I made this "bench hook style" cutting jig specifically for cutting various length dowels when making the barrels for hinges. It is designed to cut any length up to 4" long for 1/4" and 3/8" diameter dowels.

What's the big deal you might say?

This jig's cutting slot is exactly a match for my extra fine dozuki saw. The kerf is exactly 0.3mm (0.010").

So when the saw is placed in the slot it cuts a face on the dowel that is dead on perpendicular to the dowel's axis. This way when barrels are assembled the faces fit so well that the line between the intersecting faces pretty much disappears.

 

 

Here you see 1" lines as reference for cutting desired lengths.

 

 

Here you see the bench hooks. One end is for 1/4" and the other for 3/8".

They are flipped upside down so while one end is being used to cut dowels, the other end hooks over the bench. 

 

 

The actual 1/4" and 3/8" dowel grooves sit slightly above the board surface and form an arc slightly bigger than 180°. This provides a fit that acts as a lock so any dowel movement while cutting is mitigated.

 

 

 

 

Thanks for looking!

Feel free to comment, ask questions and "thumbs up 👍" if you like it!

Cheers!
MrRick

Cool jig! Love the Dozuki pull saws for hand cut dovetails.

Clever, functional design. Thanks for sharing the pics and details Rick.

Thanks Grandpadave52! To some making a jig like this may seem like overkill for cutting dowel. However, when making hidden hinges, dowel cutting accuracy is very important. Hinge knuckles must be dead flush next to each other. 

4 hours ago, lew said:

Cool jig! Love the Dozuki pull saws for hand cut dovetails.

Thanks lew! That saw I bought from Lee Valley. It's a very sharp accurate saw. Nice to do joinery with that's for sure! 

This is genius Rick! Thanks for the tip and the share! As always, impeccable work on this. 

Thanks John! Glad you like it. Cheers!