Essential Joinery - Marc Spagnuolo

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to the shop and make some joinery.

      Chapter 1

      BUTT JOINTS

      In its simplest form, joinery is nothing more than a method

       for attaching one piece of wood to another. There’s no more

       fundamental example of that than the humble 90° butt joint.

       My very first woodworking projects featured butt joints; I still

       use them today when the project calls for it. As you progress in

       your woodworking journey, you will likely move on to some of

       the more involved joints covered later in this book, but this is

       where it all begins.

      It’s important to note that a simple glued 90° butt joint is

       inherently weak. The end grain of one of your boards will soak

       up most of the glue, rendering the joint ineffective. This is why

       much of this chapter focuses on reinforcement methods for

       each joint.

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      ESSENTIAL JOINERY

      SCREW-REINFORCED 90° BUTT JOINT

      One of the most accessible ways to reinforce a basic 90° butt joint is to add screws.

       The screws not only hold the pieces tightly together but also add reinforcement

       because the screw penetrates both workpieces.

      1. Cut parts to desired size. It is

       critical that the ends are nice and

       square.

      2. Though there are many other

       options for squaring stock, a

       tablesaw outfitted with a miter

       gauge or cross-cut sled makes it

       quick work.

      1

      2

      TOOLS

      Square

      Tablesaw

      Miter gauge or cross-cut sled

      Clamp

      Drill with countersink bit

      Bandsaw or plug cutter

      Mallet

      Flush trim saw

      Plane or sanding block

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      ESSENTIAL JOINERY

      Butt Joints | SCREW-REINFORCED 90° BUTT JOINT

      3

      4

      5

      6

      3. Apply glue to the end grain

       and the face or edge of the

       adjoining piece. While the glue

       won’t add a tremendous amount

       of strength, I never let my joints

       go naked.

      4. Confirm the workpieces are

       square and adjust the clamp if

       needed.

      5. Use an adjustable

       countersink bit to pilot-drill the

       screw hole while also creating a

       nice deep recess for a wood plug.

      6. Drill at least two holes per

       joint. Since these will be visible

       in the final product, take care to

       arrange the holes so they are

       visually pleasing.

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      ESSENTIAL JOINERY

      SCREW-REINFORCED 90° BUTT JOINT | Butt Joints

      7. Drive a screw into each

       hole and remove the clamp.

      8. To cap off the screws, you can

       use a short length of dowel rod

       (typically ⅜").

      9. For end-grain plugs (like

       those cut from a dowel), apply

       glue to the holes and the plugs

       and tap them into place.

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      ESSENTIAL JOINERY

      Butt Joints | SCREW-REINFORCED 90° BUTT JOINT

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      10. A better alternative is

       to use a tapered plug cutter. Drill

       into a piece of solid stock and pop

       out the plug with a screwdriver.

      11. For a tapered plug (from the

       plug cutter), be sure to align the

       grain of the plug with the grain of

       the workpiece. Then comes the

       most exciting portion of any joint

       assembly: wait for the glue to dry.

      12. Once the glue is dry, saw off

       the excess using a flush trim saw

       and either plane or sand smooth.

       In the last photo, you can see the

       visual difference between an end-

       grain dowel (darker, on the left)

       and the face-grain piece from the

       plug cutter (almost invisible, on

       the right).

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      ESSENTIAL JOINERY

      FRAME BUTT JOINT USING POCKET SCREWS

      Pocket screws can make frame assembly quick and easy. Just cut your parts to

       length, drill the holes, and drive the screws. It’s very common to see cabinet doors

       assembled with pocket screws.

      3

      1

      2

      TOOLS

      Drill

      Drill bit and driver

      Pocket hole jig

      Clamps

      1. Arrange the parts to be

       jointed and

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