Kehoe Jig Sled Setup

Here’s where you begin to work a little, the cool part. Now I didn’t pay that close attention to Charles in the Kehoe video (but I should of... I wasted a lot of time here where to start the index) but he did say it. Notice the picture and note the alignment of the stop (the thing with magnet attached) the sled and your wood. That is key, its your index point, you should now be ready to make your cut.

Here you will be making multiple test cuts to adjust your spline fit. First, set your blade angle as Charles instructs in the video. This is blade angle on your saw in relation to the angle of your dovetail cut, meaning insuring a proper fitting spline.

Second is the width of the spline. Set this up as Charles instructs in the video. I made a test cut using the pencil line which resulted in too wide of a spline. Note how I have moved away from my pencil line on the sled, this allows for a narrower spline. My goal is to have the spline centered in the dovetail cut.

Here the sled is through its full rang of motion. The sled must stop at the magnet or you will cut through the sled base! Cut and test cut and test!

Kehoe Jig Adjusting The Cut

Oops, the first cut is too deep which causes the top portion of the cut to tear out from the rotating shank passing through the wood instead of the cutter surface. Too deep because I adjusted my router so the dovetail bearing was tracking or following dead center along the finger or slot of the jig.

My second cut (one on the right) was set with the bearing riding high enough on the finger (about half the bearing) with the top of the cutter just kissing or passing through the top of the cut. Just perfect! My pencil line is to help with the visual and not an aid for cutting or set up. Nothing difficult here at all.

The Kehoe Jig For Making Spline Dovetails

In December 2008 the Kehoe Master Jig was a Charles Neil Contest prize which I was fortunate to win. Recently I had time to learn the basic jig. Before doing so, I suggest you watch the Charles Neil demonstration video first and along with the directions supplied with your jig.

I’m telling you this jig is super easy! Even easier if you already have experience machine cutting dovetails. The spline setup on the table saw was the most time consuming. But I would expect under an hour is probably about average for a first time . Next time I bet my setup should take less than 10 minuets. It’s the getting use to it part and test cuts making sure of a perfect fit.

Frankly, the supplied splines used as a gauge will get you as close to your fit as possible like Charles describes in the video. The two (2) setup cuts most time consuming will be table saw blade angle, necessary for a tight fit without gaps. The other is width of cut so splines center within the grove of your dovetail.

Kehoe Jig in position. If you have additional spring clamps in the shop, use them. I have four (4) holding the Jig down. Rather have a wee bit more holding power.