Dovetails

[John Keane]

I am making dovetails for drawer sides with Baltic Birch. When cutting a rabbet on the inside before making the dovetails the plywood in several instances had moderate 'blowout'. The rabbet was not clean. I am using a 7518, with a 1/2" bit at 21000 RPM. Template calls for a 7/32 rabbet. My finished rabbet is 6/32 taken in 2/32 increments. This is my first experience with Baltic Birch. Is the problem the plywood or my technique?

[Jamie Buxton]

It is difficult to get a router-based jig to cut dovetails in plywood. As you've found, the router tends to splinter the face veneer. If you want dovetails, you're better off using solid lumber for the sides. If you want to use plywood, you're better off using a lock-tenon joint. It is a strong joint in plywood, and is easy to make with just a table saw.

[John Keane]

I agree. Wanted the experience.