CRAFTSMAN Router Accessory Manual L0802689
User Manual: CRAFTSMAN CRAFTSMAN Router Accessory Manual CRAFTSMAN Router Accessory Owner's Manual, CRAFTSMAN Router Accessory installation guides
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iNDUSTRiALDOVETAILJIG
IMPORTANT:.
with this
The fo!lowing
router
bits are required
for use
jig-
• VA #22437,
or MAGNA
#M 910t6,
1/4" Straight
Router
VA #22501, or MAGNA #M91114, 9t16" Dovetail Router
which are used for THROUGH
or OPEN JOINTS.
• VA #22500, or MAGNA #M91113, 1t2" Dovetail
which is used for all HALF BLIND JOINTS.
Router
Bit, and
Bit
Bit,
WARNING:
Beforeoperating product, readthis
manualand follow all its Safetyand
OperatingInstructions.
17125455
General
Safety Instructions
Additional
Introduction
for Power
Safety Instructions
Tools ..........................................
for Industrial
Dovetail
Jig ......................
............................................................................................
Unpacking
and Checking
Assembly
.....................................................
Assembly
Contents
of the Right
...
..........................................................
3
4
. 5
5
6
Side Template
Support
to the Dovetail
Base
.................. 6
Assembly of the Top Clamping Bar to the Dovetail Base ....................................
7
Assembly of the Front Clamping Bar to the Dovetail Base ...............................
9
Assembly of the Cam Handles and Pivot Shaft to the Dovetail Base ................ 10
Installation
Assembly of the Front Stop Blocks to the Dovetail Base ................................
Assembly of the Top Stop Blocks to the Dovetail Base ........................................
Assembly of the Clamping Knobs to the Dovetail Base ....................................
13
Assembly
of the Templates
..........................................................................................
15
Alignment
of the Templates
.....................................................................................
16
Assembly
of the Adapter
Assembly
of the Guide Bushing
Plate to the Router. .....................................................
to the Router
..................................................................
......
.
...
.
. . .....
.
14
14
18
.......................................................
21
.
22
.
. ..........
Operation
Styles of Dovetail Joints
........................................................................................
Half Blind Flush Joint .........................................................................................
Half Blind Flush
Offset Joint .............................................................................
Half Blind Rabbeted
Open or Through
Parts List
Joint .................................................................................
Joint
....................................................................................
Adjusting
the Depth-of-Cut
of the Router
Clamping
the Workpieces
to the Dovetail
24
24
25
25
26
Bit ......................................................
26
Base
................................................
28
Making Drawers
with Half Blind
Flush
Joints
.....................................................
29
Making Drawers
with Half Blind
Flush
Offset
Joints ..........................................
35
Making Drawers
with Half Blind
Rabbeted
Making Projects
with Open (Through)
Joints ..................................................
Joints
.......................................................
....................................................................................................
35
37
47
SAFETY
GUIDELINES
This manual contains informa-
PROBLEMS. To help you recognize this information, we use
the symbols to the righL
Please read the manual and
your
power
application
hazards
peculiar
2. Ground
Learn its
as welt as the specific
(unless
potential
double
insulated)
with an approved three-conductor
grounding type plug, it should be
into a three hole electrical
used to accommodate
a two-hole
receptacle
cord
If adapter
receptacle,
receptacle
cover plate)
Never connect
green
3. Keep
guards
Maintain
in working
the adapter
the screw securing
Never
remove
third prong
ground wire to a terminal
order, and in proper adjustment
keys
Form a habit of checking
and
5, Keep
Cluttered
work area clean
areas and benches
wrenches
from tool before
Ftoor must not be slippery
dangerous
and
turning
it ON
invite accidents
due to wax or sawdust
environment
them to rain
Provide adequate
All visitors
area
right
children
should
the
is
for which
tool
correct
apparel
gloves,
(rings, wristwatches)
in moving
parts
protective
hair covering
above
12. Use
Nomstip
protectors
footwear
long hair
if cutting
(Head
distance
from work
Wear
Roll long
Protection)
(must comply
with ANSI Standard
A_so, use face or
operation
(plugs or muffs)
Use clamps
is recommended
to contain
goggles
goggles
dust mask,
or
the elbow
safety
safety
neckties
that may get caught
is dusty, and ear
during
extended
periods
of
work
or a vise to hold work when practical
are free to operate tool
14. Do not overreach
Keep proper footing and balance
15. Maintain
tools
with care
work space
away
be kept a safe
to do a job it was
than using your hands, and both hands
Keep work area well lighted
surrounding
or remove starter keys
they were designed
11. Wear
operation
13, Secure
Do not use power tools in damp or wet locations
7. Keep
10. Use
Z87 1) at all times
to see that keys and adjusting
are removed
or expose
to perform
Wear
wrenches
6. Avoid
tool or attachment
not designed
sleeves
in place
adjusting
use of this
child-proof
Do not force
jewelry
alignment
4. Remove
workshop
Do not wear loose clothing,
(usually
regarding
They wifl do the job better and safer at the rate
wire must be attached
to a known ground
and warnings
Use padlocks, master switches,
9. Do not force tools
to this tool
all tools
If tool is equipped
and a three-prong
plugged
8. Make
carefuify
and limitations
instructions
bodily injury
tool
manual
INFORMATION
THATYOUSHOULD
PAYSPECIALAITENTIONTO
IMPORTANTSAFETYINFORMATION_A HAZARD THAT MIGHT
CAUSESERIOUSINJURYORLOSS
OFLIFE
Failure to heed all safety and operating
Read the owner's
[ NoTE]
I,AWARNINGI
pay attention to these sections.
1. Know
INFORMATION
FORPREVENTING
DAMAGETOEQUIPMENT
URGENT SAFETYINFORMATION-A
HAZARDTHATWILLCAUSESERF
OtIS INJURYORLOSSOFLIFE
information relates to protecting YOUR SAFETY and
PREVENTING EQUIPMENT
product can result in serious
I CAUTION]
IADANGER I
tion that is important for you to
know and understand. This
['_WARNINGI
- DEFINITIONS
at all times
Keep tools sharp and clean for best and safest
performance
Follow
and changing
accessories
instructions for lubricating
it's safer
Serious injury could occur if the tool is tipped or ff the cut_
ring _oot is accidentally contacted DO NOT store materials above or near the tool making it
necessary to stand on the toot to reach them
20. Check damaged parts
Before further use of the Iool, any guard or other
part that is damaged should be carefully checked to
ensure that it will operate properly and perform its
intended function Check for alignment of moving
parts, binding of moving parts, breakage of parts,
mounting, and any other conditions that may affect
its operation A guard or any other part that is
damaged should be properly repaired or replaced
21. Direction of feed
Feed work into a blade or Cutter AGAINST the
direction of rotation of the blade or cutter only
22. Never leave tool running unattended
Turn power OFF DO NOT leave tool until it comes
to a comptele stop
23. Keep hands away from cutting area
24. Store idle tools
When not in use, tools should be stored in dry,
high or locked-up place - out of reach of children
25. Do not abuse cord
Keep cord away from heat, oil and sharp edges
26. Outdoor extension cords
When tool is used outdoors, use only extension
cords suitable for use outdoors and so marked
27. Never use in an explosive atmosphere
Normal sparking of the motor could ignite fumes,
flammable liquids, or combustible items
28. Drugs, alcohol, medication
DO NOT operate tool while under the influence
of drugs, alcohol, or any medication
Read and Understand this instruction book
completely BEFORE using this product
1 Always wear eye protection that complies with
ANSI Standard Z87 1
2 Noise levels vary widely To avoid possible hearing
damage, wear ear plugs or muffs when using the
Dovetail Jig for hours at a time
3 For dusty operations, wear a dust mask along
with safety goggles
4 Do not use this Dovetail Jig with router bits or
guide bushings other than those specified for the
cuts being made
5 Follow the instructions in your Router Owner's
Manual
6 Vibrations caused by the router during use can
cause fasteners to become loose Before use and
periodically during use, check all fasteners to make
sure that they are all are tight and secure
7 Do net use this product until all assembly installation steps have been completed, and you have read
and understand all safeb/and operational instructions in this manual, and the Router Owners Manual
8 Make sure that the router bit is properly positioned
in the router so that it does not contact the guide
bushing or the template when cutting
9 The Dovetail Jig must be securely mounted to a
workbench or other stable surface when in use The
front of the base should overhang the front of the
workbench by no more than 1/4" to provide clearance when clamping workpieces to the Dovetail Jig
10 Do not use the Dovetail Jig as a work surface
Doing so may cause damage to the Dovetail Jig,
which can cause it to be unsafe to use A workbench
should be used for this purpose
11 This product is designed to cut fiat workpieces
Do not cut or attempt to cut workpieces that are
not flat or that are irregularly shaped.
12 This product is to be used for cutting wood workpieces only Do not use this product to cut metal
or any other non-wood material.
13 This product has been designed to cut workpieces having thicknesses of 3/8" to 1" Do not use
Ior workpieces of any other thicknesses
14 Do not clamp any workpieces to the Dovetail Jig
or make any adjustments to the Dovetail Jig unless
the router has been turned off, the router bit is not
turning, and the Router has been disconnected from
the electrical outlet
15 When setting "the-depth-of-cut" of the router
bit, make sure that the workpiece is clamped to the
Dovetail Jig in such a manner that the router bit
does not cut into the Dovetail base causing damage to it or possible serious injury to you.
16. Disconnect tools before servicing
:
Before servicing, when changing accessories
such as blades, bits, cutters, etc
17. Avoid accidental
starting
Make sure swilch is in OFF position before plugging in
18. Use recommended
accessories
Consult the owner's manual for recommended accessories
and follow the instructions The use
of improper accessories may cause hazards
19, Never stand on tool
16 L'_WARNING_
ALWAYS UNPLUG
THE
ROUTER FROM THE ELECTRICAL OUTLET
BEFORE INSTALLING
OR REMOVING ROUTER
BITS FROM THE ROUTER AND WHEN ADJUSTING THE CUTTING DEPTH OF THE ROUTER BIT;
OR WHEN INSTALLING OR CHANGING GUIDE
BUSHINGS.
• Your Vermont American Industrial Dovetail Jig is an
accessory that is used with Routers allowing you to
make drawers, chests, and similar items requiring
dovetail joints The joints are used to make the front,
back, and sides of the workpiece
• Your Industrial Dovetail Jig comes with two templates and two guide bushings for making halt-blind
and through or open joints
• Your Industrial Dovetail Jig also comes with a
universal router adapter plate that will permit the
Industrial Dovetail Jig to be used with most popular
routers
• The Dovetail Jig will allow you to make 1" spaced
flush, flush-offset, and 3/8" rabbeted half-blind
dovetail joints
• The Dovetail Jig will also allow you to make t"
spaced open, or through, dovetail joints
• Workpieces up to 16" wide can be accommodated
o Workpieces with thicknesses between 3f8" and 1"
can be accommodated
17 NEVER LIFT THE ROUTER UPWARDS WHEN
THE ROUTER IS "ON", THE ROUTER BtT IS
ROTATING, AND THE GUIDE BUSHING IS NEAR
OR TOUCHING THE TEMPLATE, BECAUSE THIS
WILL CAUSE THE ROUTER BIT TO CUT INTO
THE TEMPLATE AND DAMAGE IT
• The Dovetail Jig Base has six pockets molded into
its front which are gauges to aid you setting the
"depth-of- cut" for commonly used depths: 3/8", I/2",
5/8", 3/4", 7/8", and 1"
• Vermont American router bits, #22501 and #22437,
or Magna router bits, #M91113 and #M91016,
WHICH MUST BE PURCHASED SEPARATELY, are
required for making the THROUGH or OPEN joints
• Vermont American router bit, #22500, or
Magna router bit, #M91114, WHICH MUST BE
PURCHASED SEPARATELY, is required for making
the HALF-BLIND ioints
• Your Vermont American Industrial Dovetail Jig
comes with two templates and two guide bushings
Each of the templates has a label, describing the
joint that can be cut with it, along with set-up
information, the router bit and the guide bushing
required, and the the stop block setting for a
particular joint
Refer to Parts List on Page 47
• tn order to simplify handling and to minimize any
damage that may occur during shipping, your
Industrial Dovetail Jig is packaged assembled
• Separate all loose parts from the packing materials
and check each one with the illustrations and list of
parts at the end of this manual to make sure that
all loose parts are present before discarding any
packaging material
.i,A
,,any
parts
are
m,ss,ng
orcannot
be accounted for, do not attempt to assemble, instaIl,
or use the Industrial Dovetail Jig until the missing
parts have been obtained and the product has been
assembled correctly
• Contact customer service at 1-800-742-3869, ext 8359
for missing or replacement parts
ALTHOUGH
YOURINDUSTRIAL
DOVETAIL
JIG
COMES
ASSEMBLED,
THEFOLLOWING
ASSEMBLY INSTRUCTIONS ARE BEING INCLUDED FOR
REFERENCE PURPOSES SHOULD IT BECOME
NECESSARY FOR YOU TO DISASSEMBLE AND
REASSEMBLE THE DOVETAIL JIG
PROCEED TO THE SECTION ALIGNMENT OF
THE TEMPLATES AND THEN CONTINUE WITH
THE SECTIONS FOLLOWING ALIGNMENT OF
THE TEMPLATES
THE TEMPLATES MUST BE ALIGNED BEFORE
ANY ROUTING tS TO TAKE PLACE
TOOLS
neck botts into the slot in the right side of the base
REQUIRED
- A medium
sized Phillips
° A smafl or medium
screwdSver
adjustable
wrench
ASSEMBLY OF THE RIGHT SIDE TEMPLATE
SUPPORT TO THE DOVETAIL BASE
1 Ptace the dovetail base topside down on a fiat surface
2 insert one of the 5/16-18 x 2" long round head square
FIGURE
(NOTE: The right side of the base is identified by the
words RIGHT SIDE molded into it )
3 Place a 11/32" t D, x 7/8" OD washer onto the bolt as
shown in Figure
1
4 Thread a 5/16-18 hex nut onto the bolt, as shown, until
it bottoms out against the washer
5 Back off the nut from the washer between 1/4 and 1/2
10_32X 5/8" LONG PANHEAD
MACHINE SCREW
1
HEXES MUST LINE UP
5t16-18 X 2" LONG ROUND
SQUARE
NECK BOLT
HEAD
t3/64"
""
""
I D X 9/t6"
O D WASHER
# 10_32 HEX NUT
BACK OF DoVETAiL BASE
!UrpS
Align thenutsothatthecomers
ofthenu_
areverticalfyline_J
UpasshownNotethealignment
ofthehex
pocket
inlhetemplate
support
Theboltshould
befreeto
movesidetoside;ifitdoesnot,loosen
thenut1/3turnor
untilthecorners
ofthenutpointupanddown
6 Assemble
therighttemplate
support
totherightsideof
the dovetail
base so that the hex nut lines up and lits into
the hex pocket in the right template support
right template support has the words RIGHT
into it for identification
(NOTE: The
SIDE molded
)
lhe base as shown to hold the template support in place
Securely tighten thenut and screw
8 The template support should move freely front to back
along the side of the base
If it does not, it means
that the
5/16-18 hex nut is too tight on the bolt and should
ened To do this, remove the fasteners assembled
be loosin step
7, and remove
through 7
TEMPLATE
ASSEMBLY
FIGURE
2
FIGURE
3A
OF THE
DOVETAIL
1 Assemble
TOP
CLAMPING
BAR
TO
support;
repeat
steps 4
ASSEMBLE
THE LEFT SIDE TEMPLATE
SUPPORT TO
THE DOVETAIL
BASE THE SAME AS THE RIGHT SIDE
7 Assemble a #t0-32 x 5/8" long panhead machine screw,
a 13/64" I D x 9/16" O D washer, and a #10-32 hex nut to
THE
the template
SUPPORT
WAS ASSEMBLED.
BASE
one of the bolt supports
to both of the
5/16-18 X 3-l/2" long round head square neck bolts as
shown in Figure 2
2 Align the square on the bolt with lhe square
bolt support The bolt support
bolt as shown in Figure 3
is to "bottom-out"
hole in the
against
the
3, Assemble one of the spdngs to each of the nylon spring
retainers by pushing the spring over the raised cylindrical
portion of the spring retainer as shown in Figure 3A and
Figure 3B
4 Position the dovetail base on a fiat smooth surface so
the back of the base rests on the surface
[
NOTE
DOVETAIL
]
BASE
ALTHOUGH
ARE SHOWN
BOTH
ENDS OF THE
ASSEMBLED
FOLLOWING
FIGURES, THE ACTUAL
DONE ONE END AT A TIMEo
(_
IN THE
ASSEMBLY
FIGURE
NYLON
SPRING
IS
RETAINER
5 From the bottom of the base, insert a bolt with bolt support through the slot in the top of the base so the raised
COMPRESSION
portion of the bolt support
Figure 4
SPRING
FIGURE
goes into the slot, as shown
3B
in
/'J_f
SPRING TO
BOTTOM
OUT
AGAINST
SURFACE
4
SLOT IN
DOVETAIL BASE
/
BOLT
11/
/
/
FRONT OF DOVETAIL BASE
DOVETAIL BASE
/
SLOT IN
DOVETAIL
BASE k
q
BOLT AN D BOLT
SUPPORT
X
\
: :
•
6 Place
an11/32"
ID X7/8"O D washer
andthena
FIGURE
5
5/16"ID X7/8"OD thicknylonwasher
overtheboltIt
j
NOTCH
willbenecessary
toholdtheboilinplacewhenperforming
IN RIB
thisandthefollowing
steps
HELPFUL
HINTS:
Position
theboltandtheboltsupport
under
thenotch
intheribasshown
inFigure
5,tohelp
._---- SLOT IN
holdtheboltinplace
7 Place
a spring
overthebolt,asshown
inFigure
6
DOVETAIL
BASE
8 Place
a 5/16"ID X7/8"Q D thicknylonwasher
and
thenan!1/32"ID X7/8"OD washer
overtheboiland
press
downonthespring
untiljusttheendofthebolt
BOLT AND
sticksoutpasttheendofthewasher
BOLT
g Slidetheclamping
baroverthebollsothatthewashers
SUPPORT
aresandwiched
between
thespring
andtheinside
ofthe
clamping
barasshown
inFigure
6 NOTE:
THESPRING
MUST
PUSH
AGAINST
THETHICK
NYLON
WASHERS
ANDNOT
AGAINST
THESTEEL
WASHERS
t0 Place
an11/32"
t D X7/8"OD thinnylon
washer
and the bar in one way only It may be necessary to "tap" them
an11/32"
ID X7/8"O D washer
overthebellIt wilibe in by gently hitting them with a rubber mallet or a piece of
necessary
foryoutopress
downontheclamping
barwhile wood--since they fit very tlgh|ty into the clamping bar
USE CARE WHEN DOING THIS SO AS NOT TO DAMdoingthis
11Takeoneoftheclamping
knobs
andthread
itontothe AGE THE END CAPS
boilasshownDONOTTHREAD
theknobcompletely USE CARE THAT THE CAPS ARE PROPERLY ALIGNED
ontothebolt--just
enough
sotheknobhoidstheclampingAS SHOWN WHEN ASSEMBLING THEM TO THE BAR,,
barinplace
14. Tighten the clamping knobs onto the bolts so that the
t2 Repeat
above
steps4through
10fortheotherendof space between the bottom of the clamping bar should be
theclamping
bar
parallel to the top of the base
13Assemble
theendcapstotheendsoftheclamping
bar 15 After completing the above steps your Dovetail Jig
bypressing
themin;theyaredesigned
tobe"force-fit"
into should look like the illustration in Figure 7
FIGURE
6
Assemble
clamping
CLAMPING KNOB ,
',\
bar, knobs,
end caps on both ends
as shown
11/32" I.D.
X 7/8" O D WASHER
\
"
!t/32" I.D X 7/8" O D.
SPRING AND
NYLON SPRING
RETAINER FIT
]NSlDE THE
OPEN SIDE OF
THE CLAMPING
BAR
(SEE CLAMPING
BAR DETAIL)
CLAMPING
BAR DETAIL
NYLON SPRING
RETAINER
(RETAINER ABUTS THE
CLAMPING BAR
CLAMPING BAR
f_END
L_.! )
_-_\/
"_
•CLAMPING BAR
CAP
OPEN SIDE OF
THE CLAMPING BAR
POINTS TOWARD
THE TOP SURFACE
OF THE DOVETAIL
i
BASE
11/32" I,D X 7/8"
O D WASHER __
WASHER
.--[
_,
COMPRESSION
SPRING
€/1t132" I.D.
3 t12"
_,
j/*
BOLT
SUPPORT
//
l
/X
7/8" O D
/THICK
-_
NYLON
__._WASHER
//ZTOP SURFACE OF
THE DOVETAIL
RIGHT
TEMPLATE
SUPPORT
END CUT AWAY AND SECTIONED
SO NYLON SPRING RETAINER
PLACEMENT CAN BE SEEN)
CLAMP,NG AB S.OWNW,THI
COMPRESSION
SPRING
FIGURE
7
CLAMPING
BARPARALLEL
TO
TOP
OFBASE
SPACING TO BE
/ / APPROXIMATELY
t -112"
0
ASSEMBLY
THE
OF THE
DOVETAIL
t Assemble
0
FRONT
CLAMPING
0
BAR
TO
BASE
the front clamping
bar !o the front of the dove-
tail base following the same procedure used Io assemble
the top clamping bar to the dovetail base as shown in
FIGURE
Figure 8 The 5/16-18
neck bolts are used
X 4-1/2"
long round head square
8
COMPRESSION
CLAMPING BAR
(SHOWN WITH END
CUT AWAY AND
SECTIONED SO
NYLON SPRING
RETAINER PLACE r
MENT CAN BE ,.
SEEN)
"\,
SPRING
"__
\.
DOVETAIL
1/2" BOLT
BOLT SUPPORT j7
!1/32' I.D. X 7/8' O.D.
THICK NYLON WASHER
COMPRESSION
SPRING
\\
\
CLAMPING BAR f
NYLON SPRING
RETAINER
/'t"
• CLAMPING BAR
END CAP
11132" I,D X 7/8" 0 D.
THIN NYLON WASHER
tt/32" I D X 7/8" O D
CLAMPING KNOB
NYLON
SPRING
RETAINER
(RETAINER
ABUTS THE
CLAMPING
BAR)
ASSEMBLY
OFTHECAMHANDLES
ANDPIVOT
SHAFTTOTHEDOVETAIL
BASE
• After the cam handles and pivot shaft have been assem _
bled to the base, it wil! be possible to accurately position
1 Assemble one of the cam handles to the pivot shaft
using a #10-32 x 5/8" tong panhead machine screw and a
the templates
13/64"
for close fitting joints
I D x 9/16" ID
washer
as shown
in Figure 9
• Note that there are some graduations on both template
supports
• Rotating the cam handle so that the pointer lines up with
2 Use care so that the pivot shaft fits into the hex-shaped
hole in the cam handle The pivot shaft may fit tightly into
the cam handle; this is normal
one of the graduations
3 Make sure that the pivot
cam handie
permits
tioning of the template
• Cam handles are designed
adjustment
• One graduation
equals
accurate
to provide
front-to-back
posi-
infinite template
1/64" of movement
4 Securely tighten the screw
NOTE: THE NEXT TWO STEPS
rotating
5 Slide the retainer
ARE PRE-ASSEMBLY
over the end of the pivot shaft for
about 2" The retainer
may fit tightly;
this is normal
6 Thread the #10-16 x 1/2" long panhead tapping screw
into the hole in the retainer until it bottoms-out
against the
pivot shaft (The screw will fit tightly in the hole ) See
the cam handle so that the lever
moves toward the back of the base, causes the template
to also move Iowards the back of the base also
FIGURE
inside the
STEPS.
of the tem-
plate
• Rotating the cam handle so that the lever moves toward
the front of the base, causes the template to also move
towards the lront of the base
• Conversely
shaft bottoms-out
Figure
10
9
/
13/64"1D
CAM HANDLE
/
X 9/16_'O D WASHER _\
_
J
\
PIVOT SHAFT
j
<--LT-,
:
#10_32. X5/8" LONG /
PANHEAD MACHINE SCREW
FIGURE
10
#10-16 X 1/2" LONG PANHEAD TAPPING SCREW
_
RETAINER
/
x\__
10
PIVOT SHAFT
7 Loosen
thescrew
about
oneturnRemove
theretainer
fromtheshaftandsetitasidetemporarily
8 Assernble
thepivotshaftwithcamhandle
tothebaseby
inserting
theendofthepivotshaftthrough
theholesinthe
righttemplate
support
andthebase
9 MAKE
SURE
THEORIENTATION
OF THE CAM HAN-
THE RETAINER
DLE IS AS SHOWN
the teft template support as show in Figure 12
12 Make sure the end of the cam handle fits into the hole
in the base as shown
10 Place the retainer
IN FIGURE
11
at the location
and push the pivot shaft through
FIGURE
shown in Figure
THE ORIENTATION
12
OF
RELATIVE
TO THE CAM HANDLE
SCREW MUST BE AS SHOWN
NOTE: THE RETAINER
MAY FIT TIGHTLY
PIVOT
SHAFT;
THIS
WITH
ON THE
IS NORMAL,,
11 Continue pushing the pivot shaft through the holes and
the retainer until the end of the pivot shaft extends out of
11
CAM HANDLE
//
RETAINER
PIVOT SHAFT ._
HOLE IN BASE
RIGHT TEMPLATE
DOVETAIL BASE /
RGURE
12
HOLE IN BASE
PIVOT SHAFT
CAM
HANDLE
i,vo
•
._
........
HOLE tN
BASE
iA
..............
/LJJ
11
13Withthecamhandle
pushed
inagainst
thebase,
position
theretainer
agains!
thesidewallofthebase,as
shown
inFigure
13Theretainer
should
barely
touchthe
sidewallofthebaseThepurpose
oftheretainer
isto
prevent
orminimize
theside-to-side
ofthecamhandle
and
pivotshaft
14Assemble
theothercamhandle
totheotherendofthe
pivotshaftusinga 13/64"
1Dx 9/16"OD washer
and
a#10-32
X5/8"longpanhead
machine
screw,
asshown
in
Figure
14
15 Make
surethatthecamhandle
linesupwiththecam
handle
attheotherendofthepivotshaftandthattheend
FIGURE
of the cam handle fits into the hole in the base
16 Tighten
the screw securely
17 Rotate
one of the cam handles-It
and move the template
18 If this does not happen,
er and move the retainer
19 Securely
retighten
should
rotate freely
supports
loosen
the screw on the retain-
away from the side wall slightly
the screw
20 If there is too much side-to-side
movement (play) of
the cam handles; loosen the screw in the retainer and
move the retainer closer to the side wall of the base
21
Securely
retighten
the screw
13
_L OF BASE
FIGURE
14
LEFT TEMPLATE SUPPORT
j
/
J
PIVOT SHAFT
//
/ #t0_32 X 5/8" LONG
\
\
X 9/16" O D WASHER
\" CAM HANDLE
12
ASSEMBLY
OF THE FRONT
THE DOVETAIL
BASE
STOP
BLOCKS
TO
1 Assemble the front stop blocks to the front of the dovetail base, at each end, using #10-32 x 5/8" long flathead
machine screws, 13/64" I D x 9/16" O D washers, and
the front of the base
#!0-32
4 Assemble the other front stop block to opposite
the dovetail base in the same manner
2
hex nuts, as shown
in Figure
15
Make sure that the open rib portion fits into the slot in
FIGURE
The stop block will fit into the slot in
one position only
3 Tighten the screw securely
end of
15
,,oHEx
32
NUT
FOR REASONS OF CLARITY, THE FRONT
CLAMPING BAR, KNOBS, BOLTS AND
SPRINGS ARE NOT SHOWN
/L%;f PLATE
DOVETAIL BASE
RIGHT
_
TEMPLATE
../.,.._
SUPPORT
_____/_\
\'_
_
7
_T_//
" #10-32 X 5/8" LONG
FLATHEAD MACHINE
SCREW
FRONT OF DOVETAIL BASE
WASHER
FRONT STOP BLOCK
"_
\\
OD
onto the nut
V
FRONT STOP BLOCK /
/i,'_&.
#t0-,32 X 5/8" LONG FLATHEAD
MACHINE SCREW
t3
ASSEMBLY
DOVETAIL
OF THE
BASE
TOP
STOP
BLOCKS
TO THE
• The top stop blocks are assembled to the top of the
dovetail base in one of two ways depending
upon which
screw, as shown in Figure t6
hole in the bottom of the slot
style of dovetail
3 Make sure that the "A" faces the "middte
joint is to be cut:
a HALF-BLIND
FLUSH JOINTS--The
"A" on the stop
block faces toward the "middle of the base"
b HALF-BLIND
RABBET JOiNTS--The
"B" on the
, Since the flush joint is the more
commonly
6 Again make sure that the "A" faces the "middle of the
base"
used joint, the
7 Tighten
of the stop
FIGURE
x 7/8" long flathead
of the base"
5 Assemble the remaining top stop block to the opposite
end of the base in the same manner
both screws
securely
8 To reposition the stop blocks for rabbet joints, simpty
loosen the screws just enough so that the dbs on the stop
1 Position the dovetait Jig right side up on a flat surface
2 Assemble one of the top stop blocks to the top surface
of the base using a #10-32
into the
4 Make sure the open rib portion of the stop block fits into
the slot in the top surface of the base
stop block faces toward the "middle of the base"
c THROUGH
JOINTS---The
"A" on the stop block
faces toward the "middle of the base"
following instructions apply to the assembly
blocks for this style joint
The screw threads
blocks come out of the slot The stop block is then rotated
180 ° to the attemate position, so the "B" faces the middle
of the base, and securefy retighten the screws
machine
16
#10-32 X 7/8" LONG FLAT HEAD \
MACHINE SCREW
RIB ON STOP BLOCK ,
\
TOP STOP BLOCK
#10-32 X 7/8" LONG FLAT
MACHINE SCREW
\\
RIB ON STOP BLOCK
SLOT IN TO P
OF BASE
/'
BASE
SLOT IN TOP //
OF BASE
ASSEMBLY OF THE CLAMPING
KNOBS TO THE
DOVETAIL BASE
1 Assemble 11/32" ID x 7/8" O D washers onto the 5/!618 bolts at both ends of the dovetail base as shown in
Figure 17.
2 Assemble the clamping knobs onto the bolts as shown
FIGURE
3 Thread
the clamping
knobs
spacing between the washer
approximately
1/2"
4 Set the dovetail base aside
tinue on with the next section
onto the bolts so that the
and the template
supports
is
for the time being and con-
17
5/16-18 X 2" LONG ROUND
HEAD SQUARE NECK BOLT
5/16-18 X 2" LONG ROUND
HEAD SQUARE NECK BOLT
1t132" I D X 7/8"
OD
/ CLAMPING
//
CLAMPING /
KNOB
\
KNOB
1/2" SPACING BETWEEN
WASHER AND TEMPLATE
SUPPORT (BOTH ENDS)
14
ASSEMBLY
OF THE
TEMPLATES
3 MAKE SURE THAT THE TEMPLATE
ASSEMBLED
TO THE UNDERNEATH
• Ptace the template stiffener into the rectangular slot in the
underneath side of the template, as shown in Figure 16
NOTE: THE TEMPLATE
FOR cUTTING HALF-BLIND
JOINTS 1S BEING USED AS AN ILLUSTRATION
FOLLOWING
FIGURES.
1 Thread
a #8-36
x 3/16" long panhead
machine
TEMPLATE,
ALIGNMENT
IN THE
AS SHOWN IN FIGURE lg, AND THAT THE
OF THE BRACKETS
iS ALSO AS SHOWN
IN THE FIGURE
4., IT IS NOT NECESSARY
screw
BRACKETS ARE
SIDE OF THE
FOR THE SCREWS
TO BE
through each of the five holes in the template and into the
threaded holes in the template support, as shown in
TIGHTENED
AT THIS STAGE; THE TEMPLATE
BRACKETS SHOULD BE FREE TO MOVE WITH RESPECT TO
Figure 18 and securely tighten all of the screws
NOTE: ON SOME EARLY VERSIONS
OF TH1S PROD-
THE TEMPLATE
OR ELSE
TO ALIGN THE TEMPLATE
UCT, A SLOTTED BINDING HEAD MACHINE SCREW
HAS BEEN SUBSTITUTED
FOR THE PANHEAD SCREW
SPECIFIED
FOR ASSEMBLING
THE TEMPLATE SUP-
5 The assembled
NEXT SECTION
FIGURE
in Figure
template
should
took like the illustration
in Figure 20
PORTS TO THE TEMPLATES
(SEE THE SCREW ILLUSTRATION IN FIGURE 18 )
2 Assemble the template brackets to the template using
four #10-32 x 3/8" long panhead machine screws, as
shown
IT WILL NOT BE POSSIBLE
AS DESCRIBED
iN THE
6 Assemble the template stiffener and the template brackets to the TEMPLATE
FOR CUTTING THROUGH
JOINTS
using the same method described
through 5 Refer to Figure 20
in the preceding
steps 1
t9
18
!_' _
\
\
TEMPLATE
STIFFENERSLOT
RECTANGULAR
\
TEMPLATE
\
\
\
_--\
#8-36 X 3/t6" LONG
PANHEAD MACHINE
SCREW
SLOTTED BINDING HEAD
MACHINE SCREW
TEMPLATE
\
\
'\
\
/TEMPLATE
FIGURE
BRACKET "_--,o
20
15
ALIGNMENT
OFTHETEMPLATES
• In order for the Dovetail
Jig to function
properly,
it is
For initia! setup, Allow the legs of the template bracket
"bottom out" in the slots in the template supports as
shown in Figure 21
• TO REMOVE THE TEMPLATE
FROM THE DOVETAIL
necessary' for the templates to be aligned with respect to
dovetail base The reason for this, is that dovetail cuts are
at both ends of the Dovetail Jig When properly aligned,
the result being all mating comers wi}l always be lined up
• NOTE: THE TEMPLATE
FOR CUTTING HALF-BLIND
JOINTS IS BEING USED AS AN ILLUSTRATION
IN THE
FOLLOWING
JIG, LOOSEN THE CLAMPING
KNOBS SO THAT SPACING BETWEEN THE TEMPLATE
BRACKET AND THE
WASHER IS ABOUT 1/2"; GENTLY LIFTTHE
TEMPLATE
UPWARD FROM THE DOVETAIL BASE SO THAT THE
TEMPLATE BRACKET CLEARS THE SLOTS IN THE
FIGURES°
t= With the dovetail
base stiB having the 1/2" spacing
TEMPLATE
LOCATION
between the washer and the template supports (Refer to
Figure 17), assemble the template assembly to the dovetail base so that:
a) the slot in the template
bracket
b) the leg of the template bracket
and the template support, and
SUPPORT
AND STORE
2 Lightly tighten the clamping
IN A CONVENIENT
knobs at both ends of the
fits over the bo_t
base so that the template
is between
against the template supports as shown in Figure 21
3 Move the template from side to side on the templale
brackets so Ihat it is centered with respect to the template
c) the legs fit into the slots in the template
shown in Figure 21
the washer
supports,
as
brackets
are he]d in place
brackets
This means that the template and brackets
should took like one of the following figures: Figure 22,
d) NOTE: THIS PROCEDURE
MUST BE FOLLOWED
WHENEVER
THE TEMPLATE
iS INSTALLED ON THE
DOVETAIL JIG IT IS MOST IMPORTANT
THAT LEG
OF THE TEMPLATE
BRACKET
ALWAYS BE
BETWEEN THE WASHER AND THE TEMPLATE
to
Figure 23 or Figure 24 Move template front-to-back
so
that front edge of template is parallel with the front of the
dovetail base
plate brackets
SUP-
In each condition the template and the temMUST be symmetrical
with each other The
PORT OR ELSE THE TEMPLATE
WILL NOT BE
PROPERLY POSITIONED
FOR CUTTING ACCURATE
figures do not show the complete Dovetail Jig, but only the
underneath
side of the tempJate with template brackets
DOVETAILS,
correctly
FIGURE
positioned,
in order that the correct
positions
of
21
jj
RtGHTTEMPLATE
/
SUPPORT
SLOT tN THE TEMPLATE SUPPORT
BOLT
TEMPLATE BRACKET
SLOT
TEMPLATE BRACKET "BOTTOMS-OUT" AGAINST
THIS SURFACE (BOTH ENDS OF DOVETAIL BASE)
L
16
FIGURE
22
DISTANCE BETWEN THESE
SURFACES MUST BE EQUAL
AT BOTH ENDS
O
O
(
TEMPLATE BRACKET
CONDITION ONE: TEMPLATE BRACKETS PROTRUDE BEYOND TEMPLATES
FIGURE
23
'O
TEMPLATE BRACKET
CONDITION TWO: TEMPLATE PROTRUDES BEYOND TEMPLATES BRACKETS
FIGURE
24
rLr
olio
________---_
TEMPLATE
AT BOTH ENDS
0
-TEMPLATE
BRACKET
CONDITION THREE: TEMPLATE EVEN WITH TEMPLATE BRACKETS
17
4 Afterthetemplate
brackets
havebeencorrectly
positioned
onthetemplate
securely
tighten
thefourscrews
holding
the template brackets to the template
5 Remove the template
aside for now
assembly
ADJUSTMENTS MAY BE REQUIRED HOW TO MAKE
THESE ADJUSTMENTS IS EXPLAINED IN TWO OF THE
FOLLOWING SECTIONS: "TROUBLESHOOTING FOR
HALF BLIND JOINTS" or "TROUBLESHOOTING FOR
from the base and set it
OPEN (THROUGH) JOINTS"
6 Align the other template
assembly
in the same manner
7 Remove the template assembly from the base and
set it aside for now (Figure 25 below, is an example of
INCORRECTLY
positioned template brackets )
IT SHOULD BE NOTED THAT YOU MAY FIND, THAT
AFTER MAKING SOME SAMPLE CUTS, SLIGHT
FIGURE
25
TEMPLATE BRACKET ,\
TEMPLATE
,
\,,\
THE TEMPLATE EXTENDS
BEYOND THE TEMPLATE
BRACKET
BRACKET EXTENDS
BEYOND THE
TEMPLATE
o
o
CONDITION FOUR: THIS CONDITION IS NOT CORRECT TEMPLATE BRACKET EXTENDS BEYOND THE TEMPLATE AND
THE TEMPLATE EXTENDS BEYOND THE TEMPLATE BRACKET
• SIMPLY MAKE SURE BRACKETS ABE POSmONED
ASSEMBLY
ROUTER
OF THE ADAPTER
PLATE TO THE
2 Remove the router base plate now on the router, by
removing the screws holding the base plate to time router
[A¢kWARNING]
3 Depending on the make of router, either three or four of
the loIIowing screw types and sizes will have been used:
ALWAYS
MAKE SURE THATTHE
ROUTER
IS q*URNED
OFF" AND THATTHE
ELECTRICAL
CORD
HAS BEEN
UNPLUGGED
FROM THE ELECTRICAL
OUTLET
BEFORE
ASSEMBLING
THE
ADAPTER
PLATE
GUIDE BUSHING TO THE ROUTER; OR WHEN
ANY ADJUSTMENTS,
OR CHANGING
ROUTER
THE ROUTER
1 Remove
FIGURE
THE SAME AT EACH END
any router bit currently
installed
AND
a) #8 ( 164 dia) Pan Head Screw
b) #t0 (I90 din) Pan Head Screw
A
MAKING
BITS IN
in the router
c) #8 ( 164 din) Flat Countersunk
d) #10 ( t90 dia) Flat Countersunk
Head Screw
Head Screw
4 Compare
Figure 26
with those shown in
the screws
removed
26
SCREW "b"_\
SCREW ':a_'_,
SCREW 'c"
i
J
t
I
1
t
i
I
I
I
I
I
I
I
I
I
I
I
t
I
I
I
I
I
I
I
I
I
I
I
I
I
i
i
18
I
I
I
1
1
1
i
i
1
t
SCREW "d"
I
t
i
*
5 If the screws look like Screw "a" or Screw "b", use either
three or four of the 13/64" ID x 15/32" OD washers when
7 If the screws look like Screw "c", use either three or four
of the bushings with an 11/64" din hofe when installing
installing
Figure 27
the adapter plate to the router as shown in Figure 29
8 If the screws look like Screw "d", use either three or four
6 Your Dovetail Jig comes with four countersunk
bushings
with an 11/64" hole and four countersunk
bushings with a
of the bushings with a 13/64" dia hole when installing the
adapter plate to the router as shown above in Figure 29
13/64"
the adapter
hole
FIGURE
plate to the router as shown in
Refer to Figure 28
27
FIGURE
4
, PAN HEAD SCREW
i/WASHER
SCREW
//PAN
28
0 11/32
HEAD SCREW
4
(_jWASHER
--O
t1/64
PAN HEAD
SCREW
O 25/64
F
FIGURE
29
d_
#8 FLAT HEAD SCREW
'_
HEAD
SCREW
BUSHING WITH Otl/64
"-_,\
_j
\,
BUSHING--.-.
WITH Oll/64
HOLE
#8 FLAT HEAD SCREW
'0_ /
\
HOLE
BUSHING WITH
_/Oll/64
HOLE
PLATE
SCREW
BUSHING
Oll/64 HOLE
19
O 13/64
Thefigures
below
showtheviewsoftheadapter
plateasit
wouldappear
wheninstalled
ona router
withtherouter
turned
overwiththerouter
base
facing
upward
Threeofthemostpopular
mounting
holeconfiguralions
areshown
Figure
30shows
themounting
arrangement
usingthree
screws
Figure
31shows
themounting
arrangement
usingfour
screws
whenthescrews
areat45degrees
tothesideof
the front of the router
Figure 32 shows the mounting arrangement
using four
screws when the screws are in line with the front of the
down on a workbench
or other flat
lines-up
FIGURE
arrow in the adapter
plate should
head screws
with the large center
ho_e in the adapter
point
30
FIGURE
32
©
©
©
/
31
©°@
plate
15 If it does not loosen the screws and reposition the
adapter plate so the hole Iines-up with the router collet hole
16 TIGHTEN ALL SCREWS SECURELY
©
FIGURE
being
bushings, to assemble the adapter plate to the router
t3 TIGHTEN ALL SCREWS SECURELY
14 Check to see that center of the router co]Iet hole still
10 Position the adapter plate on the router so that the
threaded holes in the router base line-up with slots (or
holes) in the adapter plate
The recessed
the countersunk
3/8" long with the proper thread from a hardware store or
DYI outlet Use these with the washers, instead of the
be used
g Set the router upside
stable surface
assemble the adapter plate Io the router if the bushing are
used the heads of the screws must be flush with, or slightly below the top of the bushing
THE TOPS OF THE SCREWS MUST NOT PROTRUDE
ABOVE THE TOP SURFACE OF THE ADAPTER
PLATE
used are too short, too long, or protrude above the top of
the adapter plate, obtain pan head screws that are 1/4" or
In most cases, the adapter plate will fit your router
However, in those cases where the router is extremely
smatl or extremely large, rated at 1-3/4 HP or larger, the
plate cannot
I2 Using the screws removed in Step 2 above, in combi_
nation with either the washers or countersunk
bushings,
If for some reason
router
adapter
toward the front of the router)
11 Line-up the center of the hole in the adapter plate with
the collet hole in the router This will ensure accurate cuts
©
2O
ASSEMBLY
OF THE
GUIDE
BUSHING
TO THE
ROUTER
1 Place the router upside
down on a flat surface
tain touters it may be necessary
to remain in this position
to support
For cer-
4 Position the guide bushing so that the three threaded
holes in the guide bushing line-up with the countersunk
the router for it
2 Place the proper guide bushing required for the type of
dovetail to be cut under the router adapter plate as shown
holes in the adapter plate
5 Thread a #10-32 x 3/8" long flathead
into each of the holes
in Figure 33
3 MAKE SURE THAT THE ORIENTATION
6 SECURELY
34
GUIDE
FIGURE
BUSHING
OF THE
TIGHTEN
THE SCREWS
machine
Refer to Figure
IS AS SHOWN
33
_/
/
\
#10-32 X 3/8" LONG
_J
FLATHEAD MACHINE SCREW
ADAPTER PLATE
#10-32 X 3/8" LONG_
FLATHEAD MACHINE SCREW
/
ROUTER
s/
/
GUt0
BUSH1NG
ASSEMBLY
(1/2" DIAMETER
SHOWN)
NOTE THE
ORIENTATION
OFTHE GUIDE
BUSHING
FIGURE
34
GUIDE BUSHING ASSEMBLY
(1/2" DIAMETER SHOWN)
NOTE THE ORIENTATION
OFTHE GUIDE BUSHING
"_
ROUTER
2t
screw
[J_"]"m_WARNING'
THE DOVETAIL
BE FIRMLY AND SECURELY
2 Remove the template assembly
there is one there currently
JiG MUST ALWAYS
MOUNTED
TO A SOLID
MOUNTING
THE
OR WORKBENCH
DOVETAIL
RESULTING
PERSONAL
JIG TO A WORK
4
IN PROPINJURY
AGE, WITHOUT PERMANENTLY
YOUR WORKBENCH
TAKING
SURFACE
x 1" long panhead
Figure 35
self tapping
screws
as shown in
10 Line up the front of the mounting board
of a workbench or other sturdy surface
with the front
11 Using two clamps, such as C-clamps,
firmly clamp the
Dovetail ,Jig to the workbench by clamping on the mount-
ON
ing board as shown in Figure 36 and Figure 36A
12 Make sure that the mounting board lines up with the
front of the workbench
1 Make a solid wood mounting board, 32" long x 6-1/4"
wide x 3/4" thick
FIGURE
Jig on the top of the mounting
g Applying a small amount of soap to the screw threads
will make it easier to thread the screws into the holes
FOR STOR_
UP SPACE
the Dovetail
5 Secure the Dovetail Jig to the mounting board using
three t3/64" I.D. x 9/16" O D washers and three #10-16
USING CLAMPS
FOR USE, AND REMOVED,
Position
board so the holes in the base line up with the drilled
holes in the mounting board
USING THIS MOUNTING
METHOD ALLOWS YOU TO
MOUNT THE DOVETAIL JIG SO THAT IT CAN BE EASF
LY INSTALLED,
35
_
TO THE FRONT OF THE
DOVETAIL BASE
/
//
/
//2
,_"_'_
,_
_
TO THE FRONT OF THE .....
DOVETAIL BASE
base if
3 Ddll three 1/8" diameter holes, 3/4" deep into the mounting board as shown in illustration
AND FIRM WORK SURFACE,
SUCH AS A WORKBENCH, BEFORE USE FAILURE TO DO SO COULD
CAUSE THE DOVETAIL JIG TO TIP OVER OR SLIDE
ALONG THE WORK SURFACE,
ERTY DAMAGE AND SERIOUS
from the dovetail
//
22
i
1/8" DIAMETER DRILL
FIGURE
36
CLAMP HERE
FRONT SURFACE
OF THE MOUNTING BOARD
CLAMP HERE
FRONT SURFACE OF
THE WORKBENCH
FRONT SURFACE OF THE BASE
FIGURE
36A
FRONT SURFACE OF THE BASE
FRONT SURFACE OF THE MOUNTING BOARD
FRONT SURFACE OF THE WORKBENCH
23
STYLES
OF DOVETAIL
JOINTS
• Four different styles of dovetail joints can be made with
the Dovetail Jig using your router
• These joints are described in the following sections
Haft
Blind
Flush
NOTE: THE NORMAL DEPTH OF CUT FOR A HALF
BLIND FLUSH JOINT IS 318",
Joint
• The Half Blind Flush Joint is used when the height of
both Ihe drawer front and the drawer back is the same
height as the drawer sides; and the length of both the
drawer front and the drawer back is the same as the width
of the drawer
See Figure 37
FIGURE
37
/
F
DRAWER FRONT (PiN PIECE)
/
DRAWER SIDE (TAIL PIECE)
"_-
TAILS
\
DRAWER BACK (PIN PIECE) /
24
DRAWER SiDE (TAIL PIECE)
Half Btin d Flush
Offset Joint
o The Half Blind'Flush
Offset JOint is used when_
See Figure 38
*To obtain the offset, cut a 1/16" deep by 3/8" wide rabbet
The height of both the drawer front and the drawer back is
the same height as the drawer sides; the length of the
on the opposite
drawer
front is 1/8" longer (1/16" on a side) than the width
of the drawer; and the length of the drawer back is the
same as the width of the drawer
FIGURE
ends on the inside of the drawer
NOTE:
THE NORMAL
BLIND
FLUSH
DEPTH
OFFSET
38
front
OF CUT FOR A HALF
JOINT
IS 3t8".
DRAWER FRONT (PIN PIECE)
1/!6" OFFSET ...
DRAWER SIDE (TALL PIECE)
-_R SIDE (TAIL PIECE)
/
DRAWER BACK (PIN PIECE) J
Haft Blind
Rabbeted
• The Half Blind
Joint
Rabbeted
The drawer fronl overlaps
Joint
is the same as the widlh of the drawer; and the height of
the drawer back is the same as the height of the drawer
See Figure 39
is used when:
the opening
for the drawer
on el!
four sides of the of the drawer opening (top, bottom, and
two sides) that is; the length of the drawer front is 3/4"
longer (3/8" on a side) than the width of the drawer; the
• To obtain this joint, cut a 3/8" deep by 3/8" wide rabbet
around the inside periphery of the drawer '_ront
height of the drawer
(3/8" on side)
NOTE:
THE NORMAL
than the height of the drawer; the length of the drawer back
BLIND
RABBETED
FIGURE
front is atso 3/4" higher
DEPTH
JOINT
OF CUT FOR A HALF
!S 318'L.
39
DRAWER FRONT (PIN PIECE)
3/8" WIDE RABBETAROUND THE
PERIPHERY OF THE DRAWER FRONT
DRAWER SIDE
DRAWER S_DE (TAIL PIECE)
TAIL
DRAWER BACK (PtN PIECE)
25
Open
or Through
• The Open
NOTE:
Joint
or Through
Joint
Joint except that joint seams
is similar
are visible on the front, back,
use is for making
boxes,
OF CUT IS DETERMINED
OF THE
FRONT, BACK
BY THE
AND SIDE
• The front and back pieces (sometimes
called "tail
pieces") are cut independentIy from the side pieces
and sides of the workpiece;
on the Half Blind Joints, the
seams are visible only on the sides of the workpiece
• Although this style of joint can be also used for drawers,
its most popular
THE DEPTH
THICKNESSES
PIECE&
to the Half Blind
(some-
times called "pin pieces")
- The "pin pieces" are cut first using one edge of the tem-
and small and
plate and a dovetail router bit The depth of cut is equal to
the thickness of the "tail pieces"
large chests
• The height of both the front and the back of the drawer
• The "tail pieces" are cut next using the other edge of the
template and a straight router bit The depth of cut is equal
or chest is the same height as the sides of the drawer or
chest; and the length of both the front and the back of the
drawer or chest is the same as the width of the drawer or
to the thickness of the "pin pieces"
at this point to oblain joint fit
chest
Adjustments
are made
See Figure 40
FIGURE
40
ADJUSTING
ROUTER
THE
DEPTH-OF-CUT
OF THE
I_CAUTION
BIT
r__
[,_._,WARNINGJ ALWAYS MAKE SURETHATTHE
ROUTER
tS "TURNED
OFF"
AND THAT THE
ELECTRI-
CORD
HASBEENUNPLUGGED
FROM
THE
CAL
ELECTRICAL
OUTLET BEFORE ASSEMBLING
REMOVING
ROUTER BITS TO THE ROUTER,
• You will note that there are six pockets
OR
used to set the depth-of-cut
of a router bit
To use proceed as follows:
- DO NOT USE WITH A TEMPLATE
ASSEMBLED
ROUTER
ROUTER BIT ,,
TO
HAS BEEN
router bit to the router as explained
in
your Router Owner's Manual See Figure 41
A MINIMUM ROUTER BIT SHANK ENGAGEMENT
OF
3/4" IS REQUIRED
IN THE COLLET OF THE ROUTER
2 TIGHTEN
THE COLLET
BASEPLATE
GUIDE
BUSHING
BITS TO THE ROUTER
UNLESS THE CORRECT GUIDE BUSHING
ASSEMBLED
TO THE BASEPLATE
FIRST
1 Install the desired
SURE THAT THE ROUTER
along the front
surface of the dovetail base, and that they are identified by
a dimensions
such as 3/8, lt2,-up
to 1 These pockets are
THE BASE
o DO NOT INSTALL
i MAKE
BIT ISALIGNED WITH OR CENTERED IN THE HOLE IN
THE GUIDE BUSHING. TO DO THIS, LOOSEN SCREWS
HOLDING BASE OR ADAPTER PLATE TO ROUTER,
CENTER GUIDE BUSHING HOLE WITH RESPECT TO
ROUTER BIT AND RETtGHTEN SCREWS SECURELY_
,t
NUT SECURELY
3 Position the router over the pocket with the required
depth-of-cut
FIGURE
26
41
4 Gradually
depth-of-cut
bit touches
move the router bit outward, by using the
feature on the router, until the tip of the router
the bottom
of the pocket,
as shown
l,t_
I_._,CAUTION
iI
in
WHEN
SETTING
CUT, MAKE ABSOLUTELY
Figure 42 and Figure 42A
5 Lock the router in position
THE DEPTH
OF
SURE THAT THE COLLET
NUT DOES NOT CONTACT (TOUCH) THE GUIDE BUSHING THIS CAN CAUSE THE GUIDE BUSHING TO HEAT
UP EXCESSIVELY
DURING CUTTING WHICH CAN
6 The desired depth-of-cut
has been set
7 To set a depth-of-cut
NOT provided for on the dovetail
CAUSE DAMAGE TO THE TEMPLATE
TO CORRECT
THIS SITUATION OR PREVENT IT FROM OCCURRING
base, simply place the unused template on the router
baseplate, as shown in Figure 43 The height _rom the
REPOSITtON
THE
ROUTER
BIT IN THE ROUTER
baseplate to the end or tip of the router bit will then be the
required depth of cut
FIGURE
42
ROUTER
ROUTER BIT
FIGURE
\
POCKET
42A
ROUTER
'" POCKET
ROUTER BIT /
FIGURE
43
TEMPLATE
ti I 1'
27
--j OEPT.
O CUT
CLAMPING
THE
DOVETAIL
BASE
WORKPIECES
TO THE
ing bolts and springs
in the base
• CAUTION:
CLAMPING
- The clamping bars have been specially designed to allow
lhe clamping forces to be applied next to the workpieces
of the ctamping
and the clamping knobs when the workpieces
to the LEFT SiDE of the Dovetail Jig
pieces
FIGURE
of the clamping
When not in use etamping
knobs
knobs
BECOME
,, FOR ACCURATE
JOINTS, THE WORKPIECES
MUST
"BUTT-UP" AGAINST BOTH THE TOP AND THE FRONT
bars
STOP BLOCKS TO ENSURE
OF THE WORKPIECES
are clamped
• TO ENSURE ACCURATE
• Figure 45 illustrates the positioning
of the clamping bars
and the clamping knobs when the workpieces
are clamped
to the RIGHT SIDE of the Dovetail Jig
- Note the closeness
WHEN CLAMPING,
MAKE SURE THAT THE
KNOBS ARE NOT POSITIONED
SO CLOSE
TO THE WORKPIECES
THAT THE WASHERS
TRAPPED
UNDER THE WORKPIECES
for more efficient clamping
This is accomplished
by' being
able to position the clamping knobs in close proximity or
next to the workpieces
• Figure 44 illustrates the positioning
are free to be moved atong the slots
THE EXACT
JOINTS
POSITIONING
AND SAFE OPERA-
TION, WOOD SHAVINGS AND ACCUMULATED
DUST
MUST BE REMOVED
FROM THE DOVETAIL JIG
BEFORE EACH SETUP,
OR BY VACUUMING
to the work-
and the support-
EITHER
BY USING A BRUSH
44
INSIDE SURFACE OF DRAWER
FRONT (OR BACK) FACES UP
_
.._._._,----_
//
TOP STOP BLOCK ,_.._.
WORKPIECE
CLAMPED TO
THE TOP OF THE BASE
_y
LEAR
(
O
F HEV,
O.KP,ECES
WORKPIECE
C.AMPEO
TO
,Ns,oE
SUBFAOE
OF
°RAWER
S'DE
FAOESO0
FIGURE
T,-,EFRONTOFT.EBASE
45
WORKPfECE CLAMPED TO THE TOP OF THE
iNSIDE SURFACE
TOP CLAMPING BAR.,
• TOP STOP BLOCK
WASHER MUST BE
CLEAR OF THE
WORKPIECE
FRONT CLAMPING BAR
WASHER MUST BE CLEAR OF THE WORKPIECES "_/
FRONT STOP BLOCK
INSIDE SURFACE
WORKPIECE CLAMPED TO
THE FRONT OF THE BASE
28
MAKING
FLUSH
DRAWERS
WITH
HALF
BLIND
shows the workpieces
of the drawer)
JOINTS
• In addition,
• The thickness of both the front and back (pin pieces)
must be at least 1/2" The thickness of the sides (tail
pieces) must be at least 3/8 _
the drawer
CORNERS
Dovetail
appearance
ensure
where the four comers
view
of
4 are cut on the RIGHT
SIDE of the
Jig
• TdaJ cuts are strongly
o Figure 46 shows a drawer and the workpieces that make
it up This figure is similar to Figure 38, except that it
FIGURE
the figure shows
(or an exploded
are cut on the Dovetail Jig
1 AND 3 are cut on the LEFT SIDE of the
Dovetail Jig
CORNERS
2AND
A partial tail will be cut for side (tai! piece) thicknesses up
to 9/16" This is norma_ and will not affect the joint or its
unassembled
recommended
that the final workpieces
using scrap wood
are of the desired
to
quality
46
CORNER #1
(CUT AT THE LEFT SIDE OF
THE DOVETAIL ,JIG)
DRAWER
SURFACE LINES UP
WITH FRONT STOP,
BLOCKS
\,
(CUT AT THE RIGHT SIDE OF
THE DOVETAIL ,JIG)
FRONT
-\
SURFACE LINES UP WITH
FRONT STOP BLOCKS
/
\
H
DRAWER .\
RIGHT
",
/
/
INSIDE OF DRAWER
SURFACE LINES
UP WITH TOP
STOP BLOCKS
LEFT SiDE
OUTSIDE OF
DRAWER
-\
"- DRAWER BACK
CORNER
(CUT AT THE RIGHT SIDE OF
THE DOVETAIL JIG)
(CUT AT THE LEFT SIDE OF
TIDE DOVETAIL ,JIG)
29
GENERAL
PREPARATIONS
a Theworkpieces
comprising
thedrawer,
that is,
back, ]eft side, and right side should
length, width, and thickness(es)
b Make sure that all surfaces are smooth
each of the other surfaces
c Line up the workpieces
edge,
as shown
positioning
and square with
f l nslall Vermont
on a flat surface,
standing
on the Dovetail
Jig, prior to cut-
to the router base-
plate, as described in a previous section This the smaller
of the two guide bushings furnished with this product
American
#22500
or Magna #Mg 1113
dovetail router bit, to the router as described
Router Owner's Manual Shank engagement
minimum of 3/4"
on
in Figure 47
d With a soft lead pencil mark the front, back, left side,
and right side, as shown in Figure 47 This is to aid you in
FIGURE
the workpieces
ting the dovetails
e Assemble the 40" guide bushing
front,
be cut to the proper
in your
should be a
47
MARK "DRAWER FRONT TOP SURFAC E .
MARK "1"
MARK 'W"
_
MARK "DRAWER \
RIGHTSIDE TOP \.
_.._.._'-I'"_/_
__
\
"'"
",,
\
\
MARK
INSIDE SURFACE"
/
MARK "DRAWER RIGHT
/
;
SIDE _NSIDE SURFACE"
/
r
;
'
MARt{ "DRAWER BACK
;
,
.,,,-"
I
,'
. MARK
"DRAWER
LEFT SIDE
TOP SURFACE"
MARK
\ MARK "DRAWER
LEFT SIDE
",
",
'.
INSIDE SURFACE"
(SHOWN HIDDEN)
\
\
\
MARK "DRAWER BACK INSIDE SURFACE" (SHOWN HIDDEN)
IAII, CAUT!ON
I MAKE
IS ALIGNED
WITH
SURE THATTHE
OR CENTERED
IN THE
ROUTER
BiT
HOLE tN THE
40"
DIA
GUIDE
BUSHfNG
,_,,
GUIDE BUSHING
TO DO THIS, LOOSEN SCREWS
HOLDING BASE PLATE OR ADAPTER PLATE TO
ROUTER,
RESPECT
\
CENTER GUIDE BUSHING HOLE WtTH
TO ROUTER BIT AND RETIGHTEN
SCREWS
SECURELY
VERMONT
AMERICAN #22500
] CAUTION/ WHENSETTING
7HEDEPTHOF
OR
CUT, MAKE ABSOLUTELY
MAGNA #M911 !3
DOVETAIL
ROUTER BIT
SURE THAT THE COLLET
NUT DOES NOT CONTACT (TOUCH) THE GUIDE BUSHING THIS CAN CAUSE THE GUIDE BUSHING TO HEAT
UP EXCESSIVELY
DURING CUTTING WHICH CAN
CAUSE
DAMAGE
TO THE TEMPLATE
TO CORRECT
THIS SITUATION
OR PREVENT it FROM OCCURRING,
REPOSITtON
THE ROUTER BIT IN THE ROUTER
30
\
\
E
g Adjust
thedepth
ofcutto3/8"usingthedepth
gauge
on
thebaseoftheDovetail
Jig,asdescribed
ina previous
section
Thissetting
isapproximate
andsome
adjustment
maybe
required
FIGURE
48
h Position
bothofthetopstopblocks
sothatthe"A"faces
the"middle
ofthebase"
asshown
inFigure
48 '
i Position
thecamhandle
sothatthepointer
points
tothe
center
graduation
asshown
inFigure
48
LEFT
TOP
STOP
BLOCK
'A"FACES
TOWARD
MIDDLE
OFBASE
. "A" FACES TOWARD MIDDLE
_
OF
B___ASE
_
/
7 _------------_-\\V,_
1A_
RIGHT TOP STOP BLOCK
/
I
/- .......
//_/
It
'
___
!'[i"
V
_',",
" '_ii]ii_, ,
"\
THE
FOLLOWING
BE FOLLOWED
/_
LEFT FRONT STOP BLOCK
DESCRIBES
FOR CUTTING
THE
PROCEDURE
CORNERS
TO
The words "INSIDE
Section, GENERAL
FIGURE
SURFACE" marked in (d) in the
PREPARATIONS,
should be visible.
4 Line up the workpieces
so that the end of the drawer
side lines up with the drawer front as shown in Figure 49
5 Securely clamp the drawer side to the base
PREPARATIONS,
2 Ughtly clamp the drawer front in place
3 Position the drawer RIGHT side against
STOP BLOCK
base so that the top surface abuts the left front stop block
THE INSIDE OF THE DRAWER S_DE FACES AWAY
FROM THE FRONT OF THE BASE
1 AND 3
the top surface abuts the left top stop block THE INSIDE
OF THE DRAWER FRONT FACES AWAY FROM THE
TOP OF THE BASE The words "INSIDE SURFACE"
GENERAL
RIGHT FRONT
POINTER POINTS
TO CENTER
\ _"'_
1 FOR CORNER #1, position the drawer front on the top
of the base so that it lines up with the front of the base and
marked in (d) in the Section,
should be visible
_
_./
6 Securely clamp the drawer front to the base
7 Make sure that the parts remain lined up
the front of the
49
DRAWER FRONT
THE END OF THE DRAWER
'tNSfDE SURFACE" SHOULD BE
VISIBLE ON THIS SURFACE
SIDE MUST BE LEVEL AND \-._%
FLUSH WITH THE INSIDE
"_,.
SURFACE OF THE DRAW_
AUXILIARY TEMPLATE
%.,
ER FRONT (OR BACK)
TOP OFTHE BASE/'
SUPPORT (AS NEEDED)
\
" FRONT OF THE BASE
DRAWER RIGHT SIDE
NOTE:
WORKPIECES
WILL
BE POSITIONED
ON THE
31
JIG AS
"INSIDE SURFACE" SHOULD BE
VISIBLE ONTHIS SURFACE
FIGURE
5O
/
/"
/
DOVETAIL TEMPLATE
FOR HALF BLIND JOINT
//
(
8 Assembfe
WASHER
the DOVETAIL
TEMPLATE
FOR HALF BLIND
_'_')L],,M,WARNING,
NEVER
JOINTS to the Dovetait Jig so that THE TEMPLATE
BRACKETS
FiT BETWEEN THE WASHERS AND THE
t6
TEMPLATE
SUPPORTS as shown Figure 50
NOTE: MAKE SURE THE TEMPLATE
CLAMPING
KNOBS ARE LOOSE TO MAKE TEMPLATE
ADJUST-
ROUTER BIT ROTATING OR WHEN THE GU|DE BUSHING IS NEAR TO OR TOUCHING
THE TEMPLATE°
THIS
MENT, AFTER ADJUSTMENT
IS MADE,
TEMPLATE
CLAMPING
KNOBS.
UPWARDS
Make sure that the template
RESULT
is flush and parallel
BODILY
INJURY,,
should
51
with
FIGURE
51
DRAWER
49)
11 Clamp
knobs
the temptate
I '_WARNINGI
MAKE
IN SERIOUS
look like those illustrated in Figure
mended
Its purpose is to aid in supporting the router while
cutting It can be made from a piece of scrap wood; but its
thickness must be the same as the drawer front (Refer to
12
ROUTER
IS ON AND THE
17 After the cut has been made, the workpieces
the workpieces
clamped to base Far narrow drawer fronts,
the use of an auxiliary support for the template is recom-
Figure
LIFT THE
ROUTER
CAN CAUSE DAMAGE TO THE DOVETAIL JIG; OR
LOSS OF CONTROL OF THE ROUTER WHICH CAN
RETtGHTEN
9 Make sure that the short fingers on the template, as
shown in Figure 50, faces toward the front of the base
10
WHEN THE
in place by tightening
BEFORE
SURE THAT THE
MAKING
BIT WILL
the clamping
ANY CUTS
NOT CUT INTO THE
BASE OR ANY OTHER COMPONENT
OF THE DOVETAIL JIG,, THIS CAN CAUSE DAMAGE TO THE DOVETAIL JIG; OR LOSS OF CONTROL OF THE ROUTER
WHICH CAN RESULT IN SERIOUS BODILY INJURY,, A
TRIAL RUN WITH THE ROUTER TURNED OFF AND
UNPLUGGED
FROM THE ELECTRICAL
OUTLET
IS
STRONGLY
RECOMMENDED°
13 TURN THE ROUTER ON
14
Cut the dovetail
by moving
the router from LEFTTO
RIGHT, with the guide bushing fol!owing the template
DO
NOT FORCE ANYTHING;
MOVE THE ROUTER IN SLOW
AND SMOOTH FASHION
15 To ensure
a smooth
and uniform joint, retrace
/
DOVETAIL CUTS
the pre-
DRAWER /
vious cut by moving the router from RIGHT TO LEFT with
the guide bushing again fo_$owing the template
RIGHT SIDE
32
18 Remove the workpieces from the Dovetail ,Jig and
check how the workpieces
fit together Some adjustments
THE INSIDE
may be required
GENERAL
Refer to the section TROUBLESHOOTING
19 FOR CORNER #3, position the drawer
words
on page 37
back on the top
OF THE
"INSIDE
DRAWER
SURFACE"
SIDE FACES
marked
PREPARATIONS,
UP The
in (d) in the Section,
should be visible
22 Line up the workpieces
so that the end of the drawer
side lines up with the drawer back as shown in Figure 52
of the base so that it lines up with the front of the base and
the top edge surface abuts the left top stop block THE
INSIDE OF THE DRAWER BACK FACES UP The words
23 Continue as in Steps 5 through 16 above
24 After the cut has been made, the workpieces
took like those illustraied in Figure 53
"INSIDE
25
SURFACE"
marked
in (d) in the Section,
GENER-
Remove
the workpieces
from the Dovetail
AL PREPARATIONS,
should be visible See Figure 52
20 Lightly clamp the drawer back in place
check how the workpieces
may be required
21 Position the drawer LEFT side against the front of the
base so that the top surface abuts the left front stop block
Refer to the section TROUBLESHOOTING
FIGURE
fit together
should
Jig and
Some adjustments
on page 37
52
I
_,'_INSIDE
SURFACE" SHOULD BE VISIBLE
ON THIS SURFACE
/TOP
//
.....
....
DF_A"AER LEFT SiDE /
__""
•
//
OF THE BASE
/
_
AUXILIARY TEMPLATE SUPPORT
(AS NEEDED)
"INSIDE SURFACE" SHOULD BE VISIBLE
ON THIS SURFACE
FIGURE 53
DRAWER BACK \
DRAWER LEFT SIDE
DOVETAIL
33
THEFOLLOWING
DESCRIBES
THEPROCEDURE
TO
BEFOLLOWED
FORCUTTING
CORNERS
2AND4
CORNERS
2AND4 arecutinthesame
wayas1and3
• After the cut has been made, the workpieces should fook
Iike those illustrated in Figure 53
• The finished front, back, and sides should look iike those
except
in Figure
they are positioned
Jig as shown
Figure
. [,_CAUTION
I
on the right side of the Dovetail
BEFORE
MAKING
•
I "_cAUTION
t
CAUSE
NEVER
DAMAGE
TO THE
the front, back, and sides together,
must be made for installing
the bot-
tom, such as dadoing
or cutting
inside of the drawer parts°
ANY CUTS
MAKE SURE THAT THE BIT WILL NOT CUT INTO THE
BASE OR ANY OTHER COMPONENT
OF THE DOVETAIL JIG,, THIS CAN
TAIL JIG,,
46
• Before gluing
some provision
54
• Your drawer
a groove
around
is now ready to be glued together
DOVE-
LIFT THE ROUTER
UPWARDS
WHEN THE ROUTER IS ON AND THE
ROUTER BIT ROTATING OR WHEN THE GUIDE BUSHING IS NEAR TO OR TOUCHING
THE TEMPLATE°
CAN CAUSE DAMAGE TO THE DOVETAIL JIG.
FIGURE
THIS
54
'INSIDE SURFACE" SHOULD BE
VISIBLE ON THIS SURFACE
TOP OF THE BASE \
\
DRAWER BACK
AUXILIARY(As
NEEDED)TEMPLATESUPPORT \\
_\
/
/
FRONT OF THE BASE "/
DRAWER RIGHT SIDE
"iNSIDE SURFACE" SHOULD BE VrSIBLE ON THIs SURFACE
NOTE: WORKPIECES
WILL
BE POSITIONED
ON THE JIG AS
34
the
MAKING
DRAWERS
OFFSET
JOINTS
WITH
HALF
BLIND
FLUSH
RGURE
55
"A" FACES \
GENERAL
BACK OF
PREPARATIONS
a The iength of the drawer
front is 1/8" Ionger
length of the drawer back
b When cutting comers 1 and 4; the cam handle
two graduations
MIDDLE OF BASE \\
than the
THE BASE
\\
is rotated
toward the back of the base, thus moving
the template !/32" toward the back of the base (Refer to
Figure 55)
NOTE: MAKE SURE THE TEMPLATE
CLAMPING
KNOBS
ARE LOOSE
TO MAKE TEMPLATE
MENT, AFTER ADJUSTMENT
IS MADE,
TEMPLATE
CLAMPING
KNOBS,
ADJUST-
RE'TIGHTEN
c When cutting corners 2 and 3; the cam handle is positioned vertically, as shown in Figure 48
d All other GENERAL PREPARATIONS
are the same as
those used for "MAKING
FLUSH JOtNTS"
THE PROCEDURE
DRAWERS
FOR CUTTING
WITH
THESE
THE SAME AS THAT USED FOR "MAKING
WITH HALF BLIND FLUSH JOINTS"
HALF BLfND
JOINTS
POINTER POINT5
TO THE SECOND GRADUATION
TOWARD THE BACK OF THE BASE
FROM THE CENTER GRADUATION
IS
DRAWERS
• After aI1 dovetail cuts have been made, cut a 1/16" deep
by 3/8" deep rabbet on opposite ends of the drawer front
• The finished front, beck, and sides should look like those
as dadoing
in Figure 38
• Before gluing the front,
• Remove the pencil markings by light sanding or with a
soft eraser after the drawer parts have been glued
together
provision
back, and sides together,
must be made for installing the bottom,
or cutting
drawer parts
o Your drawer
some
such
35
a groove
around
the inside of the
is now ready to be glued together
MAKING
DRAWERS
RABBETED
WITH
HALF
THE PROCEDURE
BLIND
GENERAL
PREPARATIONS
a The length of the drawer
tength of the drawer
back
ALIGNED
° Use the side of the tempiate
1 AND 4
WHEN
MAKING
THESE
fingers
• Before gluing the front, back, and sides together,
some provision must be made for installing
the bottom, such as dadoing
or cutting
inside of the drawer parts
BELOW, THE TOP SURFACES
OF THE SIDES, FRONT,
AND BACK WILL NOT "LINE-UP" PROPERLY
EITHER
REFER TO THE SECTION "ALIGNMENT
OF THE TEM(Figure 60 illustrates a Flush Dovelail
GENERAL
PREPARATIONS,
except
that has the longest
the
• Position the template and workpieces
as shown in
Figure 57 Cut the dovetail as described in the section,
MAKING DRAWERS WITH HALF BLIND FLUSH JOINTS
JOINTS, OR ELSE, IN ADDITION TO THE JOINT SPACiNG NOT BEING EQUAL, AS SHOWN 1N FIGURE 60
PLATES"
-All other
CORNERS
° Position BOTH top stop blocks so that the "B" faces
middle of the base as shown in Figure 56
front is 3/4" longer than the
b The height of the drawer front is 314" higher than the
height of the drawer back and drawer sides
• IT tS EXTREMELY
iMPORTANT THAT THE TEMPLATE
BE PROPERLY
FOR CUTTING
IS THE SAME AS THAT USED FOR "MAKING
DRAWERS WITH HALF BLIND FLUSH JOINTS"
EXCEPT
JOINTS
• Your drawer
a groove
around
the
is now ready to be glued together
• Remove the penciI markings by fight sanding or with a
soft eraser after the drawer parts have been giued
together
Joint)
as noted
below in the procedure,
are the same as those used for
"MAKING DRAWERS WITH HALF BLIND FLUSH
J Of NTS"
FIGURE
56
LEFT TOP STOP BLOCK
,/"B"
'B" FAC ES TOWARD
OF BASE
FACES TOWARD MIDDLE OF BASE
/-/
/
/
\"LEFT
FIGURE
/
RIGHT TOP STOP BLOCK
/
POINTER POINTS TO
CENTER GRADUATION
\ RIGHT FRONT STOP BLOCK
FRONT STOP BLOCK
57
/
_
CLAMPKNOa
Na
ii--%n
-
..........
"
..... I
DOVETAIL TEMPLATE FOR
/
HALF BLlND JOINTS
-
Z /it
/ OLAMPINGK.OB
_ASHER
,_L..__'
--m'_._.__---_: ........... _
.....
i
.,C,,,
TEMPLATEORAOKET
36
RGURE 58 - JOINT IS TOO SHALLOW
TROUBLESHOOTING
o If the joint
is too loose:
INCREASE
the depth of cut by
INCREASING
the amount by which the router bit extends
beyond the baseplate by t/64" to 1/32" and make a trial
cut
Continue
adjusting
until desired
DRAWER FRONT
joint fit is attained
_-
° If the joint is too tight: DECREASE
the depth of cut by
DECREASING
the amount by which the router bit extends
beyond the baseplate by 1/64" to 1/32" and make a trial
cut Continue adjusting until desired joint fit is attained
SIDE
EXTENDS
OUT PAST
FRONT
• If the joint is too shallow:
Refer to Figure 58 Loosen
the clamping knobs holding the template brackets and
move the template INWARD half the additional
needed by tuming the cam handles Retighten
deplh
the clamp-
DRAWER
BACK
ing knobs
° If the joint
is too deep:
Refer to Figure
59
Loosen
the
_SIDE
clamping knobs holding the template brackets and move
the template OUTWARD by turning the cam handles half
the distance
needed
Retighten
the clamping
EXTENDS
OUT PAST
FRONT
knobs
° If the joint is not uniformly
spaced from top surface
of drawer:
Refer to Figure 60 (See the Section "ALIGNMENT OF THE TEMPLATES"
) With the template clamped
to the base, loosen the four screws securing the template
to the template
brackets,
and move the template
slightly
FIGURE
59 -
JOINT
IS TOO DEEP
DRAWER FRONT ...
to
the left Tighten the four screws and make a trial cut if
moving the template to the left did not correct the condition, but made it worse, loosen the screws and move the
BACK
EXTENDS
OUT
PAST
SIDE
template to the right a small amount Tighten the four
screws and make a trial cut Continue moving the template
to the right until the condition
MAKE SURE TO SECURELY
SCREWS
condition,
is completely correcled
TIGHTEN THE FOUR
DRAWER
LEFT SIDE
If moving the template to the left improves the
continue moving the template to the left until the
condifion is completely
corrected
Make sure the template
remains parallel to the front of the dovetail base MAKE
SURE TO SECURELY TIGHTEN THE FOUR SCREWS
AFTER THE TEMPLATES
HAVE BEEN CORRECTLY
DRAWER
BACK _\
BACK
EXTENDS
OUT PAST
SIDE
REALIGNED,
THEY SHOULD REQUIRE NO FURTHER
ADJUSTMENTS
IF THEY ARE HANDLED WITH CARE
FIGURE
60 -
JOINT
SPACING
IS NOT
UNIFORM
SPACING LESS THAN
DRAWER BACK
SPACING GREATER
THAN DRAWER FRO_
f_l
_
DRAWER BACK J'
j"
DRAWER FRONT
/
DRAWER LEFT SIDE j
37
MAKING
PROJECTS
WITH
OPEN
GENERAL
(THROUGH)
JOINTS
• The thickness of both the front and the back (tail pieces)
must be between 3/8" and 1"
• The thickness of the sides
between 3/8" and 1"
length, width and thickness(es)
b Make sure that all surfaces are smooth
each of the other surfaces
(pin pieces) must also be
• Figure 61 shows a project and the workpieces
if up This figure is similar to Figure 40, except
shows the workpieces
unassembied
PREPARATIONS
a. The workpieces comprising the project, that is, front,
back, left side and right side should be cut to the proper
and square
c Line up the workpieces
on a flat surface,
edge, as shown in Figure 62
d.. With a soft lead pencil mark the front,
that make
that it
standing
back
on
and two
sides, as shown in Figure 62, also. This is to aid you
in positioning
the workpieces
on the Dovetail Jig, prior
to
• Trial cuts are strongly recommended
using scrap wood to
ensure that the final workpieces
are of the desired quality
cutting
the dovetails.
e Position
both of the top stop blocks
so that the "A" faces
the "middle of the base" as shown in Figure 48
f Position the cam handle so that the pointer points
center graduation as shown in Figure 48
FIGURE
with
to the
61
CORNER#1
CORNE_
PROJECT FRONT\
_
..............
/_
SURFACE LINES
UP WITH FRONT
STOP BLOCKS
/yv
PROJECT
RIGHT SIDE
/
//SURFACE
LINES UP WITFI
FRONT STOP BLOCK
"_--_'-_0
_"
UTSIDE I
OR%EOT
PROJECT SACK
CORNER#_
CORNE_
38
-_CTLEFT SIDE
FIGURE
62
MARl,( "PROJECT FRONT TOP SURFACE" \
MARl( "1"
/ MARK "PROJECT
LEFT SIDE TOP
SURFACE"
MAflK"PROJECTFRONTOUTSIDE
t
SURFACE" (SHOWN HIDDEN)
MARt( "PROJECT RIGHT SIDE OUTSIDE
SURFACE" (SHOWN HIDDEN)
MARK "PROJECT
BACKTOP SURFACE"
//
/
MARK
MARt( "PROJECT
LEFT SIDE OUTSIDE
SURFACE"
MARK "PROJECT
BACK OUTSIDE
SURFACE"
THE FOLLOWING
DESCRIBES
BE FOLLOWED
FOR CU_ING
SIDE AND THE
PROJECT
THE
THE
PROCEDURE
TO
PROJECT RIGHT
t._i_lt,_,CAUTtON
1 WHEN
LEFT SIDE
CUT, MAKE ABSOLUTELY
SETTING
THE
DEPTH
SURE THAT THE
COLLET
NUT DOES NOT CONTACT (TOUCH)THE
GUIDE BUSHING THIS CAN CAUSE THE GUIDE BUSHING TO HEAT
UP EXCESSIVELY
DURING CUTTING WHICH CAN
NOTE: THESE WORKPtECES MUST BE CUT FIRST
BECAUSE ANY JOINT FIT ADJUSTMENTS THAT MAY
BE REQUIRED CAN ONLY BE MADE WHEN CUTTING
THE PROJECT FRONT AND PROJECT BACK-THAT iS,
THE DRAWER FRONTAND THE PROJECT BACK ARE
FIT TO THE SIDES
CAUSE
DAMAGE
TO THE TEMPLATE
TO CORRECT
THIS SITUATION
OR PREVENT IT FROM OCCURRING,
REPOSITION
THE ROUTER B1T IN THE ROUTER
1 Assembfe the 1/2" guide bushing to the router baseplate, as described in a previous section This is the larger
of the two guide bushings furnished
2 Install Vermont American #22501
with this product
or Magna #Mg1114,
1t2" DIA GUIDE BUSHING -_._
-_\
to
the router as described in your Router Owners Manual
Shank engagement
should be a minimum of 3,/4"
I ,_CAUTION
IS ALIGNED
1 MAKE
WITH
SURE THAT THE ROUTER
OR CENTERED
OF
VERMONT AMERICAN #22501
OR MAGNA #M91114
STRAIGHT ROUTER BIT
BIT
IN THE HOLE iN THE
GUIDE BUSHING
TO DO THIS, LOOSEN SCREWS
HOLDING BASE PLATE OR ADAPTER
PLATE TO
ROUTER, CENTER GUIDE BUSHING HOLE WITH
RESPECT TO ROUTER BIT AND RETIGHTEN
SCREWS
SECURELY
39
/
E
3 Adjust
thedepth
ofcutThedepth
ofcutforanOPEN NOTE: BACK-UP BOARDS ARE USED TO MINIMIZE
DOVETAIL
JOINT
isequal
tothethickness
ofthemating SPLINTERING OF PROJECT PIECES AND TO KEEP
ROUTER BIT FROM DAMAGING
THE DOVETAIL JIG.,
partThatis:
FORCORNER
#1OFTHEPROJECT
RIGHT
SIDE
6 Lightly clamp the back-up board in place
andFORCORNER
#4OFTHEPROJECT
LEFTSIDE, 7 Position the project side against the front of the base so
THEDEPTH
OFCUTiSEQUALTO
THETHICKNESSthat the top surface abuts the right front stop block The
OFTHEPROJECT
FRONT
use of a front back-up board at this step is also recomFORCORNER
#2OFTHEPROJECT
RIGHT
StDE
mended
tt is positioned between the project side and the
andFORCORNER
#3OFTHEPROJECT
LEFTSIDE, clamping bar as shown in Figure 63 The front back-up
THEDEPTH
OFCUTISEQUAL
TOTHETHICKNESSboard should have the following approximate dimensions
OFTHEPROJECT
BACK
LENGTH: 6" to 8", sufficient length so that it can be
Usethedepth
gauge
onthebaseoftheDovelail
Jig,as
clamped by the front clamping bar and be used more
described
in a previous section, as a starting point
than once;
4 At this point it wil! be necessary
for you to make a top
WIDTH: 1" to 2" wider than the width of the sides;
THICKNESS:
I/4" to 1/2"
back-up board The reasons for the top back-up board are
to minimize splintering and to provide support for the
template
The top back_up board
having the following dimensions:
THE OUTSIDE OF THE PROJECT SIDE FACES AWAY
FROM THE FRONT OF THE BASE
is a scrap piece of wood
The words "OUTSIDE SURFACE"
marked in (d) in the
Section, GENERAL
PREPARATIONS,
should have been
LENGTH: 6" to 8", sufficient iength so that it can
clamped by the top clamping bar and be used more
than once;
visible
WIDTH: 2" wider than the width of the project sides;
THICKNESS:
1/8" to 1/4" thicker than the thickness of
the project sides; this to prevent
cutting into the dovetail base
This can also be accomplished
5 TO CUT CORNER
10 Securefy
base,
by using more than one
RIGHT
SIDE,
was put in place
clamp
the top back-up
board to the top of the
(THROUGH)
JOINTS to the Dovetai! Jig so that THE TEMPLATE BRACKETS
FIT BETWEEN THE WASHERS AND
board on top of the base so that it
THE TEMPLATE
lines up with the front of the base and abuts to the fight
top stop block as shown in Figure 63
FIGURE
board
so that the end of the project
line up as shown in Figure 63
tl Make sure that the parts remain lined up
12 Assemble the DOVETAILTEMPLATE
FOR OPEN
length, width and
#1 OF THE PROJECT
position the top back-up
the front back-up
9 Securely clamp the project side and the front back-up
board to the front of the base
"ACCIDENTALLY"
,clieee of scrap as long as the resultant
thickness are as described
before
8 Line up the workpieces
side and back-up boards
SUPPORTS
as shown
be necessary to Ioosen the c!amping
the base to do this
Figure 64; it wil!
knobs at the ends of
63
AUXILIARY TEMPLATE
\
TOP BACK-UP BOARD\,_
PROJECT
RIGHT SIDE OR
PROJECT LEFT
SIDE
z
FRONT OF THE BASE'
FRONT BACK-UP BOARD //
,
"OUTSIDE SURFACE' SHOULD BE VISIBLE ON THIS SURFACE
BEFORE POSITIONING THE FRONT BACK-UP BOARD
40
/
13Make
surethatthetemplate
is oriented
as shown in
Figure 65
THIS CAN CAUSE DAMAGE TO THE DOVETAIL
JIG;
OR LOSS OF CONTROL
OF THE ROUTER WHICH CAN
14 Make sure that the template is flush and paraIlel with
the workpieces
clamped to base For narrow project sides,
RESULT IN SERIOUS BODILY
WITH THE ROUTER TURNED
the use of an auxiliary
FROM THE ELECTRICAL
RECOMMENDED,,
support for the template
is recom-
mended
Its purpose is to aid in supporting the router while
cutting It can be made from a piece of scrap wood; but its
thickness must be the same as the top back-up board
(Refer to Figure 63)
!5 Clamp the template
knobs
in place by tightening
16 TURN THE
ROUTER
SURE
THAT
OR ANY
]
THE
OTHER
FIGURE
BEFORE
the clamping
BIT WILL
COMPONENT
MAKING
ANY CUTS MAKE
NOT
INTO THE
CUT
OF THE
DOVETAIL
64
OUTLET
IS STRONGLY
ON
17 Cut the dovetail by moving the router from LEFT TO
RIGHT, with the guide bushing following the template
DO
NOT FORCE ANYTHING;
MOVE THE ROUTER IN SLOW
AND SMOOTH FASHION
18 To ensure a smooth
I _,CAUTION
INJURY, A TRIAL RUN
OFF AND UNPLUGGED
and uniform
joint,
retrace
the pre-
vious cut by moving the router from RIGHT TO LEFT with
the guide bushing again fofiowing the template
BASE
JIG.,
DOVETAIL TEMPLATE FOR
OPEN (THROUGH) ,,JOINTS
TEMPLATE BRACKET
CLAMPING
KNOB
CLAMPING KNOB
FIGURE
65
TOP BACK-UP BOARD\\
"x
0
FRONT BACK-UP BOARD
DOVETAIL CUTS"
"_
41
PROJECT RIGHT SIDE OR
PROJECT LEFT SIDE
FIGURE
66
.TOP BACK-UP BOARD
TOPOFTHEBASE
/
N
t
/
'
{J/'_'_.
.....
,
-'
R_GHTS_DE_ VI ,_ii
"OUTSIDE SURFACE" SHOULD BE
"
J
NEVER
SERVE
BACK-UP
THE TEMPLATE.
22 TO CUT CORNER
THEIR
BOARDS
THIS
31 Continue
#3 OF THE
as Steps 27 through
SIDE, position
the top back-up
FIGURE
TOP BACK-UPBOARD_
FUNC-
.........
,_.
LEFT SIDE,
RIGHT
board on top of the base so
25 Lightty clamp the back-up board in place
26 Position the project side against the front of the base
so that the top surface abuts the left front stop block The
board at this step is also recom-
mended
It is positioned between the project side and the
clamping bar as shown in Figure 67 The front back-up
board is described in Step 6 on page 40
27
Continue
as in Steps
8 through
look like those
67
that it lines up with the front of the base and abuts the left
top stop block as shown above in Figure 66
use of a front back-up
32 above
sides should
position the top back-up board on lop of the base so that it
lines with the front of the base and abuts the fight top stop
block as shown in Figure 63
23 Continue as Steps 6 through 23
24. TO CUT CORNER #2 OF THE PROJECT
LEFT SIDE,
should
BE MADE
PROJECT
#4 OF THE PROJECT
32 At this stage the project
illustrated in Figure 6!
boards from the
INTENDED
MUST
/t U2,
position the top back_up board on top of the base so that it
lines up with the front of the base and abuts the ]eft top
stop block as shown is Figure 66
Dovetail Jig
2I The back-up boards can be reused if the cut portions
of boards are cut off AFTER BEING REUSED UNTIL
NO LONGER
/ i:P _
30 TO CUT CORNER
19 After the cut has been made, the workpieces
TION, NEW
/ PonT,As
NEEOED
THE FRONT BACK-UP BOARD
ROUTER
look like those illustrated in Figure 67
20 Remove the workpieee and back-up
/
AUXILIARY TEMPLATE SUP-
°
CAN CAUSE DAMAGE TO THE DOVETAIL JIG; OR
LOSS OF CONTROL
OF THE ROUTER WHICH CAN
RESULT IN SERIOUS BODILY INJURY.
THEY
/
i
LIFT THE
TO OR TOLICHING
V
O
UPWARDS WHEN THE ROUTER IS ON AND THE
ROUTER BIT ROTATING OR WHEN THE GUIDE BUSHING IS NEAR
/
J
//
VISIBLE ON THIS SURFACE BEFORE PosmONING
[,_CAUTION
/
D
19 above
28 After the cuts have been made, the workpieces
look like those illustrated in Figure 61
should
BACK_UP
BOARD
29 Remove the workpiece and the back-up boards from
the Dovetail Jig
NOTE: THE BACK-UP
BOARDS ARE REUSABLE.
42
.J
THE
FOLLOWING
DESCRIBES
BE FOLLOWED
AND BACK
FOR CU'i-FING
THE PROCEDURE
THE PROJECT
NOTE: Any joint fit adjustments
can only be made when cutting
TO
CAUSE
FRONT
TO THE TEMPLATE
TO CORRECT
3 Adjust the depth of cut The depth of cut for an OPEN
DOVETAIL JOINT is equal to the thickness of the mating
part That is:
that may be required
the project front and
back pieces,, That is, adjustments
are made to project
front and back pieces ONLY, not to the side pieces,
1 Assemble
as described
DAMAGE
THIS S_TUATION OR PREVENT }T FROM OCCURRING,
REPOSITION
THE ROUTER BIT IN THE ROUTER
FOR CORNER #t OF THE PROJECT FRONT, THE
DEPTH OF CUT IS EQUAL TO THE THICKNESS
OF
the 40" guide bushing to the router baseplate,
in a previous section This is the smaller of
THE PROJECT
RIGHT
StDE
FOR CORNER #4 OF THE PROJECT FRONT, THE
DEPTH OF CUT IS EQUAL TO THE THICKNESS
OF
the two guide bushings furnished with this product
2 Install Vermont American #22437 or Magna #M91016
THE PROJECT
straight router bit, to the router as described in your Router
Owners Manual Shank engagement
should be a minimum
of 3/4"
FOR CORNER #2 OF THE PROJECT BACK, THE
DEPTH OF CUT IS EQUAL TO THE THfCKNESS
OF
THE PROJECT RIGHT SIDE
LEFT SIDE
FOR CORNER #3 OF THE PROJECT BACK, THE
DEPTH OF CUT IS EQUAL TO THE THICKNESS
OF
THE PROJECT LEFT SIDE
Use the depth gauge
AMERICAN
#22437 OR
MAGNA #M9!016
STRAIGHT
ROUTER BIT
described
i
I
section,
as a starting
Jig, as
point
4 At this point it will be necessary for you to make a top
back-up board The reasons for the top back-up board are
to minimize splintering, provide support for the template
0
"-_
on the base of the Dovetail
in a previous
and prevent damage to the DovetaiI Jig The top beck-up
board is a scrap piece of wood having the following
dimensions:
tI,i'_
=._CAUTION
I MAKE
1
IS AUGNED
WITH
SURE THAT THE
OR CENTERED
ROUTER
tN THE
LENGTH: 6" to 8", sufficient length so that it can be
c_amped by the top clamping bar and be used more
than once;
BIT
HOLE IN THE
GUIDE BUSHING
TO DO THIS, LOOSEN SCREWS
HOLDING BASE PLATE OR ADAPTER PLATE TO
WIDTH: 2" wider than the width of the project front
(or back)
THICKNESS:
1/8" to 1/4" thicker than the thickness
ROUTER,
RESPECT
of the project front (or back); THIS IS TO PREVENT
ACCIDENTALLY
CUTTING INTO THE DOVETAIL JIG,,
CENTER GUIDE BUSHING HOLE WITH
TO ROUTER BIT AND RETIGHTEN
SCREWS
SECURELY
This can also be accomplished
I'_CAUTION
piece of scrap as long as the resultant
thickness are as described
1 WHEN
CUT, MAKE ABSOLUTELY
SETTING
THE DEPTH
SURE THAT THE
OF
5 TO CUT CORNER
COLLET
FIGURE
more than one
length, width, and
#1 OF THE PROJECT
position the top back-up
NUT DOES NOT CONTACT (TOUCH) THE GUIDE BUSHING THIS CAN CAUSE THE GUIDE BUSHING TO HEAT
UP EXCESSIVELY
DURING CUTTING WHICH CAN
by using
FRONT,
board on top of the base so that it
lines up with the front of the base and abuts the left top
stop block as shown in Figure 68
68
TOP BACK-UP BOARD
TOP OF THE BASE
/
/
/ j
AUXILIARY TEMPLATE
SUPPORT (AS NEEDED)
J
J
PROJECT
FRONT OR
PROJECT
'"_-"-.-
BACK
\
(
_T/"]_
',
_-_//-;..:
.
_
'_
FRONT OF THE BASE
_OUTSIDE SURFACE' SHOULD BE VISIBLE ON THIS SUR*
FACE BEFORE POSITIONING THE FRONT BACK-UP BOARD
43
FIGURE
69
.9
6
Ughtiy
clamp
the back-up
board
in place
7 Posilion the project front (or back) against the front of
the base so that the top surface abuts the left front stop
biock The use of a front back_up board at this step is also
board
should
have the following
NOT
THAT
16 TURN
approximate
THE
BIT WILL
THE
ROUTER
ANY
CUT
CUTS
MAKE
INTO THE
BASE
OF THE DOVETAIL
JIGo
TO THE DOVETAIL
JIG,
ON
17 Cut the dovetailby moving the routerfrom LEFT TO
RIGHT, with the guide bushing following the template DO
NOT FORCE ANYTHING;
MOVE THE ROUTER IN SLOW
AND SMOOTH FASHION
LENGTH: 6" to 8", sufficient length so that it can clamped
by the front clamping bar and be used more than once;
WIDTH: 1" to 2" wider than the width of the front (or
back);
THICKNESS:
1/4" to 1/2"
THE OUTSIDE OF THE PROJECT
FACES AWAY FROM THE FRONT
MAKING
SURE
OR ANY OTHER
COMPONENT
THIS CAN CAUSE
DAMAGE
recommended
it is positioned between the project front
(or back) and the clamping bar as shown in Figure 68 The
front back-up
dimensions:
iWI'_cAUTION I BEFORE
18 To ensure a smooth
vious cut by moving
and uniform
joint,
retrace
the guide bushing again following the tempIate
!9 MAKE SURE THATALL
OF THE MATERIAL
FRONT (OR BACK)
OF THE BASE
the pre-
the router from RIGHT TO LEFT with
IS CUT
The words "OUTSIDE SURFACE" marked in (d) in the
Section, GENERAL
PREPARATIONS,
should have been
AWAY; FREE ROUTING MAY BE REQUIRED
TO
ACCOMPLISH
THIS EXTRA CARE IS REQUIRED IN
CONTROLLING
THE ROUTER MOVEMENT
WHILE
visible
DOING
8
before
the front back-up
Line up the workpieces
board
was put in place
FREE ROUTING.
front (or back) and back-up boards line up as shown in
Figure 68
9 Securely clamp the project front(or back) and front back-
FIGURE
70
clamp
70)
TOP BACK-UP
_
BOARD
\
up board to the front of the base
10 Securely
base
(Refer to Figure
so that the end of the project
the top back-up
board to the top of the
11 Make sure that the parts remain lined up
12 Assemble the DOVETAIL TEMPLATE
FOR OPEN
(THROUGH)
JOINTS to the Dovetail ,Jig so that THE TEM*
PLATE BRACKETS
FIT BETWEEN THE WASHERS AND
THE TEMPLATE
SUPPORTS
as shown above in Figure
6g; it wil! be necessary to loosen the clamping
the ends of the base to do this
13
Make sure that the temptate
Figure
is oriented
knobs
at
as shown in
69
14. Make sure that the template is flush and parallel with
the workpieces
clamped to base For narrow project fronts
(or backs), the use of an auxiliary support for the template
is recommended
its purpose is to aid in supporting the
router while
cutting
it can be made from a piece of scrap
DOVETAIL
CUTS
wood; but its thickness must be the same as the top backup board (Refer to Figure 68)
15 Clamp
knobs
the template
in place by tightening
the clamping
44
\
DRAWER FRONT
OR DRAWER BACK
[_CAUTION
UPWARDS
j NEVER
WHEN
THE
LIFT THE
ROUTER
the base so that the top surface abuts the right front stop
block The use of a front back-up board at this step
is also recommended.,
tt is positioned between the
ROUTER
IS ON AND
THE
ROUTER
BIT ROTATING
OR WHEN
THE GUIDE BUSHING IS NEAR TO OR TOUCHING
THE TEMPLATE.
20 After the cut has been made, the project back and front
SERVE
TION, NEW BACK-UP
23 TO CUT CORNER
THEIR
iNTENDED
the Dovetail Jig
NOTE: THE BACK-UP
FUNC-
31 TO CUT CORNER
BOARDS MUST BE MADE
#3 OF THE PROJECT BACK,
posilion
the top back-up
Position
like those illustrated
FRONT,
FIGURE
BOARDS
should look
boards from
ARE REUSABLE,,
#2 OF THE PROJECT
BACK,
in Figure
soft eraser
after the parts have been glued together
71
TOP BACK-UP BOARD \
\
TOP OF THE BASE
\
\ '_
"_
\ \f"_
(AS NEEDED)
tt_
__.XV
_FRONT
OF
THE
BASE
/
,,,:,.%.
/_
-
,,
took
61
• Your project is now ready to be glued together
• Remove the penciI markings by light sanding or with a
the front of
AUXIUARY TEMPLATE SUPPORT\
in
in Step 7
34 Check how the workpieces fit together Some adjustments may be necessary
Refer to the section,
TROUBLESHOOTING
beard on top of the base so that it
the project front (or back) against
bar as shown
is described
32 Continue as Steps 28 through 32 above
33 The finished project front, back, and sides should
lines up with the front of the base and abuts the right top
stop block as shown in Figure 7t
26 Lightly clamp the back-up board in place
27
board
position the top back-up board on top of the base so that [t
lines up with the front of the base and abuts the right top
stop block as shown is Figure 7t
position the top back-up board on top of the base so that it
Iines with the front of the base and abuts the left top stop
block as shown in Figure 68
24 Continue as Steps 6 through 24
25 TO CUT CORNER #4 OF THE PROJECT
71 The front back-up
like these illustrated in Figure 61
30 Remove the workpiece and the back-up
22 The back-up boards can be reused if the cut portions
of beards are cut off AFTER BEING REUSED UNTIL
NO LONGER
front (or back) and the clamping
Figure
above
28 Continue as in Steps 8 through 20 above
29 After the cuts have made, the workpieces
should look like these illustrated in Figure 61
21 Remove the workpieee and back-up boards from the
Dovetail Jig
THEY
drawer
2%
,.....
/
........
'_
----t
/
t
'OUTSIDE SURFACE" SHOULD BE VISIBLE ON THIS SURFACE /
BEFORE POSITIONING THE FRONT BACK-UP BOARD
45
_
""_ PROJECT FRONT OR
PROJECT BACK
TROUBLESHOOTING
• If the joint
is too
made when cutting
loose:
either
FIGURE
This adjustment
can only be
72 -
JOINT
tS TOO SHALLOW
PRoJ
FRONT
the front or the back (tail pieces)
FRONT EXTENDS
PAST SIDE
Loosen the clamping knobs holding the template brackets
and move the template OUTWARD by turning the cam
handles
Continue adjusting until desired joint fit is
attained
Retighten
• If the joint
the clamping
is too tight:
>SIDE
EXTENDS
OUT PAST
FRONT
knobs
This adjustment
too can oniy be
made when cutting either the front or the back (tail pieces)
Loosen the clamping knobs holding the template brackets
LEFT SIDE
and move the template INWARD by turning the cam handles Continue adjusting until desired ioint fit is attained
Retighten
the clamping
PROJECTo_._
BACK
"_
knobs
SIDE
EXTENDS
• If the joint is too shallow:
Refer to Figure 72
INCREASE
the depth of cut of the router bit This adjustment can be made when cutling
pieces)
the front, the back,
BACK
(tail
OUT PAST
BACK EXTENDS
OUT PAST SIDE
and the sides (pin pieces)
• If the joint is too deep: Refer to Figure 73
DECREASE
the depth of cut of lhe router bit This adjustment too can be made when cutting the front, the back,
(tail pieces)
FIGURE
and the sides (pin pieces)
• If the joint is not uniformly
spaced from top surface
of drawer:
Refer to Figure 74 (See the Section "ALIGNMENT OF THE TEMPLATES"
) With the template
clamped Io the base, loosen the four screws securing
73 -
JOINT
IS TOO DEEP
SIDE EXTENDS
OUT PAST FRONT
FRONT
the
_
FRONT
EXTENDS
template to the template brackets, and move the template
slightly to the left Tighten the four screws and make a tdal
cut If moving the template to the left did not correct the
condition, but made it worse, loosen the screws and move
PROJECT
the template to the right a small amount
Make sure the
template remains parallel to the front of the dovetail base
Tighten
moving
% PAST
LEFT SIDE_.....
the four screws and make a thai cut Continue
the template to the right until the condition is
BACK
EXTENDS
OUT PAST
SIDE
completely
corrected
PROPER ALIGNMENT
OF THE
TEMPLATES
TO THE TEMPLATE
BRACKETS IS CRITICAL FOR JOINT
UNIFORMITY
ONCE THIS
IS ACCOM-
PUSHED CORRECTLY,
IT SHOULD NOT NEED
ADJUSTMENTS
AGAIN MAKE SURE TO SECURELY
TIGHTEN THE FOUR SCREWS AFTER THE TEMPLATES HAVE BEEN CORRECTLY
SHOULD REQUIRE NO FURTHER
THEY ARE HANDLED
WITH
SIDE EXTENDS
OUT PAST BACK
REALIGNED,
THEY
ADJUSTMENTS
IF
FIGURE
74 -
JOINT
SPACING
IS NOT EQUAL
CARE
FRONT ---__
j/SPACING
{TAIL PIECE) _
,_
SIDE
(PIN PIECE) _
BACK
,
(TAIL PIECE) .,.\
GREATERAcK
THAN
/
//
7/
/ /
THAN FRONT
SPACiNa
LESS
46
PARTS
LIST
KEY
FOR VERMONT AMERICAN INDUSTRIAL DOVETAIL JIG
PART No,
DEscRIPTION
! QT¥
KEY
i- 1
24
29L-489-13
#!O*32XS/8"lg
Panhoad
Machine
Screw
1
25
29L-469-14
#10-32 X 3/8" Ig. Panhead
Machine
Screw
8
Dove|a! ! Templat e (Open .!o)n!)
26
29Lo469q5
#8=36 X 3/16" Ig. Panhead Machine
Scre w
10
29LD-882
Temp__Je SuEEport (Right Side)
27
29LD-841-2
!1-10_32X 5/8" Ig Flat Head Mac_
Scr%w
2
2gLD-B83
Tern_
28
2gLD-841-3
#!O"32 X 7/8" !g_ Fiat Head Machine
Screw
2
29L._D_:.841..:4
_;10-32 X 3/8" Ig. Flat Head Machine
Screw
3
1
29LD-87g-I
Detuxe Dovetail
Base
2
29LD_880q
Dove| aiLTem_lat e LB.rmd J_n!) ............
3
29LD-881-1
4
5
Support
(Le|t Side)
PART NO.
MODEL NO,,23461
DESCR|PTtON
QTY
6
29LD°884q
Cam Handle
i
2
7
29LD-885-1
Front Stop Block
i
2
30
29L-684o6
8
29LD-886-1
.To_£p
i
2
. 31
29L-684-7
9
29LD-887
Ciamj_.g
4
32
29A-310-15
5/!_!8
X '4:!/2"
10
29LD-888-1
Retainer
1
33
29A-310,16
5/16-18
X 3-1/2" !g:. RD HD SQ Neck Bolt
11
29LD-889-1
Bol_ Support
4
34
29A-310-17
5!16-18 X 2" _q. RD HD SQ Neck Bolt
12
29LD_890-1
Clamping
6
35
29A-242-t2
#t0-32
2
36
29A-242-13
5/16-18 t-.lex Machine
1
37
2gA_306-20
t3/64"
!3
14
29LD_891
.
29LD-892
Block
Bar End Cap_
Knob
C!#rnping Bar
.
PivoIShalt
.
= 4
29 _
15
29LD-895
Template Bracket
16
29LD_896
Template Sti|_ener
2
38
29A-306-40
17
29LD-899
Guide Bushing Assembly
1
39
t8
2gLD-900
__1
40
19
29LD-98t
2O
45A-414
Product
21
45A-416
Label {Temj?late-Blind)
22
45A-417
23
45A-415
Guide Bushin_
__n
(.4" Din,)
Assembl_"
Sprin 9
Label (Clamping
Din,)
4 _ 41
______.__ ,...__
Bar }
_plate43_)
Warning Label(C!amp!ng
.....
Bar)
29.42.43.
44. and 45 a!ong with four o! Key No
i&.Panhead
, #'i_16X!"!g
Hex Machine
3
Screw
Screw
2
2
_.2.
Nul
4
Nut
2
[D X 15132" OD X 3/64"
Thick Washer
13
11/32" ID X 7/8" OD X 1/t6" Thick Washer
8
29LD-930
II/32'
4
29LD-969
5/16" ID X 7t8" OD Thick Nylon Washer
ID X 7/8" OD Thin Nylon Washer
29LCN-1Q08
S_r}ng Retainer
29A_368"!
#8 Countersunk
43
29A-368-2
#t 0 Countersunk
1 __ 44
45
1
2gGD-375
Router Adapter PIale
VA #25500
1/2" VA Dovetail
45LCN-72
ins,'ruction Manual
loose and unassembied
4
4
42
47
!
]g_ RD HD SQ Neck Bolt
1
37 are furnished
.Taj)p}ng, Sct'ew
PanheadTa£pingscrew
1
:_
Key No's
#10.16X1/2"
._4_
Bushing
4__
Bushing
4
1
Router Bit
1
I
1
BASE ASSEMBLY
o
TEMPLATE SUPPORT ASSEMBLY
48
CLAMPING ASSEMBLY
i
ROUTER
ADAPTER
/
PLATE
49
TEMPLATES
........ o,,
o
/
,/
/
FASTENERS
@@@
@®
®@@
@
/
@@@
\
@@@
Q
50
51
To obtain a copy of this Manual in French, call
the following toll4ree number 1-800-742_3869
To obtain a copy of this Manual in Spanish, calt
the following toll-free number 1-800-742-3869
When corresponding, always give the following
information as shown in the list
1
2
3
4
Printed in U_SoAo
08/99
Manual No. 45LCN-72
i i
i
i
The
The
The
The
PART NUMBER
PART DESCRIPTION
MODEL NUMBER: 23461
ITEM NAME - INDUSTRIAL DOVETAIL JIG
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