Dowelmax Precision Joinery System
reviewed by Michael Kampen
Bring up the subject of using dowels in a project in any gathering of woodworkers and there is sure to be a lively discussion. Most of the discussion will probably revolve around two major points. The purists will argue that dowels are inferior to more traditional methods like the mortise and tenon while another large group will go on at length about the difficulty in getting dowel holes located accurately and how hard it is to line up multiple dowels for larger applications. Perhaps if you are lucky, someone in the group will have brought along the holy grail of those looking for quick, accurate, super-strong joints, a DowelMax jig. For those who haven't had the pleasure of using one of these marvels, read on.
Dowels have been used to join pieces of wood for hundreds of years but the process has never been easier than it is today. In the past, using dowels meant a multi-step process that involved measuring your stock and laying out your holes, drilling a hole in one piece, and then using a dowel center to transfer the hole into the other piece before drilling the second hole. Designed and manufactured in Vancouver, British Columbia, DowelMax is a precision jig designed to make locating and drilling dowel holes easy and foolproof. If you can operate a hand drill and a pencil, foolproof dowel joints are within your grasp.
The jig, designed by Jim Lindsay, is machined from high quality aluminum and brass, its components crafted in several independent machine shops in the Vancouver area. 
The heart of the jig is an aluminum reference block which has been drilled to receive hardened guide bushings which accommodate either 3/8" or ¼-inch drill bits. There are five drill guide bushings on the 3 1/2" reference block. Each side of the reference block has two threaded holes to receive brass threaded rods and these are used to attach the clamping face, the fence or the right angle bracket. Depending on the type of joint you are working on, you will attach a combination of these accessories to the guide block to align and clamp the guide block to the work piece. The machining on the jig is done to a tolerance of .001" and the quality of the workmanship is top notch throughout every piece.
The DowelMax can drill perfectly aligned dowel holes in every conceivable situation.
Using the included fence and clamping accessories it is possible to create any type of joint you might need for the construction of everything from small jewellery boxes, furniture, frame and panel doors and even doors for your home. Using a few shop made jigs, it is possible to create almost any other joint you may need.
The reason most woodworkers don’t use dowels is that it can be a challenge to accurately locate and drill the holes. The jig assures that the holes are always perpendicular to the face of the work piece, equidistant from each other. The 3/8” drill bit supplied with the jig includes a depth collar to allow you to drill to a preset depth without worrying about drilling through the piece. The ¼” bit is also supplied with a depth stop collar and both of these collars are set using two set screws. Cheap depth collars are locked in place on the drill bit with only one screw, but by using two screws, the collar won’t sit on the drill at an angle.
Using the DowelMax could not be easier. After using it a few times, it becomes so intuitive that becomes second nature. To keep everything lined up no matter which way you mount the jig, you need to choose two reference faces on the two pieces to be joined. In the example of an apron to a table leg, the top of the leg and apron would be one reference surface and the rear face of the leg and apron would be the second reference surface. With a check mark placed on these faces it is easy to align the DowelMax for drilling. Two clamps hold the DowelMax to the stock and the five drill bushings have been heat treated and black oxide coated to ensure a long life. When using dowels, you will only achieve maximum joint strength if you fill the available space with dowels; with the DowelMax whether you drill 2 holes or 200 holes they will all line up like clockwork. The addition of a distance gauge allows the spacing of dowels along an edge of any length. For a continuous row of holes use the indexing 
pin to lock the Dowelmax in place in the last hole drilled and then drill the next four. Keep repeating this as needed. The three spacers allow the jig to accommodate material of different dimensions.
I've been using the DowelMax for several years now and early on decided that it would be worth it to invest in a couple of extra drill bits. I have several and have the depth collars set in 1/8" increments; this way I need only grab the two bits who's depth settings add up to the length of the dowel. I usually set the shallow hole as the thickness of the wood minus 1/8" with the other piece to suit. If you are working with only one drill bit, take the time to make up a drill bit set-up block. Select a piece of hardwood and carefully drill a series of holes in a line in 1/8" increments, use a fine tip sharpie to mark the depth at each hole. To set the depth stop on the drill bit, determine the optimum depth based on the material at hand and then bottom the bit in the appropriate hole; drop the collar to the surface of the wood and tighten the Allen screw.
Yes, this is a premium priced tool. In use in our shop it has proven itself to be the best doweling jig on the market and worth every penny. Period. Without any question. Unlike some tools that are produced off shore where quality control can often suffer, the components of this tool are made by skilled craftsmen in machine shops in the Vancouver area, and the quality is apparent in the finished product. In these days when so much talk in the media is about jobs and profits being shipped off of shore, this is a prime example of your tool buying dollar supporting skilled trades jobs at home. I have never heard a user complain about the cost after having used it just once.
We use the DowelMax regularly for everything from small wooden boxes, furniture, frame and panel doors and in some cases edge gluing larger panels. One task at which where the DowelMax really shines is when making woodworking jigs - it allows 
you to create evenly spaced holes for indexing purposes or for mounting interchangeable pieces. Another task we use the DowelMax for is the drilling of shelf pin holes in book cases. In the years we have been using this tool it has served with distinction; in fact it really deserves some sort of award. I have only one complaint about the DowelMax, and yes, I have told Jim this in person. "This jig is so versatile and adaptable that a novice woodworker with the ability to produce straight and square stock now has the ability to build a house full of furniture that will last long enough to hand down to grandchildren. You've just made learning any other type of joinery optional!"
If you are an experienced woodworker you'll appreciate the value of what this tool delivers. If you are a less experienced woodworker or a novice with only a few limited tools I can't make this any easier. This should be your next tool purchase. A beginner setting up shop without a lot of money can still build quality furniture with a DowelMax and only a couple of basic power tools by purchasing dressed lumber or working with plywood. This tool should not be on your 'wish list', it should be in your shop... where it belongs. For all out, bang for the buck results, the DowelMax outshines every other joinery jig on the market.
And on that other matter, the eternal discussion about the superiority and strengths of the various 
types of joints? That will likely endure regardless of any evidence presented. In the the fall of 2007 I made up several joint samples for destructive testing. The results within the small sample group were surprising to me to say the least, with the dowel joint performing much better than the traditional joints. We'll be posting these results on a separate page in the near future. DowelMax is available online direct from OMS Tools, the company that produces it. The kit comes in two forms; the basic kit that includes everything you need to work with 3/8" dowels. If you work in stock less than ¾” thick, there is a separate kit that allows you to swap out the 3/8” bushings for ¼” bushings and this is available as an accessory. I build a lot of small wooden boxes and in keeping with the scale of these boxes use material that is 5/8" or less and as such have found the 1/4" kit indispensible.
If you have any questions, give the folks at DowelMax a call at 1-877-986-9400. DowelMax is a family business and you'll end up speaking with either Jim, Mike or Marie. They proudly stand behind their product and will be more than happy to answer any questions you may have.
For further information including some video demos, please visit the DowelMax Site.
NOTE: The Dowelmax Jig is now available through Lee Valley Stores!