Cutting Slots for Keys in a Box--How Would You Do It

[DavidCBaker]

Okay, so I have this beautiful box made and I'm scared to screw it up. I want to put some contrasting wood keys in the mitered joints, not so much to strengthen them but for decoration. I've seen two methods of cutting the slots: by hand, or with a jig that tilts the box up to 45 degrees on the table saw.

Is there a method I'm missing? Which one am I least likely to screw up?  [tongue]

 

[nickao]

This for sure is the way to go:

http://www.dovetailspline.com/

I love the Kehoe jig.

 

[DavidCBaker]

Here's a sample of the jig I'm talking about:

http://2.bp.blogspot.com/_yf1uL7B9y5o/Sb8SbSiTOFI/AAAAAAAADn0/RL8vdZEknj4/s1600-h/jigs011.jpg

 

[nickao]

That is pretty chancy if you have not done it before. You will need to make the jig from scratch and practice on a bunch of boxes. The keyhoe jig is fool proof. Plus, it is tough to get the angle just right like that, one of the reasons the kehoe jig was invented. It will work though. Good luck whichever way you go, cutting into something already done and perfect is always nerve racking.

 

[DavidCBaker]

Nick, I just watched that video. It's a slick jig. Thanks for pointing it out.

 

[nickao]

If only it could cost 50.00, but really what is these days.

 

[Jesse Cloud]

Hey David,
Here's what I use
[attachimg=#1]

As you can see, it didn't take long to make it.   Its a good idea to make it reasonably tall to improve the chance of being able to clamp the box to the jig.  I hold the jig against the fence from the back.   Never had any trouble with it.   The Kehoe jig is cool, too!

 

[DavidCBaker]

Thanks--I decided to build a sled/jig, similar to that. I just mitered some practice corners to try in it.

 

[nickao]

Jesse are you angling the blade? Or are you just making box shape as opposed to dovetail shape. If you are making the dovetail shape what jig do you use to angle the actual key(spline)?

 

[lym]

would you recommend the table saw or miter saw unit?

 

[DavidCBaker]

I just did it with a table saw, and it worked great!

 

[nickao]

Oh yeah for sure, but a lot of the Festool guys have no table saw. I was wondering how they would do it.

This is a cut where the table saw excels and a nice Miter gauge wouldn't be bad either.

 

[danjames]

I have seen it done with a biscuit cutter, by adding a 90 degree fence that in effect makes an outside corner and then attaching this to your biscuit cutter fence. Seems to work well.

Dan.

 

[tbellemare]

Jesse are you angling the blade? Or are you just making box shape as opposed to dovetail shape.

Is it actually possible to get proper dovetail corners with an angled blade?

I would think to get a dovetail shape, you'd have to use a dovetail bit. The corners are acute angles.

Tom

 

[lym]

sorry, i was referring to the kehoe jig.  my fingers were moving faster than my brain.  they have two models.  has anyone tried the miter saw unit?  i was thinking of using it with my kapex or would i be better off with my table saw?