How To Rout Inlaid Through and Half-Blind Dovetails On ... · PDF fileHow To Rout Inlaid...

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1. Lay out joint design and open each pair of fingers by two shim thicknesses. See formula, Fig. 1-3.

6. Close pin guides together.

7. Raise dovetail cutter by inlay stripe thickness.

8. Re-rout tails (pin sockets).

9. Rout the Pins.

10. Glue/assemble as usual.

2. Rout the tails (Pin Sockets).

3. Rout Inlay Pin Board vertically in TD Pin Mode.

4. Glue/join inlay pins to tails.

5. Saw off inlay pins.

How To Rout Inlaid Through and Half-Blind Dovetails

On Your Leigh Jig

Procedure Overview

These instructions are based on the assumption that you are fully conversant with the dovetailing instructions in the Leigh Jig User Guide. Do not attempt the following procedures until you are.

I N L A I D T H R O U G H D O V E T A I L S

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Select the dovetail cutter which comes closestto the maximum depth of cut required, whichis the thickness of the first pin board or inlay

board.Note: The inlay board must also be thicker than thefinal pin board by the inlay “band” thickness.

1 This procedure requires precise movementof the guide fingers between two of therouting steps. First determine the thickness

of the inlay band you want ➀. Make up two “shims”about 1”[25mm] x 4”[100mm] by the thickness ofthe inlay band required ➁ multiplied by the offsetfactor described below.

2

To achieve the correct inlay thickness alongthe angled cuts, the shims must be thickerthan the desired inlay thickness. This is to

compensate for the geometry of the angled cutand changing cutter depth. Multiply the inlaythickness as follows:

8° cutter: inlay thickness x 1.15This illustration shows why the compensation isnecessary.

3 For full pins, open up each pair of guides bytwo shim thicknesses ➀.4

Move both half pin fingers in by one shimwidth. An easy way to do this is temporari-ly position the pair’s “spare” finger ➀

against the half pin finger and lock. Unlock thehalf pin finger ➁, insert the shim, and lock. Thenunlock and reposition the spare fingers ➀securely out of the way.

5 Rotate the finger assembly to D TD TAILSmode, and lower the assembly to touch thehorizontal spacer board and tail board.

Rout all the pin and half pin sockets to full depthof inlay pin board thickness.

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I N L A I D T H R O U G H D O V E T A I L S 2

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... or further back by the thickness ofthe inlay, which looks like this (Type 2).

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Rotate the finger assembly to d TD PINSmode. Rout the pins in the dark inlay board.7 Glue pins to sockets and allow to fully cure.8

Saw off the pin pieces either flush to theback of the tails, which looks like this (Type 1)...9 10

The latter, Type 2 method leaves a fillet onthe inside corner ➀. This is best removedbefore gluing the pins ➁.

Close the guide fingers together in thissequence: Place one shim betweenpairs of fingers. Loosen one finger and

move it toward the other, and against the shim.Lock it, remove the shim, and move the other fingerto the first finger and lock. Move the half-pinguides out by the shim thickness, using the sparefingers and shim as described in 1-5.

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Raise the dovetail cutter by the thick-ness of the inlay ➀. Rotate fingers toD TD TAILS mode and re-rout all the

pin sockets through the inlay (Type 1 shownhere).

13Rotate fingers to d TD PINS mode.Rout all the pin boards. Adjust thestraight cutter depth of cut to suit

either Type 1 or Type 2.

Glue and assemble in the usual way.15


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1. Use one dovetail cutter and 7/16" bush.

7. Saw inlay board off flush with pin board.

9. Rout the tail board vertically.

10. Re-rout the pin board horizontally.

8. Using shims, reset guide fingers apart by 2 times the inlay width.See formula, Fig 2-3.

4. Rout pin board horizontally.

5. Rout inlay board also horizontally.

6. Glue pins and inlay end-on-end.

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11. Glue & assemble in the usual way.

2. Set fingers with at least 2 shim thicknesses between each pair.

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Procedure Overview

I N L A I D H A L F - B L I N D D O V E T A I L S

These instructions are based on the assumption that you are fully conversant with the dovetailing instructions in the Leigh Jig User Guide. Do not attempt the following procedures until you are.

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For these instructions we’re showing whitepin and tail boards and a dark inlay board.First, establish the precise cutting depth of

the chosen dovetail cutter for perfect joint fit.The dark inlay board thickness ➀ should equal:Cutting Depth + Inlay Thickness required.

1 This procedure requires precise movementof the guide fingers between two of therouting steps. Make up two “shims” about

1”[25mm] x 4”[100mm] by the thickness of theinlay band required ➁ multiplied by the factordescribed below.

2

For correct inlay thickness along the angledcuts, the shims must be thicker than thedesired inlay thickness. This illustration

shows why the compensation is necessary.Shim multiplication factor is:

18° cutter: inlay thickness x 1.3714° cutter: inlay thickness x 1.2810° cutter: inlay thickness x 1.198° cutter: inlay thickness x 1.15

3 When first laying out the guide fingersmake sure there is room for at least twoshims between each pair of fingers ➀. This

ensures room for repositioning later.4

Rotate the assembly to the hHB PINSmode. Set the pin scale on the thickness ofthe final tail board as usual.

Rout the pin board first (this is opposite to thenormal procedure in your jig guide). Remove thepin board and the stop block.

5 Clamp a final tail board in the front clamp,the top edge slightly below the top of the jigbody ➀. Rotate the finger assembly to the

H HB TAILS mode, flush onto the inlay board.Set the scale on the thickness of the tail board.Mount the inlay board in the rear clamp, the endedge flush with the outer edge of the vertical tailboard. Insert bridge pieces if required ➁.

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I N L A I D H A L F - B L I N D D O V E T A I L S 4

The jig is still in the H HB TAILS mode.Remove any bridge pieces. Loosen thefinger lock screw on all right hand fingers

only. Leave the half pin guides for now. Move theloosened fingers to the right. Insert one of the“inlay” shims ➀ between a right and left handfinger. Trap the shim with the right finger andtighten its lock screw. Repeat with each pair.

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Rout around the tail guides.There is no horizontal rear stop forthe router. Rout back far enough to

ensure there is enough “tail” to fill the tail sockets➀. If you are routing a lot of precious inlay wood,and want to avoid waste, make up a stop block tofit between the rear clamp bar and router base ➁.

7 Glue the pin board and inlay board togetherend on end and allow to cure.8

Saw off the inlay board flush with the end ofthe pin board.9 10

Loosen each left hand finger and movethem to the left. Insert both “inlay” shimsbetween right and left fingers. Move left

finger to trap the pair of shims and tighten fingerlock screw. Repeat for each finger.

Move the half pin guides in by one shimthickness. An easy way to do this istemporarily position the pair’s “spare”

finger ➀ against the half pin finger and lock.Unlock the half pin finger ➁, insert the shim, andlock. Then unlock and reposition the spare fingerssecurely out of the way.

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Rout the tail sockets out of the darkinlay.

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Fit new shorter bridge pieces if required.Confirm the H HB TAILS scale is stillset on the tail board thickness. With the

finger assembly on the spacer board, mount androut the tail board.

13 Rotate the finger assembly to the hHB PINS mode and raise the fingerassembly. Clamp the pin board with

inlay in the rear clamp, front inlay end against ascrap block in the front clamp.

The top of the inlay wood is above the pin-board surface by the inlay thickness. Make

up a spacer ➀ the same thickness to support therear ends of the fingers.

14

Lower the finger assembly flush ontothe spacer ➀ and inlay wood ➁. Levelthe assembly and tighten support

bracket knobs. Make sure the fingers are touch-ing the actual inlay material ➁.Set the scale on tailboard thickness.

15 16

Glue and assemble in the usual way.17

LEIGH INDUSTRIES LTD.Manufacturers of PrecisionWoodworking Tools

PO Box 357(104-1585 Broadway St.)Port Coquitlam, BCCanada V3C 4K6www.leighjigs.com

Joining Tradition with Today


© 1998 Leigh Industries Ltd. Allrights reserved.No part of this publication may bereproduced, stored in a retrieval sys-tem, or transmitted in any form orby any means, electronic, mechani-cal, recording, or otherwise, withoutthe prior written permission of LeighIndustries Ltd. 01/2000

How To Rout Inlaid Through and Half-Blind Dovetails On ... · PDF fileHow To Rout Inlaid...

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