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Perfect JointHow to create perfect joints
The Kehoe Jig is a tool for making dovetail joints that will never come apart. The joints created using the jig are unbelievably strong and fit perfectly every time. What makes all of this possible is the one-degree taper which is built into the finger slots of the jig and the corresponding one degree taper of the splines which are tapped into the tapered keyhole in the corner joint of your project.


Clamping Jig on corner

The steps are as follows:

1. Glue your project together first. Use either a 45 degree miter joint, a rabbet joint, a butt joint, a Z joint, a glue lock joint, or any other type of joint you want to use. Select the joint for aesthetics because your strength is going to come from the employment of the splines.

2. Place the dovetail spline jig on the corner of the workpiece and clamp it in place.

 

3. Use a router fitted with a 5/8 O.D. collar or bushing, or you can also use a 5/8'' bearing (template guide) and a dovetail bit; 1/2" 14 degree is the most popular bit. Other size bits work well also.  For your convenience, we have very affordably priced carbide bits on our catalogue page with bearings already installed.

4. Make the cuts with the router. The tapered finger slots will guide your router in and out.

 

5. Tap a tapered spline into the tapered slot after applying a thin layer of glue. 99% of the glue is going to be squeezed out, but that 1% that remains is never going to fail provided the glue is not faulty.

6. Cut the spline off even with the sides of the project and sand.

You now have a perfect dovetail spline joint that will amaze even you every time you make one!



How to make perfect dovetail splines

You can make your own dovetail splines with our spline-making jig.

1. Mount the spline-maker on the table saw with the mitre gauge set at 90 degrees.

2. Tilt the blade to 14 degrees (or the degree of whatever dovetail bit you are using in your router), straddle the saw blade with the spline-maker saw guide. Run the mitre gauge through the groove to the spline maker and clamp or screw it on.

3. Be careful that you don't push the conveyor so far that you cut into the "Made in the USA" sticker. It's there as a convenient reminder where to stop your cut! Set up the magnetic stop block provided in your kit to index the thickness of the splines, noting that it is 1/16 higher than the conveyor.

4. Then simply run your material through and turn it back and forth to make splines. You'll get so effecient at making splines you'll make dozens or even hundreds in a single session!

 

 

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