together and flat on the work table and move the guide rail to the next female dovetail groove center line and make the next cut.