Replies

1. 
   jackplane | Apr 22, 2004 03:23pm | #1

   You can build a template for your router and take successive passes till you reach your desired depth.Or you could cut it on the tablesaw and clean up with a chisel. I'd cut the key then trace the outline for the female cut.

1. 
   bubinga | Apr 22, 2004 06:08pm | #2

   Thanks,

   What is the best way for the grain to run on the Butterfly so that you minimize the chances of it breaking under tension?

   JMCD

1. 
   jackplane | Apr 22, 2004 09:44pm | #4

   Run the grain lengthwise for best strength,i.e. from butterfly wing-to-wing.

2. 
   AlanTurner | Apr 22, 2004 06:10pm | #3

   I use these quite a bit, and like you, I use them structurally.  These are PITA to make, but I do them on a TS.  Note that you are using an endgrain cut.  If your key is to be 1" thick, and 1.5" wide, then take a 1" thick piece of wood, and cross cut 1.5" off of it.  The wider the board, the better!

   The blade is tilted in towards the fence.  Leave a flat lip, top and bottom, which you remove later, on a sled.  Flip it over, and you have your Dutchman.

   Or, make you first cuts, and then, make up a piece of wood to attach to your fence which contains a "point" which is the same set of angles as you just cut.  Then run the cut side against this point.  Use a full length pusher, of course.  Either way, this is a dangerous set of cuts.  When I do them, I generally make up a bunch of extra, in several woods, and keep them around.  It is the setup that takes the time, not the cutting.

   I then take some 6mm BB ply, and trace the Dutchman on to it with a pencil.  I cut to the line, and file it pretty smooth.  This is the  template for pattern routing.  Take your Dutchman to the stock, mark the stock tight with a knife.  Clamp the template in place, and rout out the bulk of the waste.  The difference between the dia. of the bit, and the dia. of the bushing, will be what you need to chisel out later.  Should be about 1/16" or so.  And, of course, the chisel registers in the knife line.  Save the template, marked, for your run of Dutchmen, and the next time you need that size, most of the work is already done.  I usually have 6 sizes or so in the shop at any given time.

   Alan

   Alan

   http://www.alanturnerfurnituremaker.com

   
   

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   Edited 4/22/2004 11:12 am ET by s4s

1. 
   bubinga | Apr 23, 2004 12:41am | #5

   S4s

   Thanks for the help! I am having difficulty visualizing the second method with the angled wood attached to the fence.

   Cheers

   JMCD

   P.S. Nice woodwork on your web site.