How would you make this?

[Porter Bassett]

This image shows the ends of a couple of identical pieces of wood that lock together when the top one is flipped over and placed on top of the bottom one.

If you were going to make this, how would you do it?

The part with the hole could be done with a drill for the hole and a router template for the cutout.

It's probably possible, but I don't know how to use a template to make the "peg" on the other piece.

http://mr.porteiro.head.googlepages.com/Joker_connectors_small.jpg

[Charles Wiggins]

First thought - Plug Cutter (http://www.rockler.com/product.cfm?page=10614) & a Chisel

[Todd Bin]

I would make the pin and the hole while both pieces were still square. I would make a circle template and use an inlay bit.

Just my first impression.

[Steve Clardy]

Drill the hole like the other one then glue in a dowel pin, if strength isn't an issue.

[Rick Hutcheson]

How about a 2 part template for the peg half. First template to make the top part of the peg, the template for the peg could still be attached to the main body of the template at the bottom. Then attach the peg template to the top part of the main template and cut the bottom half of the peg part.

[Steve Rozmiarek]

How many will need to be made at a time?

[Porter Bassett]

I'll be making at least six at a time.

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Rick -- wow! That's quite an illustration you whipped out there., and it does a great job of illustrating what would have been extremely hard to explain otherwise.

[Rick Fisher]

I havent got it figured out in my head, but I am picturing something with a template and a bosch colt style router.

Stick the board into a jig and router...

Dunno if that would work.

[John Keeton]

How about a 2 part template for the peg half. First template to make the top part of the peg, the template for the peg could still be attached to the main body of the template at the bottom. Then attach the peg template to the top part of the main template and cut the bottom half of the peg part.
Rick, that is some slick work! Was that done on Sketchup? It is in .pdf format, so didn't know.

FWIW, that looks like the best answer yet - like Charles, I would have said plug cutter and chisel until Porter said "six at a time." Sounds like there could be repeat jobs and a repeatable process would be a necessity.

[Doug Shepard]

First thought - Plug Cutter (http://www.rockler.com/product.cfm?page=10614) & a Chisel

That's my thought too but not the tapered plug type cutters but something like http://www.woodcraft.com/family.aspx?familyid=2088 that also takes away a bit more waste. Drill both halves to depth with the plug cutter then switch to a brad point or forstner to drill the rest of the way through the plug on the side with the hole. Then chisels and gouges to make the rest of the curved shoulders.

[Mark Rakestraw]

While I like the looks of the face grain pin in the picture it seems like it would shear off easily. Just like popping plugs out of a block you've drillled with your plug cutter.
Mark

[John Lucas]

If you look real close, both boards are comprised of top and borrom, like they resawed the piece in two. The grains matched perfecty but the button, hole, and curve are done to one of the boards and then glued back on. That makes for much easier crafting and I do think a plug cutter that has straight sides created the button.

[Rick Hutcheson]

John,
That was drawn in Corel Draw 9. Then I use EZ Metrics to make the 3D look and stacked the colored parts.
Corel will do a lot of neat stuff once you learn it. I run version 9, 12, and X3 because each one has little parts I need.