Hollow a dowel for eye-popping joints
I always look for ways to add interesting details to boxes, so I developed a means of hollowing a dowel to create a "double dowel" joint reinforcement, as shown below.
First, make a disposable wood fixture to hold the dowels for hollowing by placing 3⁄8 " drill guides in the jig and drill 11⁄2 " deep into the end of a scrap board. Then add a drop of cyanoacrylate glue to one end only of 3⁄8 " dowels 11⁄2 " long, and use a longer dowel to press the dowels to the bottom of each hole.
Next, place 1⁄4 " drill guides in the jig and redrill the holes with a 1⁄4 " bit. Crosscut the board about 11⁄4 " from the end. Use a 3⁄8 " dowel to push out the hollow dowels.
After inserting a hollow dowel in a joint, you can fill it with contrasting wood, brass or aluminum rod, or epoxy.
—Jeff Baenen, Kenosha, Wis.