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iNDUSTRiALDOVETAILJIG IMPORTANT : . The fo ! lowing router bits are required for use with this jig - 17125455 • VA # 22437 , or MAGNA # M 910t6 , 1 / 4 " Straight Router Bit , and VA # 22501 , or MAGNA # M91114 , 9t16 " Dovetail Router Bit which are used for THROUGH or OPEN JOINTS . • VA # 22500 , or MAGNA # M91113 , 1t2 " Dovetail Router Bit , which is used for all HALF BLIND JOINTS . WARNING : Beforeoperating product , readthis manualand follow all its Safetyand OperatingInstructions .
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General Safety Instructions for Power Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Additional Safety Instructions for Industrial Dovetail Jig . . . . . . . . . . . . . . . . . . . . . . 4 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Unpacking and Checking Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assembly of the Right 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 the Cam Handles and Pivot Shaft to the Dovetail Base . . . . . . . . . . . . . . . . 10 Assembly of Assembly of the Front Stop Blocks to the Dovetail Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Assembly of the Top Stop Blocks to the Dovetail Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Assembly of the Clamping Knobs to the Dovetail Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Assembly of the Templates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Alignment of the Templates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Assembly of the Adapter Plate to the Router . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Assembly of the Guide Bushing to the Router . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Operation Styles of Dovetail Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Half Blind Flush Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Half Blind Flush Offset Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Half Blind Rabbeted Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Open or Through Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Adjusting the Depth - of - Cut of the Router Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Clamping the Workpieces to the Dovetail 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 Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Making Projects with Open ( Through ) Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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SAFETY GUIDELINES - DEFINITIONS This manual contains informa - I CAUTION ] IADANGER I tion that is important for you to URGENTSAFETYINFORMATION - A INFORMATIONFORPREVENTING know and understand . This HAZARDTHATWILLCAUSESERF DAMAGETOEQUIPMENT information relates to protect - OtISINJURYORLOSSOFLIFE ing YOUR SAFETY and PREVENTING EQUIPMENT PROBLEMS . To help you rec - I , AWARNINGI [ NoTE ] ognize this information , we use IMPORTANTSAFETYINFORMA - INFORMATIONTHATYOUSHOULD the symbols to the righL TION _ AHAZARDTHATMIGHT PAYSPECIALAITENTIONTO Please read the manual and CAUSESERIOUSINJURYORLOSS pay attention to these sections . OFLIFE [ ' _ WARNINGI Failure to heed all safety and operating instructions and warnings regarding use of this product can result in serious bodily injury 1 . Know your power tool 8 . Make workshop child - proof Read the owner's manual carefuify Learn its Use padlocks , master switches , or remove starter keys 9 . Do not force tools application and limitations as welt as the specific potential hazards peculiar to this tool Do not force tool or attachment to do a job it was 2 . Ground all tools ( unless double insulated ) not designed to perform 10 . Use the right tool If tool is equipped with an approved three - conductor cord and a three - prong grounding type plug , it should be They wifl do the job better and safer at the rate plugged into a three hole electrical receptacle If adapter is for which they were designed used to accommodate a two - hole receptacle , the adapter 11 . Wear correct apparel wire must be attached Do not wear loose clothing , gloves , neckties or to a known ground ( usually the screw securing jewelry ( rings , wristwatches ) that may get caught receptacle cover plate ) Never remove third prong in moving parts Nomstip footwear is recommended Wear Never connect green ground wire to a terminal protective hair covering to contain long hair Roll long sleeves above the elbow 3 . Keep guards in place Maintain in working order , and in proper adjustment and 12 . Use safety goggles ( Head Protection ) alignment Wear safety goggles ( must comply with ANSI Standard 4 . Remove adjusting keys and wrenches Z87 1 ) at all times A _ so , use face or Form a habit of checking to see that keys and adjusting dust mask , if cutting operation is dusty , and ear wrenches are removed from tool before turning it ON protectors ( plugs or muffs ) during extended periods of 5 , Keep work area clean operation Cluttered areas and benches invite accidents 13 , Secure work Use clamps or a vise to hold work when practical it's safer Ftoor must not be slippery due to wax or sawdust 6 . Avoid dangerous environment than using your hands , and both hands are free to operate tool Do not use power tools in damp or wet locations 14 . Do not overreach or expose them to rain Keep work area well lighted Keep proper footing and balance at all times Provide adequate surrounding work space 15 . Maintain tools with care 7 . Keep children away All visitors should be kept a safe distance from work Keep tools sharp and clean for best and safest area performance Follow instructions for lubricating and changing accessories
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16 . Disconnect tools before servicing 21 . Direction of feed : Feed work into a blade or Cutter AGAINST the Before servicing , when changing accessories such as blades , bits , cutters , etc direction of rotation of the blade or cutter only 17 . Avoid accidental starting 22 . Never leave tool running unattended Make sure swilch is in OFF position before plugging in Turn power OFF DO NOT leave tool until it comes 18 . Use recommended accessories to a comptele stop Consult the owner's manual for recommended accessories 23 . Keep hands away from cutting area 24 . Store idle tools and follow the instructions The use of improper accessories may cause hazards When not in use , tools should be stored in dry , 19 , Never stand on tool high or locked - up place - out of reach of children 25 . Do not abuse cord Serious injury could occur if the tool is tipped or ff the cut _ ring _ oot is accidentally contacted DO NOT store materi - Keep cord away from heat , oil and sharp edges 26 . Outdoor extension cords als above or near the tool making it necessary to stand on the toot to reach them When tool is used outdoors , use only extension cords suitable for use outdoors and so marked 20 . Check damaged parts Before further use of the Iool , any guard or other 27 . Never use in an explosive atmosphere part that is damaged should be carefully checked to Normal sparking of the motor could ignite fumes , ensure that it will operate properly and perform its flammable liquids , or combustible items intended function Check for alignment of moving 28 . Drugs , alcohol , medication parts , binding of moving parts , breakage of parts , DO NOT operate tool while under the influence mounting , and any other conditions that may affect of drugs , alcohol , or any medication its operation A guard or any other part that is Read and Understand this instruction book damaged should be properly repaired or replaced completely BEFORE using this product 1 Always wear eye protection that complies with workbench by no more than 1 / 4 " to provide clear - ANSI Standard Z87 1 ance when clamping workpieces to the Dovetail Jig 2 Noise levels vary widely To avoid possible hearing 10 Do not use the Dovetail Jig as a work surface damage , wear ear plugs or muffs when using the Doing so may cause damage to the Dovetail Jig , Dovetail Jig for hours at a time which can cause it to be unsafe to use A workbench 3 For dusty operations , wear a dust mask along should be used for this purpose with safety goggles 11 This product is designed to cut fiat workpieces 4 Do not use this Dovetail Jig with router bits or Do not cut or attempt to cut workpieces that are guide bushings other than those specified for the not flat or that are irregularly shaped . cuts being made 12 This product is to be used for cutting wood work - 5 Follow the instructions in your Router Owner's pieces only Do not use this product to cut metal Manual or any other non - wood material . 6 Vibrations caused by the router during use can 13 This product has been designed to cut work - cause fasteners to become loose Before use and pieces having thicknesses of 3 / 8 " to 1 " Do not use periodically during use , check all fasteners to make Ior workpieces of any other thicknesses sure that they are all are tight and secure 14 Do not clamp any workpieces to the Dovetail Jig 7 Do net use this product until all assembly installa - or make any adjustments to the Dovetail Jig unless tion steps have been completed , and you have read the router has been turned off , the router bit is not and understand all safeb / and operational instruc - turning , and the Router has been disconnected from tions in this manual , and the Router Owners Manual the electrical outlet 8 Make sure that the router bit is properly positioned 15 When setting " the - depth - of - cut " of the router in the router so that it does not contact the guide bit , make sure that the workpiece is clamped to the bushing or the template when cutting Dovetail Jig in such a manner that the router bit 9 The Dovetail Jig must be securely mounted to a workbench or other stable surface when in use The does not cut into the Dovetail base causing dam - age to it or possible serious injury to you . front of the base should overhang the front of the
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17 NEVER LIFT THE ROUTER UPWARDS WHEN 16 L ' _ WARNING _ ALWAYS UNPLUG THE THE ROUTER IS " ON " , THE ROUTER BtT IS ROUTER FROM THE ELECTRICAL OUTLET ROTATING , AND THE GUIDE BUSHING IS NEAR BEFORE INSTALLING OR REMOVING ROUTER OR TOUCHING THE TEMPLATE , BECAUSE THIS WILL CAUSE THE ROUTER BIT TO CUT INTO BITS FROM THE ROUTER AND WHEN ADJUST - THE TEMPLATE AND DAMAGE IT ING THE CUTTING DEPTH OF THE ROUTER BIT ; OR WHEN INSTALLING OR CHANGING GUIDE BUSHINGS . • Your Vermont American Industrial Dovetail Jig is an • The Dovetail Jig Base has six pockets molded into accessory that is used with Routers allowing you to its front which are gauges to aid you setting the make drawers , chests , and similar items requiring " depth - of - cut " for commonly used depths : 3 / 8 " , I / 2 " , 5 / 8 " , 3 / 4 " , 7 / 8 " , and 1 " dovetail joints The joints are used to make the front , back , and sides of the workpiece • Vermont American router bits , # 22501 and # 22437 , • Your Industrial Dovetail Jig comes with two tem - or Magna router bits , # M91113 and # M91016 , plates and two guide bushings for making halt - blind WHICH MUST BE PURCHASED SEPARATELY , are and through or open joints required for making the THROUGH or OPEN joints • Your Industrial Dovetail Jig also comes with a • Vermont American router bit , # 22500 , or universal router adapter plate that will permit the Magna router bit , # M91114 , WHICH MUST BE Industrial Dovetail Jig to be used with most popular PURCHASED SEPARATELY , is required for making routers the HALF - BLIND ioints • The Dovetail Jig will allow you to make 1 " spaced • Your Vermont American Industrial Dovetail Jig flush , flush - offset , and 3 / 8 " rabbeted half - blind comes with two templates and two guide bushings dovetail joints Each of the templates has a label , describing the • The Dovetail Jig will also allow you to make t " joint that can be cut with it , along with set - up spaced open , or through , dovetail joints information , the router bit and the guide bushing • Workpieces up to 16 " wide can be accommodated required , and the the stop block setting for a oWorkpieces with thicknesses between 3f8 " and 1 " particular joint can be accommodated Refer to Parts List on Page 47 • tn order to simplify handling and to minimize any . iA , , , anpyaratsrme , sso , crnagnnot damage that may occur during shipping , your be accounted for , do not attempt to assemble , instaIl , Industrial Dovetail Jig is packaged assembled or use the Industrial Dovetail Jig until the missing • Separate all loose parts from the packing materials parts have been obtained and the product has been and check each one with the illustrations and list of assembled correctly parts at the end of this manual to make sure that • Contact customer service at 1 - 800 - 742 - 3869 , ext 8359 all loose parts are present before discarding any for missing or replacement parts packaging material
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ALTHOUGYHOURINDUSTRIADLOVETAJILIG PROCEED TO THE SECTION ALIGNMENT OF THE TEMPLATES AND THEN CONTINUE WITH COMESASSEMBLETDH , EFOLLOWINAGSSEM - BLY INSTRUCTIONS ARE BEING INCLUDED FOR THE SECTIONS FOLLOWING ALIGNMENT OF REFERENCE PURPOSES SHOULD IT BECOME THE TEMPLATES NECESSARY FOR YOU TO DISASSEMBLE AND THE TEMPLATES MUST BE ALIGNED BEFORE REASSEMBLE THE DOVETAIL JIG ANY ROUTING tS TO TAKE PLACE TOOLS REQUIRED neck botts into the slot in the right side of the base ( NOTE : The right side of the base is identified by the - A medium sized Phillips screwdSver words RIGHT SIDE molded into it ) ° A smafl or medium adjustable wrench 3 Place a 11 / 32 " t D , x 7 / 8 " OD washer onto the bolt as ASSEMBLY OF THE RIGHT SIDE TEMPLATE shown in Figure 1 SUPPORT TO THE DOVETAIL BASE 4 Thread a 5 / 16 - 18 hex nut onto the bolt , as shown , until it bottoms out against the washer 1 Ptace the dovetail base topside down on a fiat surface 5 Back off the nut from the washer between 1 / 4 and 1 / 2 2 insert one of the 5 / 16 - 18 x 2 " long round head square 10 _ 32X 5 / 8 " LONG PANHEAD FIGURE 1 MACHINE SCREW HEXES MUST LINE UP 5t16 - 18 X 2 " LONG ROUND HEAD SQUARE NECK BOLT t3 / 64 " I D X 9 / t6 " O D WASHER " " # 10 _ 32 HEX NUT " " BACK OF DoVETAiL BASE
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! UrpSAlignthenutsothatthecomerosfthenu _ areverti - lhe base as shown to hold the template support in place calfyline _ UJpasshownNotethealignmeonftthehex Securely tighten thenut and screw : : • pockeintlhetemplasteupporTthebolst houlbdefreeto 8 The template support should move freely front to back movesidetosidei ; fitdoesnot , loosetnhenut1 / 3turnor along the side of the base If it does not , it means that the untitlhecorneorsfthenutpoinut panddown 5 / 16 - 18 hex nut is too tight on the bolt and should be loos - 6 Assembthleerighttemplasteuppotrottherighstideof ened To do this , remove the fasteners assembled in step the dovetail base so that the hex nut lines up and lits into 7 , and remove the template support ; repeat steps 4 the hex pocket in the right template support ( NOTE : The through 7 right template support has the words RIGHT SIDE molded ASSEMBLE THE LEFT SIDE TEMPLATE SUPPORT TO into it for identification ) THE DOVETAIL BASE THE SAME AS THE RIGHT SIDE 7 Assemble a # t0 - 32 x 5 / 8 " long panhead machine screw , TEMPLATE SUPPORT WAS ASSEMBLED . a 13 / 64 " I D x 9 / 16 " O D washer , and a # 10 - 32 hex nut to ASSEMBLY OF THE TOP CLAMPING BAR TO FIGURE 2 THE DOVETAIL BASE 1 Assemble 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 hole in the bolt support The bolt support is to " bottom - out " against the bolt as shown in Figure 3 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 FIGURE 3A FIGURE 3B the back of the base rests on the surface [ NOTE ] ALTHOUGH BOTH ENDS OF THE ( _ NYLON DOVETAIL BASE ARE SHOWN ASSEMBLED IN THE SPRING FOLLOWING FIGURES , THE ACTUAL ASSEMBLY IS DONE ONE END AT A TIMEo SPRING TO RETAINER BOTTOM 5 From the bottom of the base , insert a bolt with bolt sup - COMPRESSION / ' J _ f OUT port through the slot in the top of the base so the raised AGAINST portion of the bolt support goes into the slot , as shown in SURFACE SPRING Figure 4 FIGURE 4 SLOT IN BOLT AN D BOLT SLOT IN DOVETAIL SUPPORT DOVETAIL BASE DOVETAIL BASE BASE k q X / / \ BOLT 11 / / / FRONT OF DOVETAIL BASE
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6 Placaen11 / 32I " D X7 / 8 " OD washearndthena FIGUR5E 5 / 16I " D X7 / 8 " OD thicknylonwasheorvetrheboltIt j INOTCHB willbenecessatoryholdtheboilinplacewhenperforming IN R thisandthefollowinsgteps HELPFUHLINTSP : ositiotnhebolat ndthebolst upport undetrhenotchintheribasshowinnFigur5e , tohelp . _ - - - - SLOT IN holdtheboltinplace 7 Placaesprinogvetrhebolta , sshowinnFigur6e DOVETAIL BASE 8 Placae5 / 16I " D X7 / 8 " QD thicknylonwashearnd thenan ! 1 / 32I " D X7 / 8 " OD washeorvetrheboial nd presdsownonthesprinugntijlusttheendofthebolt BOLT AND sticksoutpasttheendofthewasher BOLT g Slidetheclampinbgarovetrhebolsl othatthewashers SUPPORT aresandwichbeedtweethnesprinagndtheinsidoefthe clampinbgarasshowinnFigur6e NOTET : HESPRING MUSTPUSHAGAINSTTHETHICKNYLOWNASHERS ANDNOTAGAINSTTHESTEEWL ASHERS t0 Placaen11 / 32t " D X7 / 8 " OD thinnylown ashearnd the bar in one way only It may be necessary to " tap " them an11 / 32I " D X7 / 8 " OD washeorvetrhebellItwilibe in by gently hitting them with a rubber mallet or a piece of necessaforyryoutopresdsownontheclampinbgarwhile wood - - since they fit very tlgh | ty into the clamping bar USE CARE WHEN DOING THIS SO AS NOT TO DAM - doingthis 11Takeoneoftheclampinkgnobasndthreaidtontothe AGE THE END CAPS boial sshownDONOTTHREAtDheknobcompletely USE CARE THAT THE CAPS ARE PROPERLY ALIGNED ontothebolt - - jusetnougshotheknobhoidstheclampingAS SHOWN WHEN ASSEMBLING THEM TO THE BAR , , barinplace 14 . Tighten the clamping knobs onto the bolts so that the t2 Repeaatbovseteps4throug1h0fortheotheerndof space between the bottom of the clamping bar should be theclampinbgar parallel to the top of the base 13Assembthleeendcapstotheendsoftheclampinbgar 15 After completing the above steps your Dovetail Jig bypressinthgemin ; theyaredesignetodbe " force - fiint " to should look like the illustration in Figure 7 FIGURE 6 Assemble clamping bar , knobs , end caps on both ends as shown CLAMPING KNOB , 11 / 32 " I . D . ' , \ X 7 / 8 " O D WASHER \ CLAMPING BAR DETAIL " ! t / 32 " I . D X 7 / 8 " O D . NYLON SPRING SPRING AND RETAINER CLAMPING BAR NYLON SPRING ( RETAINER ABUTS THE RETAINER FIT • CLAMPING BAR 11 / 32 " I , D X 7 / 8 " CLAMPING BAR f _ END CAP ] NSlDE THE OPEN SIDE OF L _ . ! ) OPEN SIDE OF O D WASHER _ _ THE CLAMPING _ - _ \ / THE CLAMPING BAR POINTS TOWARD BAR " _ THE TOP SURFACE ( SEE CLAMPING OF THE DOVETAIL BAR DETAIL ) i BASE WASHER . - - [ _ , COMPRESSION SPRING € / 1t132 " I . D . 3 t12 " _ , / X 7 / 8 " O D / THICK j / * END CUT AWAY AND SECTIONED - _ NYLON BOLT / / l SO NYLON SPRING ARETAINERB CLAMP , NG S . OWNW , THI SUPPORT PLACEMENT CAN BE SEEN ) _ _ . _ WASHER COMPRESSION SPRING / / Z - RIGHT TEMPLATE TOP SURFACE OF SUPPORT THE DOVETAIL
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FIGUR7E CLAMPIBNAGRPARALTLOEL TOPOFBASE SPACING TO BE / / APPROXIMATELY t - 112 " 0 0 0 ASSEMBLY OF THE FRONT CLAMPING BAR TO THE DOVETAIL BASE t Assemble the front clamping bar ! o the front of the dove - Figure 8 The 5 / 16 - 18 X 4 - 1 / 2 " long round head square neck bolts are used tail base following the same procedure used Io assemble the top clamping bar to the dovetail base as shown in FIGURE 8 COMPRESSION CLAMPING BAR ( SHOWN WITH END CUT AWAY AND SECTIONED SO NYLON SPRING RETAINER PLACE r SPRING " _ _ MENT CAN BE , . SEEN ) " \ , \ . 1 / 2 " BOLT DOVETAIL ! 1 / 32 ' I . D . X 7 / 8 ' O . D . BOLT SUPPORT j7 THICK NYLON WASHER COMPRESSION SPRING \ \ \ • CLAMPING BAR NYLON END CAP SPRING CLAMPING BAR f RETAINER ( RETAINER 11132 " I , D X 7 / 8 " 0 D . NYLON SPRING / ' t " ABUTS THE THIN NYLON WASHER RETAINER CLAMPING tt / 32 " I D X 7 / 8 " O D BAR ) CLAMPING KNOB
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ASSEMBLOYFTHECAMHANDLEASNDPIVOT SHAFTTOTHEDOVETAIBLASE • After the cam handles and pivot shaft have been assem _ 1 Assemble one of the cam handles to the pivot shaft bled to the base , it wil ! be possible to accurately position using a # 10 - 32 x 5 / 8 " tong panhead machine screw and a the templates for close fitting joints 13 / 64 " I D x 9 / 16 " ID washer as shown in Figure 9 • Note that there are some graduations on both template 2 Use care so that the pivot shaft fits into the hex - shaped supports hole in the cam handle The pivot shaft may fit tightly into • Rotating the cam handle so that the pointer lines up with the cam handle ; this is normal one of the graduations permits accurate front - to - back posi - 3 Make sure that the pivot shaft bottoms - out inside the cam handie tioning of the template • Cam handles are designed to provide infinite template 4 Securely tighten the screw NOTE : THE NEXT TWO STEPS ARE PRE - ASSEMBLY adjustment STEPS . • One graduation equals 1 / 64 " of movement of the tem - 5 Slide the retainer over the end of the pivot shaft for plate • Rotating the cam handle so that the lever moves toward about 2 " The retainer may fit tightly ; this is normal the front of the base , causes the template to also move 6 Thread the # 10 - 16 x 1 / 2 " long panhead tapping screw towards the lront of the base into the hole in the retainer until it bottoms - out against the • Conversely rotating the cam handle so that the lever pivot shaft ( The screw will fit tightly in the hole ) See moves toward the back of the base , causes the template Figure 10 to also move Iowards the back of the base also FIGURE 9 / CAM HANDLE / _ PIVOT SHAFT 13 / 64 " 1D X 9 / 16 _ ' O D WASHER _ \ \ J j < - - LT - , : # 10 _ 32 . X5 / 8 " LONG / PANHEAD MACHINE SCREW FIGURE 10 # 10 - 16 X 1 / 2 " LONG PANHEAD TAPPING SCREW _ RETAINER / x \ _ _ PIVOT SHAFT 10
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THE RETAINER RELATIVE TO THE CAM HANDLE WITH 7 LoosetnhescrewabouotneturnRemovtheeretainer SCREW MUST BE AS SHOWN fromtheshafatndsetitasidetemporarily NOTE : THE RETAINER MAY FIT TIGHTLY ON THE 8 Assernbthleepivosthafwt ithcamhandlteothebaseby insertinthgeendofthepivosthaftthrougthheholesinthe PIVOT SHAFT ; THIS IS NORMAL , , righttemplasteuppoartndthebase 11 Continue pushing the pivot shaft through the holes and 9 MAKESURETHEORIENTATOIOF NTHE CAM HAN - the retainer until the end of the pivot shaft extends out of DLE IS AS SHOWN IN FIGURE 11 the teft template support as show in Figure 12 12 Make sure the end of the cam handle fits into the hole 10 Place the retainer at the location shown in Figure 12 in the base as shown and push the pivot shaft through THE ORIENTATION OF FIGURE 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 . . . / . . L . . J . . J . . . . . 11
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of the cam handle fits into the hole in the base 13Withthecamhandlpeusheidnagainstht ebase , positiotnheretaineargainsth ! esidewalol fthebasea , s 16 Tighten the screw securely showinnFigur1e3Theretainesrhoulbdareltyouchthe 17 Rotate one of the cam handles - It should rotate freely sidewallofthebaseThepurposoeftheretaineisrto and move the template supports prevenotrminimiztheeside - to - siodfethecamhandlaend 18 If this does not happen , loosen the screw on the retain - pivosthaft er and move the retainer away from the side wall slightly 14Assembthleeothecramhandlteotheotheerndofthe 19 Securely retighten the screw pivosthafutsinga13 / 641 " Dx 9 / 16O " D washearnd a # 10 - 3X25 / 8 " longpanheamdachinsecrewa , sshowinn 20 If there is too much side - to - side movement ( play ) of Figure14 the cam handles ; loosen the screw in the retainer and move the retainer closer to the side wall of the base 15Makesurethatthecamhandlleinesupwiththecam 21 Securely retighten the screw handlaettheotheer ndofthepivosthafatndthattheend FIGURE 13 _ L OF BASE FIGURE 14 LEFT TEMPLATE SUPPORT j PIVOT SHAFT / J / / / # t0 _ 32 X 5 / 8 " LONG \ \ X 9 / 16 " O D WASHER \ " CAM HANDLE 12
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ASSEMBLY OF THE FRONT STOP BLOCKS TO THE DOVETAIL BASE 1 Assemble the front stop blocks to the front of the dove - the front of the base The stop block will fit into the slot in tail base , at each end , using # 10 - 32 x 5 / 8 " long flathead one position only machine screws , 13 / 64 " I D x 9 / 16 " O D washers , and 3 Tighten the screw securely onto the nut # ! 0 - 32 hex nuts , as shown in Figure 15 4 Assemble the other front stop block to opposite end of the dovetail base in the same manner 2 Make sure that the open rib portion fits into the slot in FIGURE 15 FOR REASONS OF CLARITY , THE FRONT , , oH3NE2xUT CLAMPING BAR , KNOBS , BOLTS AND SPRINGS ARE NOT SHOWN DOVETAIL BASE / L % ; f PLATE RIGHT _ TEMPLATE . . / . , . . _ \ ' _ 7 _ T _ / / FRONT STOP BLOCK SUPPORT _ _ _ _ _ / _ \ _ " _ " # 10 - 32 X 5 / 8 " LONG \ \ FLATHEAD MACHINE SCREW FRONT OF DOVETAIL BASE OD WASHER V / i , ' _ & . # t0 - , 32 X 5 / 8 " LONG FLATHEAD FRONT STOP BLOCK / MACHINE SCREW t3
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ASSEMBLY OF THE TOP STOP BLOCKS TO THE DOVETAIL BASE • The top stop blocks are assembled to the top of the screw , as shown in Figure t6 The screw threads into the hole in the bottom of the slot dovetail base in one of two ways depending upon which 3 Make sure that the " A " faces the " middte of the base " style of dovetail joint is to be cut : a HALF - BLIND FLUSH JOINTS - - The " A " on the stop 4 Make sure the open rib portion of the stop block fits into block faces toward the " middle of the base " the slot in the top surface of the base b HALF - BLIND RABBET JOiNTS - - The " B " on the 5 Assemble the remaining top stop block to the opposite end of the base in the same manner stop block faces toward the " middle of the base " c THROUGH JOINTS - - - The " A " on the stop block 6 Again make sure that the " A " faces the " middle of the faces toward the " middle of the base " base " , Since the flush joint is the more commonly used joint , the 7 Tighten both screws securely following instructions apply to the assembly of the stop 8 To reposition the stop blocks for rabbet joints , simpty blocks for this style joint loosen the screws just enough so that the dbs on the stop 1 Position the dovetait Jig right side up on a flat surface blocks come out of the slot The stop block is then rotated 2 Assemble one of the top stop blocks to the top surface 180 ° to the attemate position , so the " B " faces the middle of the base using a # 10 - 32 x 7 / 8 " long flathead machine of the base , and securefy retighten the screws FIGURE 16 RIB ON STOP BLOCK , # 10 - 32 X 7 / 8 " LONG FLAT HEAD \ # 10 - 32 X 7 / 8 " LONG FLAT MACHINE SCREW \ \ MACHINE SCREW \ TOP STOP BLOCK 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 / ! 6 - 3 Thread the clamping knobs onto the bolts so that the 18 bolts at both ends of the dovetail base as shown in spacing between the washer and the template supports is Figure 17 . approximately 1 / 2 " 2 Assemble the clamping knobs onto the bolts as shown 4 Set the dovetail base aside for the time being and con - tinue on with the next section FIGURE 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 / / KNOB CLAMPING / \ KNOB 1 / 2 " SPACING BETWEEN WASHER AND TEMPLATE SUPPORT ( BOTH ENDS ) 14
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ASSEMBLY OF THE TEMPLATES 3 MAKE SURE THAT THE TEMPLATE BRACKETS ARE • Ptace the template stiffener into the rectangular slot in the ASSEMBLED TO THE UNDERNEATH SIDE OF THE underneath side of the template , as shown in Figure 16 NOTE : THE TEMPLATE FOR cUTTING HALF - BLIND TEMPLATE , AS SHOWN IN FIGURE lg , AND THAT THE JOINTS 1S BEING USED AS AN ILLUSTRATION IN THE ALIGNMENT OF THE BRACKETS iS ALSO AS SHOWN FOLLOWING FIGURES . IN THE FIGURE 4 . , IT IS NOT NECESSARY FOR THE SCREWS TO BE 1 Thread a # 8 - 36 x 3 / 16 " long panhead machine screw TIGHTENED AT THIS STAGE ; THE TEMPLATE BRACK - through each of the five holes in the template and into the ETS SHOULD BE FREE TO MOVE WITH RESPECT TO threaded holes in the template support , as shown in THE TEMPLATE OR ELSE IT WILL NOT BE POSSIBLE Figure 18 and securely tighten all of the screws NOTE : ON SOME EARLY VERSIONS OF TH1S PROD - TO ALIGN THE TEMPLATE AS DESCRIBED iN THE NEXT SECTION UCT , A SLOTTED BINDING HEAD MACHINE SCREW HAS BEEN SUBSTITUTED FOR THE PANHEAD SCREW 5 The assembled template should took like the illustration SPECIFIED FOR ASSEMBLING THE TEMPLATE SUP - in Figure 20 PORTS TO THE TEMPLATES ( SEE THE SCREW ILLUS - 6 Assemble the template stiffener and the template brack - ets to the TEMPLATE FOR CUTTING THROUGH JOINTS TRATION IN FIGURE 18 ) 2 Assemble the template brackets to the template using using the same method described in the preceding steps 1 four # 10 - 32 x 3 / 8 " long panhead machine screws , as through 5 Refer to Figure 20 shown in Figure t9 FIGURE 18 ! _ ' _ TEMPLATE STIFFENERSLOT RECTANGULAR \ \ \ TEMPLATE _ - - - # 8 - 36 X 3 / t6 " LONG \ \ \ \ PANHEAD MACHINE SCREW SLOTTED BINDING HEAD MACHINE SCREW TEMPLATE \ ' \ \ \ / TEMPLATE BRACKET " _ - - , o FIGURE 20 15
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ALIGNMENOTFTHETEMPLATES • In order for the Dovetail Jig to function properly , it is For initia ! setup , Allow the legs of the template bracket to " bottom out " in the slots in the template supports as necessary ' for the templates to be aligned with respect to dovetail base The reason for this , is that dovetail cuts are shown in Figure 21 • TO REMOVE THE TEMPLATE FROM THE DOVETAIL at both ends of the Dovetail Jig When properly aligned , JIG , LOOSEN THE CLAMPING KNOBS SO THAT SPAC - the result being all mating comers wi } l always be lined up ING BETWEEN THE TEMPLATE BRACKET AND THE • NOTE : THE TEMPLATE FOR CUTTING HALF - BLIND JOINTS IS BEING USED AS AN ILLUSTRATION IN THE WASHER IS ABOUT 1 / 2 " ; GENTLY LIFTTHE TEMPLATE UPWARD FROM THE DOVETAIL BASE SO THAT THE FOLLOWING FIGURES ° TEMPLATE BRACKET CLEARS THE SLOTS IN THE t = With the dovetail base stiB having the 1 / 2 " spacing TEMPLATE SUPPORT AND STORE IN A CONVENIENT between the washer and the template supports ( Refer to LOCATION Figure 17 ) , assemble the template assembly to the dove - tail base so that : 2 Lightly tighten the clamping knobs at both ends of the a ) the slot in the template bracket fits over the bo _ t base so that the template brackets are he ] d in place b ) the leg of the template bracket is between the washer against the template supports as shown in Figure 21 and the template support , and 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 supports , as shown in Figure 21 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 Figure 23 or Figure 24 Move template front - to - back so DOVETAIL JIG IT IS MOST IMPORTANT THAT LEG that front edge of template is parallel with the front of the OF THE TEMPLATE BRACKET ALWAYS BE dovetail base In each condition the template and the tem - BETWEEN THE WASHER AND THE TEMPLATE SUP - plate brackets MUST be symmetrical with each other The PORT OR ELSE THE TEMPLATE WILL NOT BE figures do not show the complete Dovetail Jig , but only the PROPERLY POSITIONED FOR CUTTING ACCURATE underneath side of the tempJate with template brackets DOVETAILS , correctly positioned , in order that the correct positions of FIGURE 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
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FIGUR2E2 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 _ _ _ _ _ _ _ _ - - - _ TEMPLATE rLr AT BOTH ENDS 0 olio - TEMPLATE BRACKET CONDITION THREE : TEMPLATE EVEN WITH TEMPLATE BRACKETS 17
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ADJUSTMENTS MAY BE REQUIRED HOW TO MAKE 4 Aftetrhetemplabterackehtsavebeencorrectplyosi - THESE ADJUSTMENTS IS EXPLAINED IN TWO OF THE tioneodnthetemplasteecuretliyghtetnhefourscrews FOLLOWING SECTIONS : " TROUBLESHOOTING FOR holdintghe template brackets to the template HALF BLIND JOINTS " or " TROUBLESHOOTING FOR 5 Remove the template assembly from the base and set it aside for now OPEN ( THROUGH ) JOINTS " 6 Align the other template assembly in the same manner 7 Remove the template assembly from the base and IT SHOULD BE NOTED THAT YOU MAY FIND , THAT set it aside for now ( Figure 25 below , is an example of AFTER MAKING SOME SAMPLE CUTS , SLIGHT INCORRECTLY positioned template brackets ) FIGURE 25 TEMPLATE BRACKET , \ TEMPLATE , \ , , \ THE TEMPLATE EXTENDS BEYOND THE TEMPLATE BRACKET EXTENDS BRACKET 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 THE SAME AT EACH END ASSEMBLY OF THE ADAPTER PLATE TO THE ROUTER 2 Remove the router base plate now on the router , by [ A ¢ kWARNING ] removing the screws holding the base plate to time router ALWAYS MAKE SURE THATTHE ROUTER IS q * URNED 3 Depending on the make of router , either three or four of OFF " AND THATTHE ELECTRICAL CORD HAS BEEN the loIIowing screw types and sizes will have been used : UNPLUGGED FROM THE ELECTRICAL OUTLET a ) # 8 ( 164 dia ) Pan Head Screw BEFORE ASSEMBLING THE ADAPTER PLATE AND A b ) # t0 ( I90 din ) Pan Head Screw c ) # 8 ( 164 din ) Flat Countersunk Head Screw GUIDE BUSHING TO THE ROUTER ; OR WHEN MAKING d ) # 10 ( t90 dia ) Flat Countersunk Head Screw ANY ADJUSTMENTS , OR CHANGING ROUTER BITS IN THE ROUTER 4 Compare the screws removed with those shown in Figure 26 1 Remove any router bit currently installed in the router FIGURE 26 SCREW " b " _ \ SCREW ' : a _ _ ' , SCREW ' c " SCREW " d " I I i i I I I I t I I 1 J I I I I 1 t I I I I 1 I I I I I t 1 I I I t I I I i 1 I I i t i * i i 18
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5 If the screws look like Screw " a " or Screw " b " , use either 7 If the screws look like Screw " c " , use either three or four three or four of the 13 / 64 " ID x 15 / 32 " OD washers when of the bushings with an 11 / 64 " din hofe when installing installing the adapter plate to the router as shown in the adapter plate to the router as shown in Figure 29 Figure 27 8 If the screws look like Screw " d " , use either three or four 6 Your Dovetail Jig comes with four countersunk bushings of the bushings with a 13 / 64 " dia hole when installing the with an 11 / 64 " hole and four countersunk bushings with a adapter plate to the router as shown above in Figure 29 13 / 64 " hole Refer to Figure 28 FIGURE 27 FIGURE 28 , PAN HEAD SCREW i / WASHER 0 11 / 32 4 SCREW / / PAN HEAD SCREW ( _ jWASHER 4 - - O t1 / 64 PAN HEAD SCREW O 25 / 64 F O 13 / 64 FIGURE 29 d _ # 8 FLAT HEAD SCREW ' _ BUSHING WITH Otl / 64 HOLE HEAD " - _ , \ _ j # 8 FLAT HEAD SCREW SCREW \ , ' 0 _ / BUSHING WITH BUSHING - - . - . WITH Oll / 64 \ _ / Oll / 64 HOLE HOLE PLATE SCREW BUSHING Oll / 64 HOLE 19
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Thefigurebselowshowtheviewsoftheadapteprlateasit toward the front of the router ) wouldappeawrheninstalleodnaroutewriththerouter 11 Line - up the center of the hole in the adapter plate with the collet hole in the router This will ensure accurate cuts turnedovewr iththeroutebrasefacingupward Threeofthemospt opulamrountinhgoleconfiguralions I2 Using the screws removed in Step 2 above , in combi _ areshown nation with either the washers or countersunk bushings , Figur3e0showtshemountinagrrangemuesnitngthree assemble the adapter plate Io the router if the bushing are screws used the heads of the screws must be flush with , or slight - Figur3e1showtshemountinagrrangemuesnitngfour ly below the top of the bushing THE TOPS OF THE SCREWS MUST NOT PROTRUDE screwwshenthescrewasreat45degreetosthesideof the front of the router ABOVE THE TOP SURFACE OF THE ADAPTER PLATE Figure 32 shows the mounting arrangement using four If for some reason the countersunk head screws being screws when the screws are in line with the front of the used are too short , too long , or protrude above the top of router the adapter plate , obtain pan head screws that are 1 / 4 " or In most cases , the adapter plate will fit your router 3 / 8 " long with the proper thread from a hardware store or However , in those cases where the router is extremely DYI outlet Use these with the washers , instead of the smatl or extremely large , rated at 1 - 3 / 4 HP or larger , the bushings , to assemble the adapter plate to the router t3 TIGHTEN ALL SCREWS SECURELY adapter plate cannot be used 14 Check to see that center of the router co ] Iet hole still g Set the router upside down on a workbench or other flat stable surface lines - up with the large center ho _ e in the adapter plate 10 Position the adapter plate on the router so that the 15 If it does not loosen the screws and reposition the threaded holes in the router base line - up with slots ( or adapter plate so the hole Iines - up with the router collet hole 16 TIGHTEN ALL SCREWS SECURELY holes ) in the adapter plate The recessed arrow in the adapter plate should point FIGURE 30 FIGURE 32 © © © © / FIGURE 31 © ° @ © 2O
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ASSEMBLY OF THE GUIDE BUSHING TO THE ROUTER 1 Place the router upside down on a flat surface For cer - 4 Position the guide bushing so that the three threaded tain touters it may be necessary to support the router for it holes in the guide bushing line - up with the countersunk to remain in this position holes in the adapter plate 2 Place the proper guide bushing required for the type of 5 Thread a # 10 - 32 x 3 / 8 " long flathead machine screw into each of the holes dovetail to be cut under the router adapter plate as shown in Figure 33 6 SECURELY TIGHTEN THE SCREWS Refer to Figure 3 MAKE SURE THAT THE ORIENTATION OF THE 34 GUIDE BUSHING IS AS SHOWN FIGURE 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
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2 Remove the template assembly from the dovetail base if [ J _ " ] " m _ WARNING ' THE DOVETAIL JiG MUST ALWAYS there is one there currently BE FIRMLY AND SECURELY MOUNTED TO A SOLID 3 Ddll three 1 / 8 " diameter holes , 3 / 4 " deep into the mount - ing board as shown in illustration AND FIRM WORK SURFACE , SUCH AS A WORK - 4 Position the Dovetail Jig on the top of the mounting BENCH , BEFORE USE FAILURE TO DO SO COULD CAUSE THE DOVETAIL JIG TO TIP OVER OR SLIDE board so the holes in the base line up with the drilled holes in the mounting board ALONG THE WORK SURFACE , RESULTING IN PROP - ERTY DAMAGE AND SERIOUS PERSONAL INJURY 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 MOUNTING THE DOVETAIL JIG TO A WORK SURFACE x 1 " long panhead self tapping screws as shown in Figure 35 OR WORKBENCH USING CLAMPS g Applying a small amount of soap to the screw threads will make it easier to thread the screws into the holes USING THIS MOUNTING METHOD ALLOWS YOU TO MOUNT THE DOVETAIL JIG SO THAT IT CAN BE EASF 10 Line up the front of the mounting board with the front of a workbench or other sturdy surface LY INSTALLED , FOR USE , AND REMOVED , FOR STOR _ 11 Using two clamps , such as C - clamps , firmly clamp the AGE , WITHOUT PERMANENTLY TAKING UP SPACE ON Dovetail , Jig to the workbench by clamping on the mount - YOUR WORKBENCH ing board as shown in Figure 36 and Figure 36A 1 Make a solid wood mounting board , 32 " long x 6 - 1 / 4 " 12 Make sure that the mounting board lines up with the wide x 3 / 4 " thick front of the workbench FIGURE 35 _ / / / / / / 2 TO THE FRONT OF THE , _ " _ ' _ , _ 1 / 8 " DIAMETER DRILL DOVETAIL BASE _ i / / TO THE FRONT OF THE . . . . . DOVETAIL BASE 22
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FIGURE 36 CLAMP HERE FRONT SURFACE OF THE MOUNT - CLAMP HERE ING BOARD 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
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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 Joint NOTE : THE NORMAL DEPTH OF CUT FOR A HALF BLIND FLUSH JOINT IS 318 " , • 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 / DRAWER FRONT ( PiN PIECE ) / F DRAWER SIDE ( TAIL PIECE ) " _ - DRAWER SiDE ( TAIL PIECE ) TAILS \ DRAWER BACK ( PIN PIECE ) / 24
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See Figure 38 Half Btin d Flush Offset Joint * To obtain the offset , cut a 1 / 16 " deep by 3 / 8 " wide rabbet oThe Half Blind'Flush Offset JOint is used when _ on the opposite ends on the inside of the drawer front The height of both the drawer front and the drawer back is the same height as the drawer sides ; the length of the NOTE : THE NORMAL DEPTH OF CUT FOR A HALF drawer front is 1 / 8 " longer ( 1 / 16 " on a side ) than the width BLIND FLUSH OFFSET JOINT IS 3t8 " . of the drawer ; and the length of the drawer back is the same as the width of the drawer FIGURE 38 DRAWER FRONT ( PIN PIECE ) 1 / ! 6 " OFFSET . . . DRAWER SIDE ( TALLPIECE ) - _ RSIDE ( TAIL PIECE ) / DRAWER BACK ( PIN PIECE ) J Haft Blind Rabbeted Joint is the same as the widlh of the drawer ; and the height of • The Half Blind Rabbeted Joint is used when : the drawer back is the same as the height of the drawer See Figure 39 The drawer fronl overlaps the opening for the drawer on el ! • To obtain this joint , cut a 3 / 8 " deep by 3 / 8 " wide rabbet four sides of the of the drawer opening ( top , bottom , and around the inside periphery of the drawer ' _ ront 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 NOTE : THE NORMAL DEPTH OF CUT FOR A HALF height of the drawer front is atso 3 / 4 " higher ( 3 / 8 " on side ) BLIND RABBETED JOINT ! S 318 ' L . than the height of the drawer ; the length of the drawer back FIGURE 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
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NOTE : THE DEPTH OF CUT IS DETERMINED BY THE Open or Through Joint THICKNESSES OF THE FRONT , BACK AND SIDE • The Open or Through Joint is similar to the Half Blind PIECE & Joint except that joint seams are visible on the front , back , • The front and back pieces ( sometimes called " tail and sides of the workpiece ; on the Half Blind Joints , the pieces " ) are cut independentIy from the side pieces ( some - seams are visible only on the sides of the workpiece times called " pin pieces " ) • Although this style of joint can be also used for drawers , - The " pin pieces " are cut first using one edge of the tem - its most popular use is for making boxes , and small and plate and a dovetail router bit The depth of cut is equal to large chests the thickness of the " tail pieces " • The height of both the front and the back of the drawer • The " tail pieces " are cut next using the other edge of the or chest is the same height as the sides of the drawer or template and a straight router bit The depth of cut is equal chest ; and the length of both the front and the back of the to the thickness of the " pin pieces " Adjustments are made drawer or chest is the same as the width of the drawer or at this point to oblain joint fit chest See Figure 40 FIGURE 40 ADJUSTING THE DEPTH - OF - CUT OF THE I _ CAUTION i MAKE SURE THAT THE ROUTER ROUTER BIT r _ _ , t BIT ISALIGNED WITH OR CENTERED INTHE HOLE IN [ , _ . _ , WARNINGJ ALWAYS MAKE SURETHATTHE THE GUIDE BUSHING . TO DO THIS , LOOSEN SCREWS HOLDING BASE OR ADAPTER PLATE TO ROUTER , ROUTER tS " TURNED OFF " AND THAT THE ELECTRI - CENTER GUIDE BUSHING HOLE WITH RESPECT TO CAL CORDHASBEENUNPLUGGFERDOMTHE ROUTER BIT AND RETtGHTEN SCREWS SECURELY _ ELECTRICAL OUTLET BEFORE ASSEMBLING OR REMOVING ROUTER BITS TO THE ROUTER , ROUTER BIT , , BASEPLATE • You will note that there are six pockets along the front surface of the dovetail base , and that they are identified by GUIDE a dimensions such as 3 / 8 , lt2 , - up to 1 These pockets are BUSHING used to set the depth - of - cut of a router bit To use proceed as follows : - DO NOT USE WITH A TEMPLATE ASSEMBLED TO THE BASE o DO NOT INSTALL ROUTER BITS TO THE ROUTER UNLESS THE CORRECT GUIDE BUSHING HAS BEEN ASSEMBLED TO THE BASEPLATE FIRST 1 Install the desired 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 NUT SECURELY 3 Position the router over the pocket with the required FIGURE 41 depth - of - cut 26
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4 Gradually move the router bit outward , by using the lI , _ t _ . _ , CAUTION Ii WHEN SETTING THE DEPTH OF depth - of - cut feature on the router , until the tip of the router bit touches the bottom of the pocket , as shown in CUT , MAKE ABSOLUTELY SURE THAT THE COLLET Figure 42 and Figure 42A NUT DOES NOT CONTACT ( TOUCH ) THE GUIDE BUSH - 5 Lock the router in position ING 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 \ POCKET FIGURE 42A ROUTER ' " POCKET ROUTER BIT / FIGURE 43 TEMPLATE ti I 1 ' - - j OEPOTC . UT 27
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CLAMPING THE WORKPIECES TO THE ing bolts and springs are free to be moved atong the slots in the base DOVETAIL BASE • CAUTION : WHEN CLAMPING , MAKE SURE THAT THE - The clamping bars have been specially designed to allow CLAMPING KNOBS ARE NOT POSITIONED SO CLOSE lhe clamping forces to be applied next to the workpieces TO THE WORKPIECES THAT THE WASHERS BECOME for more efficient clamping This is accomplished by ' being TRAPPED UNDER THE WORKPIECES able to position the clamping knobs in close proximity or , , FOR ACCURATE JOINTS , THE WORKPIECES MUST next to the workpieces " BUTT - UP " AGAINST BOTH THE TOP AND THE FRONT • Figure 44 illustrates the positioning of the ctamping bars STOP BLOCKS TO ENSURE THE EXACT POSITIONING and the clamping knobs when the workpieces are clamped OF THE WORKPIECES to the LEFT SiDE of the Dovetail Jig • TO ENSURE ACCURATE JOINTS AND SAFE OPERA - • Figure 45 illustrates the positioning of the clamping bars TION , WOOD SHAVINGS AND ACCUMULATED DUST and the clamping knobs when the workpieces are clamped MUST BE REMOVED FROM THE DOVETAIL JIG to the RIGHT SIDE of the Dovetail Jig BEFORE EACH SETUP , EITHER BY USING A BRUSH - Note the closeness of the clamping knobs to the work - OR BY VACUUMING pieces When not in use etamping knobs and the support - FIGURE 44 INSIDE SURFACE OF DRAWER FRONT ( OR BACK ) FACES UP _ . . _ . _ . _ , - - - - _ WORKPIECE CLAMPED TO / / THE TOP OF THE BASE TOP STOP BLOCK , _ . . _ . _ y LEAR ( OF HOE . VK , P , ECES , Ns , SoUEBFOA ° FROAEWS'EDRE WORKCP . AIEMCTPEOEO FAOESO0 T , - , EFRONTOFT . EBASE FIGURE 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
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MAKING DRAWERS WITH HALF BLIND shows the workpieces unassembled ( or an exploded view FLUSH JOINTS of the drawer ) • In addition , the figure shows where the four comers of • The thickness of both the front and back ( pin pieces ) the drawer are cut on the Dovetail Jig must be at least 1 / 2 " The thickness of the sides ( tail CORNERS 1 AND 3 are cut on the LEFT SIDE of the pieces ) must be at least 3 / 8 _ Dovetail Jig A partial tail will be cut for side ( tai ! piece ) thicknesses up CORNERS 2AND 4 are cut on the RIGHT SIDE of the to 9 / 16 " This is norma _ and will not affect the joint or its Dovetail Jig appearance • TdaJ cuts are strongly recommended using scrap wood to o Figure 46 shows a drawer and the workpieces that make ensure that the final workpieces are of the desired quality it up This figure is similar to Figure 38 , except that it FIGURE 46 CORNER # 1 ( CUT AT THE LEFT SIDE OF ( CUT AT THE RIGHT SIDE OF THE DOVETAIL , JIG ) THE DOVETAIL , JIG ) SURFACE LINES UP WITH DRAWER FRONT - \ FRONT STOP BLOCKS / 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 ( CUT AT THE LEFT SIDE OF THE DOVETAIL JIG ) TIDE DOVETAIL , JIG ) 29
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GENERAPLREPARATIONS positioning the workpieces on the Dovetail Jig , prior to cut - ting the dovetails a Theworkpiecceosmprisitnhgedrawetrh , at is , front , e Assemble the 40 " guide bushing to the router base - back , ] eft side , and right side should be cut to the proper plate , as described in a previous section This the smaller length , width , and thickness ( es ) of the two guide bushings furnished with this product b Make sure that all surfaces are smooth and square with f l nslall Vermont American # 22500 or Magna # Mg 1113 each of the other surfaces dovetail router bit , to the router as described in your c Line up the workpieces on a flat surface , standing on Router Owner's Manual Shank engagement should be a edge , as shown in Figure 47 minimum of 3 / 4 " 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 47 MARK " DRAWER FRONT TOP SURFAC E . MARK ' W " MARK " 1 " _ _ . . _ . . _ ' - I ' " _ / _ MARK " DRAWER \ _ _ RIGHTSIDE TOP \ . \ " , , \ \ " ' " MARK INSIDE SURFACE " / MARK " DRAWER RIGHT / SIDE _ NSIDE SURFACE " r ; ; . MARK / MARt { " DRAWER BACK ' " DRAWER ; . , , , - " , ' LEFT SIDE , I TOP SURFACE " MARK \ MARK " DRAWER " , LEFT SIDE " , INSIDE SURFACE " ' . \ ( SHOWN HIDDEN ) \ \ MARK " DRAWER BACK INSIDE SURFACE " ( SHOWN HIDDEN ) IAII , CAUT ! ONI MAKE SURE THATTHE ROUTER BiT IS ALIGNED WITH OR CENTERED IN THE HOLE tN THE 40 " DIA GUIDE BUSHfNG , _ , , GUIDE BUSHING TO DO THIS , LOOSEN SCREWS HOLDING BASE PLATE OR ADAPTER PLATE TO \ ROUTER , CENTER GUIDE BUSHING HOLE WtTH RESPECT TO ROUTER BIT AND RETIGHTEN SCREWS VERMONT \ SECURELY AMERICAN # 22500 \ MAGNA # M911 ! 3 E ] CAUTION / WHENSETTIN7GHEDEPTHOF OR DOVETAIL CUT , MAKE ABSOLUTELY SURE THAT THE COLLET ROUTER BIT NUT DOES NOT CONTACT ( TOUCH ) THE GUIDE BUSH - ING 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
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gAdjustthedepthofcutto3 / 8 " usingthedepthgaugeon h Positiobnothofthetopstopblockssothatthe " A " faces the " middolefthebasea " sshowinnFigur4e8 ' thebaseoftheDovetaJiilg , asdescribeindaprevious esectionttinigsapproximaatnedsomeadjustmemnat i Positiotnhecamhandlseothatthepointeprointtsothe Thiss ybe centegrraduatiaosnshowinnFigur4e8 required FIGUR4E8 LEFTTOPSTOBPLOCK ' A " FACETSOWARMDIDDLE OFBASE . " A " FACES TOWARD MIDDLE _ OBF _ _ _ ASE _ / RIGHT TOP STOP BLOCK / - . . . . . . . 7 _ - - - - - - - - - - - - _ - \ \ V , _ 1A _ / I / / _ / POINTER POINTS ' It _ . / TO CENTER _ _ _ ! ' [ Vi " _ ' , " " , ' _ ii ] ii _ , , / _ _ RIGHT FRONT STOP BLOCK " \ LEFT FRONT STOP BLOCK \ _ " ' _ THE FOLLOWING DESCRIBES THE PROCEDURE TO base so that the top surface abuts the left front stop block BE FOLLOWED FOR CUTTING CORNERS 1 AND 3 THE INSIDE OF THE DRAWER S _ DE FACES AWAY FROM THE FRONT OF THE BASE 1 FOR CORNER # 1 , position the drawer front on the top The words " INSIDE SURFACE " marked in ( d ) in the of the base so that it lines up with the front of the base and Section , GENERAL PREPARATIONS , should be visible . the top surface abuts the left top stop block THE INSIDE OF THE DRAWER FRONT FACES AWAY FROM THE 4 Line up the workpieces so that the end of the drawer TOP OF THE BASE The words " INSIDE SURFACE " side lines up with the drawer front as shown in Figure 49 5 Securely clamp the drawer side to the base marked in ( d ) in the Section , GENERAL PREPARATIONS , should be visible 6 Securely clamp the drawer front to the base 7 Make sure that the parts remain lined up 2 Ughtly clamp the drawer front in place 3 Position the drawer RIGHT side against the front of the FIGURE 49 DRAWER FRONT ' tNSfDE SURFACE " SHOULD BE VISIBLE ON THIS SURFACE THE END OF THE DRAWER SIDE MUST BE LEVEL AND \ - . _ % AUXILIARY TEMPLATE FLUSH WITH THE INSIDE " _ , . SURFACE OF THE DRAW _ % . , TOP OFTHE BASE / ' SUPPORT ( AS NEEDED ) ER FRONT ( OR BACK ) \ " FRONT OF THE BASE DRAWER RIGHT SIDE " INSIDE SURFACE " SHOULD BE NOTE : WORKPIECES WILL BE POSITIONED ON THE JIG AS VISIBLE ONTHIS SURFACE 31
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FIGUR5EO / DOVETAIL TEMPLATE / " FOR HALF BLIND JOINT / / / WASHER ( 8 Assembfe the DOVETAIL TEMPLATE FOR HALF BLIND t6 _ ' _ ' ) L ] , , M , WARNINNGE , VER LIFT THE ROUTER JOINTS to the Dovetait Jig so that THE TEMPLATE BRACKETS FiT BETWEEN THE WASHERS AND THE UPWARDS WHEN THE ROUTER IS ON AND THE TEMPLATE SUPPORTS as shown Figure 50 ROUTER BIT ROTATING OR WHEN THE GU | DE BUSH - NOTE : MAKE SURE THE TEMPLATE CLAMPING ING IS NEAR TO OR TOUCHING THE TEMPLATE ° THIS KNOBS ARE LOOSE TO MAKE TEMPLATE ADJUST - CAN CAUSE DAMAGE TO THE DOVETAIL JIG ; OR MENT , AFTER ADJUSTMENT IS MADE , RETtGHTEN LOSS OF CONTROL OF THE ROUTER WHICH CAN TEMPLATE CLAMPING KNOBS . RESULT IN SERIOUS BODILY INJURY , , 9 Make sure that the short fingers on the template , as 17 After the cut has been made , the workpieces should shown in Figure 50 , faces toward the front of the base look like those illustrated in Figure 51 10 Make sure that the template is flush and parallel with the workpieces clamped to base Far narrow drawer fronts , the use of an auxiliary support for the template is recom - FIGURE 51 mended Its purpose is to aid in supporting the router while cutting It can be made from a piece of scrap wood ; but its DRAWER thickness must be the same as the drawer front ( Refer to Figure 49 ) 11 Clamp the temptate in place by tightening the clamping knobs 12 I ' _ WARNINGI BEFORE MAKING ANY CUTS MAKE SURE THAT THE BIT WILL NOT CUT INTO THE BASE OR ANY OTHER COMPONENT OF THE DOVE - TAIL JIG , , THIS CAN CAUSE DAMAGE TO THE DOVE - TAIL 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 / DOVETAIL CUTS 15 To ensure a smooth and uniform joint , retrace the pre - DRAWER / vious cut by moving the router from RIGHT TO LEFT with RIGHT SIDE the guide bushing again fo _ $ owing the template 32
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THE INSIDE OF THE DRAWER SIDE FACES UP The 18 Remove the workpieces from the Dovetail , Jig and check how the workpieces fit together Some adjustments words " INSIDE SURFACE " marked in ( d ) in the Section , may be required GENERAL PREPARATIONS , should be visible Refer to the section TROUBLESHOOTING on page 37 22 Line up the workpieces so that the end of the drawer 19 FOR CORNER # 3 , position the drawer back on the top 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 23 Continue as in Steps 5 through 16 above 24 After the cut has been made , the workpieces should the top edge surface abuts the left top stop block THE INSIDE OF THE DRAWER BACK FACES UP The words took like those illustraied in Figure 53 " INSIDE SURFACE " marked in ( d ) in the Section , GENER - 25 Remove the workpieces from the Dovetail Jig and AL PREPARATIONS , should be visible See Figure 52 check how the workpieces fit together Some adjustments 20 Lightly clamp the drawer back in place may be required 21 Position the drawer LEFT side against the front of the Refer to the section TROUBLESHOOTING on page 37 base so that the top surface abuts the left front stop block FIGURE 52 I _ , ' _ INSSIDUERFACE " SHOULD BE VISIBLE ON THIS SURFACE / TOP OF THE BASE / AUXILIARY TEMPLATE SUPPORT / / _ ( AS NEEDED ) / / . . . . . . . . . • DF _ A " AER LEFT SiDE / _ _ " " " INSIDE SURFACE " SHOULD BE VISIBLE ON THIS SURFACE FIGURE 53 DRAWER BACK \ DRAWER LEFT SIDE DOVETAIL 33
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THEFOLLOWINDGESCRIBTEHSEPROCEDUTROE • After the cut has been made , the workpieces should fook BEFOLLOWEFDORCUTTINCGORNER2SAND4 Iike those illustrated in Figure 53 • The finished front , back , and sides should look iike those CORNER2SAND4arecutinthesamewayas1and3 in Figure 46 except they are positioned on the right side of the Dovetail • Before gluing the front , back , and sides together , Jig as shown Figure 54 some provision must be made for installing the bot - tom , such as dadoing or cutting a groove around the . [ , _ CAUTION I BEFORE MAKING ANY CUTS inside of the drawer parts ° MAKE SURE THAT THE BIT WILL NOT CUT INTO THE • Your drawer is now ready to be glued together BASE OR ANY OTHER COMPONENT OF THE DOVE - TAIL JIG , , THIS CAN CAUSE DAMAGE TO THE DOVE - TAIL JIG , , • I " _ cAUTION t NEVER LIFT THE ROUTER UPWARDS WHEN THE ROUTER IS ON AND THE ROUTER BIT ROTATING OR WHEN THE GUIDE BUSH - ING IS NEAR TO OR TOUCHING THE TEMPLATE ° THIS CAN CAUSE DAMAGE TO THE DOVETAIL JIG . FIGURE 54 ' INSIDE SURFACE " SHOULD BE TOP OF THE BASE \ \ VISIBLE ON THIS SURFACE DRAWER BACK AUXINLEIAERDYE ( ADs ) 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
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MAKING DRAWERS WITH HALF BLIND FLUSH RGURE 55 OFFSET JOINTS " A " FACES \ BACK OF GENERAL PREPARATIONS MIDDLE OF BASE \ \ THE BASE a The iength of the drawer front is 1 / 8 " Ionger than the \ length of the drawer back \ b When cutting comers 1 and 4 ; the cam handle is rotated two graduations 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 ADJUST - MENT , AFTER ADJUSTMENT IS MADE , RE'TIGHTEN TEMPLATE CLAMPING KNOBS , c When cutting corners 2 and 3 ; the cam handle is posi - tioned vertically , as shown in Figure 48 d All other GENERAL PREPARATIONS are the same as those used for " MAKING DRAWERS WITH HALF BLfND FLUSH JOtNTS " POINTER POINT5 TO THE SECOND GRADUATION THE PROCEDURE FOR CUTTING THESE JOINTS IS TOWARD THE BACK OF THE BASE THE SAME AS THAT USED FOR " MAKING DRAWERS FROM THE CENTER GRADUATION WITH HALF BLIND FLUSH JOINTS " as dadoing or cutting a groove around the inside of the • After aI1 dovetail cuts have been made , cut a 1 / 16 " deep by 3 / 8 " deep rabbet on opposite ends of the drawer front drawer parts • The finished front , beck , and sides should look like those o Your drawer is now ready to be glued together in Figure 38 • Remove the pencil markings by light sanding or with a • Before gluing the front , back , and sides together , some soft eraser after the drawer parts have been glued together provision must be made for installing the bottom , such 35
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THE PROCEDURE FOR CUTTING CORNERS 1 AND 4 MAKING DRAWERS WITH HALF BLIND IS THE SAME AS THAT USED FOR " MAKING DRAW - RABBETED JOINTS ERS WITH HALF BLIND FLUSH JOINTS " EXCEPT GENERAL PREPARATIONS ° Position BOTH top stop blocks so that the " B " faces the a The length of the drawer front is 3 / 4 " longer than the middle of the base as shown in Figure 56 tength of the drawer back ° Use the side of the tempiate that has the longest fingers b The height of the drawer front is 314 " higher than the • Position the template and workpieces as shown in height of the drawer back and drawer sides Figure 57 Cut the dovetail as described in the section , • IT tS EXTREMELY iMPORTANT THAT THE TEMPLATE MAKING DRAWERS WITH HALF BLIND FLUSH JOINTS BE PROPERLY ALIGNED WHEN MAKING THESE • Before gluing the front , back , and sides together , JOINTS , OR ELSE , IN ADDITION TO THE JOINT SPAC - some provision must be made for installing the bot - iNG NOT BEING EQUAL , AS SHOWN 1N FIGURE 60 tom , such as dadoing or cutting a groove around the BELOW , THE TOP SURFACES OF THE SIDES , FRONT , inside of the drawer parts AND BACK WILL NOT " LINE - UP " PROPERLY EITHER • Your drawer is now ready to be glued together REFER TO THE SECTION " ALIGNMENT OF THE TEM - • Remove the penciI markings by fight sanding or with a PLATES " ( Figure 60 illustrates a Flush Dovelail Joint ) soft eraser after the drawer parts have been giued - All other GENERAL PREPARATIONS , except as noted together 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 " FAC ES TOWARD OF BASE , / " B " FACES TOWARD MIDDLE OF BASE / - / / RIGHT TOP STOP BLOCK / / / POINTER POINTS TO CENTER GRADUATION \ RIGHT FRONT STOP BLOCK \ " LEFT FRONT STOP BLOCK FIGURE 57 / DOVETAIL TEMPLATE FOR _ . . . . . . . . . . / HALF BLlND JOINTS CLAMPKNNOa a ii - - % n - " . . . . . I - Z / it / OLAMPINGK . OB _ ASHER , _ L . . _ _ ' - - m ' _ . _ . _ _ - - - _ : . . . . . . . . . . . _ . . . . . i . , C , , , TEMPLATEORAOKET 36
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TROUBLESHOOTING RGURE 58 - JOINT IS TOO SHALLOW o If the joint is too loose : INCREASE the depth of cut by INCREASING the amount by which the router bit extends DRAWER FRONT beyond the baseplate by t / 64 " to 1 / 32 " and make a trial cut Continue adjusting until desired joint fit is attained _ - SIDE ° If the joint is too tight : DECREASE the depth of cut by EXTENDS OUT PAST 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 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 deplh DRAWER needed by tuming the cam handles Retighten the clamp - BACK ing knobs ° If the joint is too deep : Refer to Figure 59 Loosen the _ SIDE clamping knobs holding the template brackets and move EXTENDS the template OUTWARD by turning the cam handles half OUT PAST FRONT the distance needed Retighten the clamping knobs ° If the joint is not uniformly spaced from top surface of drawer : Refer to Figure 60 ( See the Section " ALIGN - MENT OF THE TEMPLATES " ) With the template clamped FIGURE 59 - JOINT IS TOO DEEP to the base , loosen the four screws securing the template DRAWER FRONT . . . to the template brackets , and move the template slightly to the left Tighten the four screws and make a trial cut if moving the template to the left did not correct the condi - tion , but made it worse , loosen the screws and move the BACK template to the right a small amount Tighten the four EXTENDS OUT screws and make a trial cut Continue moving the template PAST to the right until the condition is completely correcled SIDE DRAWER MAKE SURE TO SECURELY TIGHTEN THE FOUR LEFT SIDE SCREWS If moving the template to the left improves the condition , continue moving the template to the left until the condifion is completely corrected Make sure the template DRAWER _ \ BACK remains parallel to the front of the dovetail base MAKE SURE TO SECURELY TIGHTEN THE FOUR SCREWS AFTER THE TEMPLATES HAVE BEEN CORRECTLY BACK REALIGNED , THEY SHOULD REQUIRE NO FURTHER EXTENDS ADJUSTMENTS IF THEY ARE HANDLED WITH CARE OUT PAST SIDE 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
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GENERAL PREPARATIONS MAKING PROJECTS WITH OPEN ( THROUGH ) JOINTS a . The workpieces comprising the project , that is , front , back , left side and right side should be cut to the proper • The thickness of both the front and the back ( tail pieces ) length , width and thickness ( es ) must be between 3 / 8 " and 1 " b Make sure that all surfaces are smooth and square with • The thickness of the sides ( pin pieces ) must also be each of the other surfaces between 3 / 8 " and 1 " c Line up the workpieces on a flat surface , standing on • Figure 61 shows a project and the workpieces that make edge , as shown in Figure 62 if up This figure is similar to Figure 40 , except that it d . . With a soft lead pencil mark the front , back and two shows the workpieces unassembied sides , as shown in Figure 62 , also . This is to aid you • Trial cuts are strongly recommended using scrap wood to in positioning the workpieces on the Dovetail Jig , prior ensure that the final workpieces are of the desired quality to 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 to the center graduation as shown in Figure 48 FIGURE 61 CORNER # 1 CORNE _ SURFACE LINES PROJECT FRONT \ _ UP WITH FRONT . . . . . . . . . . . . . . / _ STOP BLOCKS / yv PROJECT RIGHT SIDE / / SURFACE LINES UP WITFI FRONT STOP BLOCK / - _ CTLEFT SIDE " _ - - _ ' - _ 0 UTSIDE I OR % EOT _ " PROJECT SACK CORNER # _ CORNE _ 38
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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 MARK " PROJECT SURFACE " BACK OUTSIDE SURFACE " THE FOLLOWING DESCRIBES THE PROCEDURE TO t . _ i _ lt , _ , CAUTtO1NWHEN SETTING THE DEPTH OF BE FOLLOWED FOR CU _ ING THE PROJECT RIGHT SIDE AND THE PROJECT LEFT SIDE CUT , MAKE ABSOLUTELY SURE THAT THE COLLET NUT DOES NOT CONTACT ( TOUCH ) THE GUIDE BUSH - ING THIS CAN CAUSE THE GUIDE BUSHING TO HEAT NOTE : THESE WORKPtECES MUST BE CUT FIRST UP EXCESSIVELY DURING CUTTING WHICH CAN BECAUSE ANY JOINT FIT ADJUSTMENTS THAT MAY CAUSE DAMAGE TO THE TEMPLATE TO CORRECT BE REQUIRED CAN ONLY BE MADE WHEN CUTTING THIS SITUATION OR PREVENT IT FROM OCCURRING , THE PROJECT FRONT AND PROJECT BACK - THAT iS , REPOSITION THE ROUTER B1T IN THE ROUTER THE DRAWER FRONTAND THE PROJECT BACK ARE FIT TO THE SIDES 1 Assembfe the 1 / 2 " guide bushing to the router base - plate , as described in a previous section This is the larger of the two guide bushings furnished with this product 1t2 " DIA GUIDE BUSHING - _ . _ 2 Install Vermont American # 22501 or Magna # Mg1114 , to - _ \ the router as described in your Router Owners Manual Shank engagement should be a minimum of 3 , / 4 " E / VERMONT AMERICAN # 22501 I , _ CAUTION 1 MAKE SURE THAT THE ROUTER BIT OR MAGNA # M91114 IS ALIGNED WITH OR CENTERED IN THE HOLE iN THE STRAIGHT ROUTER BIT 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
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NOTE : BACK - UP BOARDS ARE USED TO MINIMIZE 3 Adjustht edepthofcutThedepthofcutforanOPEN SPLINTERING OF PROJECT PIECES AND TO KEEP DOVETAJOILINTisequatol thethicknesosfthemating ROUTER BIT FROM DAMAGING THE DOVETAIL JIG . , partThaits : FORCORNE # R1OFTHEPROJECRTIGHSTIDE 6 Lightly clamp the back - up board in place andFORCORNE # R4OFTHEPROJECLTEFTSIDE , 7 Position the project side against the front of the base so THEDEPTOHFCUTiSEQUALTTOHETHICKNESSthat the top surface abuts the right front stop block The OFTHEPROJECFTRONT use of a front back - up board at this step is also recom - FORCORNE # R2OFTHEPROJECRTIGHSTtDE mended tt is positioned between the project side and the andFORCORNE # R3OFTHEPROJECLTEFTSIDE , clamping bar as shown in Figure 63 The front back - up THEDEPTOHFCUTISEQUATLOTHETHICKNESSboard should have the following approximate dimensions eOFTHEPROJECBTACKbaseoftheDovelaJiilg , LENGTH : 6 " to 8 " , sufficient length so that it can be Usethedepthgaugoenth as clamped by the front clamping bar and be used more describeinda 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 THE OUTSIDE OF THE PROJECT SIDE FACES AWAY to minimize splintering and to provide support for the FROM THE FRONT OF THE BASE template The top back _ up board is a scrap piece of wood having the following dimensions : 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 visible before the front back - up board was put in place than once ; 8 Line up the workpieces so that the end of the project WIDTH : 2 " wider than the width of the project sides ; side and back - up boards line up as shown in Figure 63 THICKNESS : 1 / 8 " to 1 / 4 " thicker than the thickness of 9 Securely clamp the project side and the front back - up board to the front of the base the project sides ; this to prevent " ACCIDENTALLY " cutting into the dovetail base 10 Securefy clamp the top back - up board to the top of the base , This can also be accomplished by using more than one tl Make sure that the parts remain lined up , clieee of scrap as long as the resultant length , width and thickness are as described 12 Assemble the DOVETAILTEMPLATE FOR OPEN 5 TO CUT CORNER # 1 OF THE PROJECT RIGHT SIDE , ( THROUGH ) JOINTS to the Dovetai ! Jig so that THE TEM - PLATE BRACKETS FIT BETWEEN THE WASHERS AND position the top back - up board on top of the base so that it THE TEMPLATE SUPPORTS as shown Figure 64 ; it wil ! lines up with the front of the base and abuts to the fight top stop block as shown in Figure 63 be necessary to Ioosen the c ! amping knobs at the ends of the base to do this FIGURE 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
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13Makesurethatthetemplaitseoriented as shown in THIS CAN CAUSE DAMAGE TO THE DOVETAIL JIG ; Figure 65 OR LOSS OF CONTROL OF THE ROUTER WHICH CAN 14 Make sure that the template is flush and paraIlel with RESULT IN SERIOUS BODILY INJURY , A TRIAL RUN the workpieces clamped to base For narrow project sides , WITH THE ROUTER TURNED OFF AND UNPLUGGED the use of an auxiliary support for the template is recom - FROM THE ELECTRICAL OUTLET IS STRONGLY RECOMMENDED , , mended Its purpose is to aid in supporting the router while cutting It can be made from a piece of scrap wood ; but its 16 TURN THE ROUTER ON thickness must be the same as the top back - up board 17 Cut the dovetail by moving the router from LEFT TO ( Refer to Figure 63 ) RIGHT , with the guide bushing following the template DO ! 5 Clamp the template in place by tightening the clamping NOT FORCE ANYTHING ; MOVE THE ROUTER IN SLOW knobs AND SMOOTH FASHION 18 To ensure a smooth and uniform joint , retrace the pre - I _ , CAUTION ] BEFORE MAKING ANY CUTS MAKE vious cut by moving the router from RIGHT TO LEFT with the guide bushing again fofiowing the template SURE THAT THE BIT WILL NOT CUT INTO THE BASE OR ANY OTHER COMPONENT OF THE DOVETAIL JIG . , FIGURE 64 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 " " _ PROJECT RIGHT SIDE OR PROJECT LEFT SIDE 41
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FIGURE 66 . TOP BACK - UP BOARD TOPOFTHEBASE / / { J / ' _ ' _ . / / AUXILIARY TEMPLATE SUP - N . . . , . . / PonTN , EAEsOED t ' - ' J V / R _ GHTS _ DE _ VI , _ ii / / O / / i : P _ / t U2 , " OUTSIDE SURFACE " SHOULD BE " i ° VISIBLE ON THIS SURFACE BEFORE PosmONING THE FRONT BACK - UP BOARD [ , _ CAUTION J NEVER LIFT THE ROUTER 30 TO CUT CORNER # 4 OF THE PROJECT LEFT SIDE , UPWARDS WHEN THE ROUTER IS ON AND THE position the top back _ up board on top of the base so that it ROUTER BIT ROTATING OR WHEN THE GUIDE BUSH - lines up with the front of the base and abuts the ] eft top ING IS NEAR TO OR TOLICHING THE TEMPLATE . THIS stop block as shown is Figure 66 CAN CAUSE DAMAGE TO THE DOVETAIL JIG ; OR 31 Continue as Steps 27 through 32 above LOSS OF CONTROL OF THE ROUTER WHICH CAN 32 At this stage the project sides should look like those RESULT IN SERIOUS BODILY INJURY . illustrated in Figure 6 ! 19 After the cut has been made , the workpieces should look like those illustrated in Figure 67 20 Remove the workpieee and back - up boards from the FIGURE 67 Dovetail Jig 2I The back - up boards can be reused if the cut portions TOP BACK - UPBOARD _ of boards are cut off AFTER BEING REUSED UNTIL THEY NO LONGER SERVE THEIR INTENDED FUNC - . . . . . . , . _ . . . . J TION , NEW BACK - UP BOARDS MUST BE MADE 22 TO CUT CORNER # 3 OF THE PROJECT LEFT SIDE , 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 RIGHT SIDE , 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 left top stop block as shown above in Figure 66 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 use of a front back - up 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 D 27 Continue as in Steps 8 through 19 above 28 After the cuts have been made , the workpieces should BACK _ UP look like those illustrated in Figure 61 BOARD 29 Remove the workpiece and the back - up boards from the Dovetail Jig NOTE : THE BACK - UP BOARDS ARE REUSABLE . 42
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THE FOLLOWING DESCRIBES THE PROCEDURE TO CAUSE DAMAGE TO THE TEMPLATE TO CORRECT BE FOLLOWED FOR CU'i - FING THE PROJECT FRONT THIS S _ TUATION OR PREVENT } T FROM OCCURRING , AND BACK REPOSITION THE ROUTER BIT IN THE ROUTER 3 Adjust the depth of cut The depth of cut for an OPEN NOTE : Any joint fit adjustments that may be required DOVETAIL JOINT is equal to the thickness of the mating can only be made when cutting the project front and part That is : back pieces , , That is , adjustments are made to project FOR CORNER # t OF THE PROJECT FRONT , THE front and back pieces ONLY , not to the side pieces , DEPTH OF CUT IS EQUAL TO THE THICKNESS OF 1 Assemble the 40 " guide bushing to the router baseplate , THE PROJECT RIGHT StDE as described in a previous section This is the smaller of FOR CORNER # 4 OF THE PROJECT FRONT , THE the two guide bushings furnished with this product DEPTH OF CUT IS EQUAL TO THE THICKNESS OF 2 Install Vermont American # 22437 or Magna # M91016 THE PROJECT LEFT SIDE straight router bit , to the router as described in your Router FOR CORNER # 2 OF THE PROJECT BACK , THE Owners Manual Shank engagement should be a minimum DEPTH OF CUT IS EQUAL TO THE THfCKNESS OF of 3 / 4 " THE PROJECT RIGHT 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 on the base of the Dovetail Jig , as AMERICAN described in a previous section , as a starting point # 22437 OR 4 At this point it will be necessary for you to make a top MAGNA # M9 ! 016 i 0 back - up board The reasons for the top back - up board are STRAIGHT I " - _ ROUTER BIT to minimize splintering , provide support for the template and prevent damage to the DovetaiI Jig The top beck - up board is a scrap piece of wood having the following dimensions : LENGTH : 6 " to 8 " , sufficient length so that it can be c _ amped by the top clamping bar and be used more It , i = ' _ . _ CAUTION I1 MAKE SURE THAT THE ROUTER BIT than once ; IS AUGNED WITH OR CENTERED tN THE HOLE IN THE WIDTH : 2 " wider than the width of the project front GUIDE BUSHING TO DO THIS , LOOSEN SCREWS ( or back ) HOLDING BASE PLATE OR ADAPTER PLATE TO THICKNESS : 1 / 8 " to 1 / 4 " thicker than the thickness ROUTER , CENTER GUIDE BUSHING HOLE WITH of the project front ( or back ) ; THIS IS TO PREVENT RESPECT TO ROUTER BIT AND RETIGHTEN SCREWS ACCIDENTALLY CUTTING INTO THE DOVETAIL JIG , , SECURELY This can also be accomplished by using more than one piece of scrap as long as the resultant length , width , and thickness are as described I ' _ CAUTION 1 WHEN SETTING THE DEPTH OF 5 TO CUT CORNER # 1 OF THE PROJECT FRONT , CUT , MAKE ABSOLUTELY SURE THAT THE COLLET position the top back - up board on top of the base so that it NUT DOES NOT CONTACT ( TOUCH ) THE GUIDE BUSH - lines up with the front of the base and abuts the left top ING THIS CAN CAUSE THE GUIDE BUSHING TO HEAT stop block as shown in Figure 68 UP EXCESSIVELY DURING CUTTING WHICH CAN FIGURE 68 TOP BACK - UP BOARD TOP OF THE BASE / AUXILIARY TEMPLATE / j 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
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FIGURE 69 . 9 6 Ughtiy clamp the back - up board in place iWI ' _ cAUTIONIBEFORE MAKING ANY CUTS MAKE 7 Posilion the project front ( or back ) against the front of the base so that the top surface abuts the left front stop SURE THAT THE BIT WILL NOT CUT INTO THE BASE biock The use of a front back _ up board at this step is also OR ANY OTHER COMPONENT OF THE DOVETAIL JIGo recommended it is positioned between the project front THIS CAN CAUSE DAMAGE TO THE DOVETAIL JIG , ( or back ) and the clamping bar as shown in Figure 68 The 16 TURN THE ROUTER ON front back - up board should have the following approximate 17 Cut thedovetailby moving the routerfrom LEFT TO dimensions : RIGHT , with the guide bushing following the template DO LENGTH : 6 " to 8 " , sufficient length so that it can clamped NOT FORCE ANYTHING ; MOVE THE ROUTER IN SLOW by the front clamping bar and be used more than once ; AND SMOOTH FASHION WIDTH : 1 " to 2 " wider than the width of the front ( or 18 To ensure a smooth and uniform joint , retrace the pre - back ) ; vious cut by moving the router from RIGHT TO LEFT with THICKNESS : 1 / 4 " to 1 / 2 " the guide bushing again following the tempIate THE OUTSIDE OF THE PROJECT FRONT ( OR BACK ) ! 9 MAKE SURE THATALL OF THE MATERIAL IS CUT FACES AWAY FROM THE FRONT OF THE BASE AWAY ; FREE ROUTING MAY BE REQUIRED TO The words " OUTSIDE SURFACE " marked in ( d ) in the ACCOMPLISH THIS EXTRA CARE IS REQUIRED IN Section , GENERAL PREPARATIONS , should have been CONTROLLING THE ROUTER MOVEMENT WHILE visible before the front back - up board was put in place DOING FREE ROUTING . ( Refer to Figure 70 ) 8 Line up the workpieces so that the end of the project front ( or back ) and back - up boards line up as shown in FIGURE 70 TOP BACK - UP Figure 68 9 Securely clamp the project front ( or back ) and front back - _ BOARD \ up board to the front of the base 10 Securely clamp the top back - up board to the top of the base 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 knobs at the ends of the base to do this 13 Make sure that the temptate is oriented as shown in Figure 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 DRAWER FRONT wood ; but its thickness must be the same as the top back - CUTS OR DRAWER BACK up board ( Refer to Figure 68 ) 15 Clamp the template in place by tightening the clamping knobs 44
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the base so that the top surface abuts the right front stop [ _ CAUTION jNEVER LIFT THE ROUTER block The use of a front back - up board at this step is also recommended . , tt is positioned between the UPWARDS WHEN THE ROUTER IS ON AND THE drawer front ( or back ) and the clamping bar as shown in ROUTER BIT ROTATING OR WHEN THE GUIDE BUSH - Figure 71 The front back - up board is described in Step 7 ING IS NEAR TO OR TOUCHING THE TEMPLATE . above 20 After the cut has been made , the project back and front 28 Continue as in Steps 8 through 20 above should look like these illustrated in Figure 61 29 After the cuts have made , the workpieces should look 21 Remove the workpieee and back - up boards from the like these illustrated in Figure 61 Dovetail Jig 30 Remove the workpiece and the back - up boards from 22 The back - up boards can be reused if the cut portions the Dovetail Jig of beards are cut off AFTER BEING REUSED UNTIL NOTE : THE BACK - UP BOARDS ARE REUSABLE , , THEY NO LONGER SERVE THEIR iNTENDED FUNC - 31 TO CUT CORNER # 2 OF THE PROJECT BACK , TION , NEW BACK - UP BOARDS MUST BE MADE position the top back - up board on top of the base so that [ t 23 TO CUT CORNER # 3 OF THE PROJECT BACK , lines up with the front of the base and abuts the right top position the top back - up board on top of the base so that it stop block as shown is Figure 7t Iines with the front of the base and abuts the left top stop 32 Continue as Steps 28 through 32 above block as shown in Figure 68 33 The finished project front , back , and sides should took 24 Continue as Steps 6 through 24 like those illustrated in Figure 61 25 TO CUT CORNER # 4 OF THE PROJECT FRONT , 34 Check how the workpieces fit together Some adjust - posilion the top back - up beard on top of the base so that it ments may be necessary Refer to the section , lines up with the front of the base and abuts the right top TROUBLESHOOTING stop block as shown in Figure 7t • Your project is now ready to be glued together 26 Lightly clamp the back - up board in place • Remove the penciI markings by light sanding or with a 27 Position the project front ( or back ) against the front of soft eraser after the parts have been glued together FIGURE 71 TOP BACK - UP BOARD \ \ TOP OF THE BASE \ AUXIUARY TEMPLATE SUPPORT \ \ ' _ " _ \ \ f " _ ( AS NEEDED ) tt _ _ _ . XV - 2 % _ - , , , : , . % . , , , . . . . . FRONT OF THE BASE / / _ / . . . . . . . . ' _ - - - - t / _ " " _ PROJECT FRONT OR t PROJECT BACK ' OUTSIDE SURFACE " SHOULD BE VISIBLE ON THIS SURFACE / BEFORE POSITIONING THE FRONT BACK - UP BOARD 45
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FIGURE 72 - JOINT tS TOO SHALLOW TROUBLESHOOTING • If the joint is too loose : This adjustment can only be PRoJ FRONT EXTENDS FRONT PAST SIDE made when cutting either the front or the back ( tail pieces ) Loosen the clamping knobs holding the template brackets and move the template OUTWARD by turning the cam > SIDE handles Continue adjusting until desired joint fit is EXTENDS attained Retighten the clamping knobs OUT PAST FRONT • If the joint is too tight : This adjustment too can oniy be made when cutting either the front or the back ( tail pieces ) LEFT SIDE Loosen the clamping knobs holding the template brackets and move the template INWARD by turning the cam han - PROJECTo _ . _ dles Continue adjusting until desired ioint fit is attained BACK " _ SIDE Retighten the clamping knobs EXTENDS • If the joint is too shallow : Refer to Figure 72 BACK INCREASE the depth of cut of the router bit This adjust - ment can be made when cutling the front , the back , ( tail OUT PASTDS pieces ) and the sides ( pin pieces ) BACK EXTEN OUT PAST SIDE • If the joint is too deep : Refer to Figure 73 DECREASE the depth of cut of lhe router bit This adjust - ment too can be made when cutting the front , the back , FIGURE 73 - JOINT IS TOO DEEP ( tail pieces ) and the sides ( pin pieces ) SIDE EXTENDS • If the joint is not uniformly spaced from top surface FRONT OUT PAST FRONT of drawer : Refer to Figure 74 ( See the Section " ALIGN - MENT OF THE TEMPLATES " ) With the template clamped Io the base , loosen the four screws securing the _ FRONT template to the template brackets , and move the template EXTENDS slightly to the left Tighten the four screws and make a tdal cut If moving the template to the left did not correct the PROJECT condition , but made it worse , loosen the screws and move LEFT SIDE _ . . . . . % PAST the template to the right a small amount Make sure the template remains parallel to the front of the dovetail base Tighten the four screws and make a thai cut Continue BACK moving the template to the right until the condition is EXTENDS completely corrected PROPER ALIGNMENT OF THE OUT PAST TEMPLATES TO THE TEMPLATE BRACKETS IS CRITI - SIDE CAL FOR JOINT UNIFORMITY ONCE THIS IS ACCOM - PUSHED CORRECTLY , IT SHOULD NOT NEED SIDE EXTENDS ADJUSTMENTS AGAIN MAKE SURE TO SECURELY OUT PAST BACK TIGHTEN THE FOUR SCREWS AFTER THE TEM - PLATES HAVE BEEN CORRECTLY REALIGNED , THEY SHOULD REQUIRE NO FURTHER ADJUSTMENTS IF FIGURE 74 - JOINT SPACING IS NOT EQUAL THEY ARE HANDLED WITH CARE FRONT - - - _ _ j / SPACING { TAIL PIECE ) _ , _ GREATERATcKHAN SIDE / ( PIN PIECE ) _ / / BACK , 7 / ( TAIL PIECE ) . , . \ / / THAN FRONT SPACiNLEaSS 46
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PARTLSIST FOR VERMONT AMERICAN INDUSTRIAL DOVETAIL JIG MODEL NO , , 23461 KEY PART No , DEscRIPTION ! QT ¥ KEY PART NO . DESCR | PTtON QTY 1 29LD - 87g - I Detuxe Dovetail Base i - 1 24 29L - 489 - 13 # ! O * 32XS / 8 " lg Panhoad Machine Screw . _ 4 _ 2 29LD _ 880q Dove | aiLTem _ lat e LB . rmdJ _ n ! ) . . . . . . . . . . . . 1 25 29L - 469 - 14 # 10 - 32 X 3 / 8 " Ig . Panhead Machine Screw 8 3 29LD - 881 - 1 Dove | a ! ! Templat e ( Open . ! o ) n ! ) 26 29Lo469q5 # 8 = 36 X 3 / 16 " Ig . Panhead Machine Scre w 10 4 29LD - 882 Temp _ _ Je SuEEport ( Right Side ) 27 29LD - 841 - 2 ! 1 - 10 _ 32X 5 / 8 " Ig Flat Head Mac _ Scr % w 2 28 2gLD - 841 - 3 # ! O " 32 X 7 / 8 " ! g _ Fiat Head Machine Screw 2 5 2gLD - B83 Tern _ Support ( Le | t Side ) 6 29LD ° 884q Cam Handle i 2 29 _ 29L . _ D _ : . 841 - . . : 4 _ ; 10 - 32 X 3 / 8 " Ig . Flat Head Machine Screw 3 7 29LD - 885 - 1 Front Stop Block i 2 30 29L - 684o6 # 10.16X1 / 2 " i & . Panhead . Taj ) p } ng , Sct'ew ! 8 29LD - 886 - 1 . To _ £ p Block i 2 . 31 29L - 684 - 7 , # ' i _ 16X ! " ! g PanheadTa £ pingscrew 3 9 29LD - 887 Ciamj _ . g Bar End Cap _ 4 32 29A - 310 - 15 5 / ! _ ! 8 X ' 4 : ! / 2 " ] g _ RD HD SQ Neck Bolt 2 10 29LD - 888 - 1 Retainer 1 33 29A - 310,16 5 / 16 - 18 X 3 - 1 / 2 " ! g : . RD HD SQ Neck Bolt 2 11 29LD - 889 - 1 Bol _ Support 4 34 29A - 310 - 17 5 ! 16 - 18 X 2 " _ q . RD HD SQ Neck Bolt _ . 2 . 6 35 29A - 242 - t2 # t0 - 32 Hex Machine Screw Nul 4 12 29LD _ 890 - 1 Clamping Knob 2 36 29A - 242 - 13 5 / 16 - 18 t - . lex Machine Screw Nut 2 ! 3 29LD _ 891 C ! # rnping Bar 37 2gA _ 306 - 20 t3 / 64 " [ D X 15132 " OD X 3 / 64 " 14 . 29LD - 892 . PivoIShalt . 1 15 29LD - 895 Template Bracket = 4 Thick Washer 13 2 38 29A - 306 - 40 11 / 32 " ID X 7 / 8 " OD X 1 / t6 " Thick Washer 8 16 29LD _ 896 Template Sti | _ ener 17 29LD - 899 1 39 29LD - 930 II / 32 ' ID X 7 / 8 " OD Thin Nylon Washer 4 Guide Bushing Assembly ( . 4 " Din , ) 2gLD - 900 1 40 29LD - 969 5 / 16 " ID X 7t8 " OD Thick Nylon Washer 4 t8 Guide Bushin _ Assembl _ " Din , ) _ _ 19 29LD - 98t 4 41 29LCN - 1Q08 S _ r } ng Retainer 4 _ _ n Sprin 9 _ _ _ _ _ _ . _ _ , . . . _ _ _ 2O 45A - 414 Product Label ( Clamping Bar } 1 42 29A _ 368 " ! # 8 Countersunk Bushing 4 _ _ 21 45A - 416 Label { Temj ? late - Blind ) 1 43 29A - 368 - 2 # t 0 Countersunk Bushing 4 22 44 2gGD - 375 Router Adapter PIale 1 45A - 417 _ plate43 _ ) . . . . . 1 _ _ 45 VA # 25500 1 / 2 " VA Dovetail Router Bit 1 23 45A - 415 Warning Label ( C ! amp ! ng Bar ) 1 : _ 45LCN - 72 ins , ' ruction Manual I 1 Key No's 29.42.43 . 44 . and 45 a ! ong with four o ! Key No 37 are furnished loose and unassembied 47
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BASE ASSEMBLY o TEMPLATE SUPPORT ASSEMBLY 48
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CLAMPING ASSEMBLY i / ROUTER ADAPTER PLATE 49
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TEMPLATES / . . . . . . . . o , , o , / / FASTENERS @ @ @ @ ® ® @ @ @ / @ @ @ \ @ @ @ Q 50
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51
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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 The PART NUMBER Printed in U _ SoAo 2 The PART DESCRIPTION 08 / 99 3 The MODEL NUMBER : 23461 Manual No . 45LCN - 72 4 The ITEM NAME - INDUSTRIAL DOVETAIL JIG i i i i
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