Craftsman 17125450 Owner’s Manual

ModelNo,

171.25450

CRAFT$1VlAK

INDUSTRIAL

DOVETAIL

FIXTURE

• Assembly

• Operation

iMPORTANT;Thefollowingrouterbitsarerequired

for usewiththis fixture:#25414-1/4-in. Straight Router Bitand

#25415-9/16-in. DovetailRouter Bitwhich are used

for THROUGHor OPENJOINTS.

: #25505 or #26318-1/2-in. DovetailRouterBit which

are usedfor a!l HALFBLINDJOINTS.

Readandfollow

all instructions carefully.

KEEPTHIS MANUALFOR

' FUTURE

REFERENCE,

Sold by Sears,Roebuckand Co,, Hoffman Estates,IL 60179

# 83463

, i i

FAILURETO HEEDALLSAFETYANDOPERATINGINSTRUCTIONS ANDWARNINGSREGARDINGUSEOF THISPRODUCTCANRESULT

IN SERIOUSBODILYINJURY

1) KNOWYOURPOWERTOOL Readtheowner'smanualcarefully.Learnitsapplicationsand

Iimitatlonsaswell asthespecificpotentialhazardsparticularto thistool.

2) GROUNDALLTOOLS(UNLESSDOUBLEINSULATED) Iftoolis equippedwithanapproved3-conductorcordanda3-

pronggroundingtypeplug,itshouldbepluggedintoathreehole electricalreceptaute.It adapteris usedtoaccommodateatwo-

prongreceptacle,theadapterwiremustbeattachedto known ground,(usuallythescrewsecuringreceptaclecoverplate). Neverremovethirdprong.Neverconnectgreengroundwireto a

terminal.

3) KEEPGUARDSINPLACE

--in workingorder,andinproperadjustmentandalignment.

4) REMOVEADJUSTINGKEYSANDWRENCHES

Forma habitof checkingtoseethatkeysandadjustingwrenches areremovedfromtoolbeforeturningit on.

5) KEEPWORKAREACLEAN

Clutteredareasandbenchesinviteaccidents.Floormustnot be slipperydoeto waxor sawdust.

6} AVOIDDANGEROUSENVIRONMENT

Donot usepowertoolsindamporwetlocationsorexposethornto rain.KeepworkareawelIlighted.Provideadequatesurrounding workspace.

7) KEEPCHILDRENAWAY

All visitorsshooktbekeptata safedistancefromworkarea.

B) MAKEWORKSHOPCHILD-PROOF

--with padlocks,masterswitches,or byremovingstarterkeys.

9) DONOTFORCETOOL

It willdothejob betterandsaferatthe rateforwhichitwas designed.

10)USEAPPROPRIATETOOL

Donotforcetoolor attachmentto doajob forwhichitwasnot designed.

11)WEARAPPROPRIATEAPPAREL

Donotwearlooseclothing,gloves,necktiesorjewelry(rings,

wristwatches)to getcaughtin movingparts.Nonslipfootwearis

recommended.Wearprotectivehaircoveringtocontainlonghair. Rolllongsleevesel;Dyetheelbow.

12)USESAFETYGOGGLES(HeadProtection)

WearSafetyGoggles(mustcomptywith ANSIZ87.1) atalltimes.

Also,usefaceordustmaskif cuttingoperationis dusty,andear

protectors(plugsormuffs)duringextendedperiodsofoperation.

13)SECUREWORK

Useclampsora viseto holdworkwhenpractical,it'ssaferthan usingyourhandandfreesbothhandsto operatetool.

14)DONOTOVERREACH Keepproperfootingandbalanceatalltimes.

15)MAINTAINTOOLSWITHCARE Keeptools sharpandc]eanfor bestandsafestperformance.Follow instructionsfor lubricatingandchangingaccessories.

16)DISCONNECTTOOLSBEFORESERVICING

-when changingaccessoriessuchasblades,bits,cutters,etc.

17)AVOIDACCIDENTALSTARTING Makesureswitchisin OFFpositionbeforepluggingin.

18)USERECOMMENDEDACCESSORIES

Consulttheowner'smanualfor recommendedaccessories.Follow

theinstructionsthataccompanytheaccessories.Theuseof

improperaccessoriesmaycausehazards.

19)NEVERSTANDONTOOL Seriousinjurycouldoccur;fthetool Istippedorthecuttingtool is

accidentallycontacted.0o notstorematerialsaboveor nearthetool thatwouldmakeit necessaryto standon thetoolto reachthem.

20)CHECKDAMAGEDPARTS

BeforefurtheruseofthetooI,aguardor otherpartthatis damaged

shouldbecarefullycheckedto ensurethatitwill operateproperly andperformitsintendedfunction.Checkfor alignmentof racy(rig

parts,bindingofmovingparts,breakageof parts,mounting,andany otherconditionsthat mayaffectitsoperation.Aguardorotherpart

thatisdamagedshouldbeproperlyrepairedorreplaced.

21)DIRECTIONOFFEED

Feedworkintoabladeorcutteronlyagainstthedirectionof rotation ofthe bladeor cutter.

22)NEVERLEAVETOOLRUNNINGUNA'n'ENDED

Turnpoweroff. Donotleavetooluntilit comesto a completestop.

23)KEEPHANDSAWAYFROMCUT(1NGAREA

24)STOREIDLETOOLS

Whennotin use,toolsshouldbestoredindry,highorIocked-up place---outof reachofchildren.

25)O0HOTABUSECORD

Keepcordawayfrom heat,oil,andsharpedges.

28)OUTDOOREXTENSIONCORDS

Whentoo!isusedoutdoors,useonlyextensioncordssuitablefor useoutdoors,andso marked.

27)NEVERUSEINANEXPLOSIVEATMOSPHERE

Normalsparkingofthemotorcouldignitefumes,flarnmab;eliquids, or combustibleitems.

28)DRUGS,ALCOHOL,MEDICATION

Donotoperatetoolwhile undertheinfluenceofdrags,alcohol,or anymedication.

READANDUNDERSTANDTHISCOMPLETEINSTRUCTIONBOOK

BEFOREUSINGTHISPRODUCT

ADDITIONALSAFETYINSTRUCTIONSFORYOUR

INDUSTRIALDOVETAILFIXTURE

1) AlwaysweareyeprotectionthatcomplieswithcurrentANSI StandardZ78A.

2) Noiselevelsvarywidely.Toavoidpossiblehearingdamage,wear earpIugsor muffswhenusingtheDovetailFixturefor hoursata time.

3) Wearadust maskalongwiththesafetygoggles.

4) Donotusethis DovetailFixturewith routerbitsor guide bushingsotherthanthosespecifiedforthecuts beingmade.

5) FollowtheinstructionsinyourRouterOwnersManual.

6) Vibrationscausedbytherouterduringusecancausefasteners to becomeloose.Beforeuseandperiodicallyduringusecheckall

fastenerstomakesurethattheyareagtightandsecure.

7) Donotusethis productuntilallassemblyinstallationstepshave beencompleted,andyouhavereadandunderstandnitsafetyand operationalinstructionsinthis manual,andtheRouterOwners

ManuaL

8) Makesurethattherouterbitis properlypositionedin therouter sothatit doesnotcontacttheguidebushingorthetemplatewhen cutting.

9) TheDovetailFixturemustbesecurelymountedtoaworkbench or otherstablesurfacewheninuse.Thefrontof thebaseshould

overhangthe frontof theworkbenchbynomerethan1/4"to provide clearancewhenclampingworkpiecestotheDovetailFixture.

10) DonotusetheDovetailFixtureasaworksurface.Doingsomay causedamageto theDovetailFixture,whichcancauseitto beunsafe to use.Aworkbenchshouldbeusedforthispurpose.

11)Thisproductis designedtocutflatworkpieces.Donotcutor

attempttocutworkpiecesthatarenotflat orthatareirregularly shaped.

12)Thisproductis to beusedforcuttingwoodworkpiecesonly.Do notusethisproducttocutmetaloranyothernon-woadmaterial.

13)Thisproducthasbeendesignedto cutworkpieceshaving thicknessesof3/8"to 1".Donotuseforworkpiecesofanyother

thicknesses.

14)DonotclampanyworkpiecestotheDovetailFixtureormakeany adjustmentsto theDovetailFixtureunlesstherouterhasbeenturned

off,the routerbitisnotturning,andthe Routerhasbeen disconnectedfromtheelectricaloutlet.

15)Whensetting"lhe-dopth-ot-cut"oftherouterbit,makesurethat theworkplaceis clampedto theDovetailFixturein sucha.manner

thattherouterbitdoesnotcutinto the Dovetailbasecausing

damagetoit orpassibleseriousinjurytoyou.

16) ALWAYSUNPLUGTHEROUTERFROMTHE ELECTRICALOUTLETBEFOREINSTALLINGORREMOVINGROUTER

BITSFROMTHEROUTERANDWHENADJUSTINGTHECUTTING DEPTHOFTHEROUTERBIT;ORWHENINSTALLINGORCHANGING

GUIDEBUSHINGS,

17)NEVERLiFTTHEROUTERUPWARDSWHENTHEROUTERiS "ON",THEROUTERBITISROTATING,ANDTHEGUIDEBUSHINGiS NEARORTOUCHINGTHETEMPLATE,BECAUSETHISWILLCAUSE

THEROUTERBITTOCUTINTOTHETEMPLATEANDDAMAGEIT.

INTRODUCTION

o Your Sears/Craftsmanindustrial DovetailFixture is an accessory used with your Routerto allow you to make drawers, chests, and the like

where dovetail joints are used to join the front, back,and sides of the workpiece. TheDovetail Fixturewig allow you to make1" spaced flush andflush offset and 318"rabbetedhaif-bfind dovetail joints, in addition you can

make1" spaced (or open) dovetail joints.

• Workplace widths up to 16"can beaccommodated. Workplacethicknesses between318"and1" can beaccommodated,

The Dovetail Basehas six pockets molded into its front which are gauges to aid you in setting the "depth-of-cut" for commonly used depths: 3/8", 1/2", 5/8", 3/4'1,7/8", and 1".

The Dovetail Fixture comeswith two templates andtwo guide bushings for making bait-blind and through or openjoints. Sears/Craftsman router bits,#25414 and#25415, WHICH MUST BEPURCHASEDSEPARATELY,are required to makethe THROUGHor

OPENjoints. Sears/Craftsman router bit, #25505 or #26318, WHICH MUSTBE PURCHASEDSEPARATELY,is required for making the haIf-bIind joints.

• Eachtemplate has a label, describing the joint that can becut, along with set up information, the bit and guide bushing required, and the stop block setting for a particular joint.

The Dovetail Fixture can be used with al! Sears/Craftsman Routers. With a separately purchasedSears/Craftsman#25326, Universal Router Adapter,the DovetagFixture can be usedwith many non- Craftsman Routers, such as, Black & Decker,Makita,and SkiL

UNPACKINGANDCHECKINGCONTENTS

in orderto simplify handIingand to minimize any damagethat may occur during shipping, your Industrial Dovetail Fixtureis packaged

unassembled, Separateall parts from the packing materials and check eachonewith the igustrations and list of partsat the endof this manuaIto make sure that ag parts are presentbefore discarding any packaging material.

• Ifany parts aremissing or cannot beaccounted for, do not attemptto assemble,install, or use the industrial DovetailFixture until the missing parts havebeenobtained and the product has beenassembled correctly. Contactyour localSearsRetail Outletfor a repIacement product or for the missing parts.

ASSEMBLYINSTRUCTIONS

Thefollowingtoolsare requiredforassembly:

1) AmediumsizedPhillipsscrewdriver,

2) Asmallor mediumsizedadjustablewrench.

ASSEMBLYOFTHERIGHTSIDETEMPLATESUPPORTTOTHEDOVETAILBASE

1). Placethedovetailbasetopsidedownonaflatsurface.

2) insertoneof the5/16-18x2"longroundheadsquareneckboltsintothes!otintherightsideofthebase.(NOTE:Therightsideof the baseis identifiedbythewordsRIGHTSIDEmoldedintoit.)

3) Placea11/32"I.D_x 7/8"O.D.washerontothe boltasshownin Figure1,

4) Threada5/16-18hexnutontothebolt,asshown,untilit bottomsoutagainstthe washer,

5) Backoffthenutfromthe washerbetween1/4 and1/2turns.NighthenutsothatthecornersofthenutareverticallYlineduPasshown. Notethe alignmentofthe hexpocketinthetemplatesupport.Theboltshouldbefreeto movesidetoside;if it doesnot,loosenthenut1/3

turnor untilthe cornersofthenutpointupanddown.

8) Assembletherighttemplatesupportto therightside ofthedovetailbaseso thatthe hexoutlinesupandf ts intothehexpocketinthe righttemplatesupport,(NOTE:TherighttemplatesupporthasthewordsRIGHTSIDEmoldedintoitfor identification.)

7) Assemblea#10-32x5/8°tongpanheadmachinescrew,a 13/64"!.D.x 9/16"O.D.washer,anda#10"32hexnutt° thebaseassh°wnt° holdthetemplatesupportin place.Securelytightenthenut andscrew_

8) Thetemplatesupportshouldmovefreelyfrontto backalongthe sideofthe base,If it doesnot,it meansthatthe5/16-18hexnutis too tight ontheboltandshouldbeloosened.Todothis, removethefastenersassembledinstepT,andremovethetemplatesupport;repeatsteps 4 through7.

• ASSEMBLE THE LEFT SIDE TEMPLATE SUPPORT TO THE DOVETAIL BASETHE SAME AS THE RIGHT SIDE

TEMPLATE SUPPORT WAS ASSEMBLED

Fig. 1

11/32"LO.XT/8"O.D.WASHER

5/16-18X2"tongROUNDHEAD SQUARENECKBOLT

DOVETAILBASE

"/8"longPANHEADMACHINESCREW

MUSTLINEUP

_.D.WASHER

?HEXNUT

_ BACKOFDOVETAILBASE

ASSEMBLYOFTHETOPCLAMPINGBARTOTHEDOVETAILBASE

1) Assembleoneoftheboltsupportsto bothofthe 5/16-18X3-1/2"longroundheadsquareneckboltsasshowninFigure2.

2) Alignthesquareonthe boltwiththesquareholeinthe boltsupport.Theboltsupportisto =bottom-out"againstthebolt asshownin

Figure3.

FIG.2 5/16-18X3-1/2"FIG.3

longROUND HEADSQUARE _-x

FIG. 3a

,o,,

3) Assembleoneofthespringsto eachof thenylonspringretainersbypushingthespringovertheraisedcylindricalportionof the springretaineras shownin Figure3aandFigure3b,

4) Positionthedovetailbaseonafiat smoothsurfacesothebackof thebaserestsonthesurface.

NOTE:ALTHOUGHBOTHENDSOFTHEDOVETAILBASEARESHOWNASSEMBLEDINTHEFOLLOWINGFIGURES,THEACTUALASSEM- BLYIS DONEONEENDATATIME.

5) Fromthebottomofthe base,insertaboltwithboltsupportthroughtheslotin thetop of thebasesothe raisedportionofthe bolt

supportgoesinto theslot,asshowninFigure4,

Fig, 4 SLOTIN SLOTIN

BOLTAND BOLTSUPPORT

FRONTOFDOVETAILBASE

6) Placea5/16"I.D.X 7/8"O.D.thick nylonwasheroverthe boltsothatthecountersinkfacesawayfromthedovetailbaseasshownin Figure6. It will benecessaryfor youto holdthebolt in placewhenperformingthis andthefollowingsteps. HELPFULHINTS:Positionthe boltandtheboltsupportunderthenotchin theribas shownin Figure5,to helpholdtheboltin place,

Fig. 5 _ NOTCHINRIB

DOVETAIL DOVETAILEASE DOVETAIL BOLTANDBOLT

EASE / BASE

SLOTINDOVETAILBASE

BOLTANDBOLTSUPPORT

7) Placeaspringandspringretainer,assembledinstep3, overtheboltsothespringfitsintothecountersinkinthethickwasherasshown InFigure6.

8) Pressdownonthespringretaineruntiljusttheendofthebolt sticksoutpasttheendofthe springretainer.

9) Slidetheclampingbaroverthebolt sothatthespringretainerabutstheinsideoftheclampingbarasshownin figure6.NOTE:THE SPRINGRETAINERMUSTPUSHAGAINSTTHECLAMPNGBAR.

10)Placean11/32"I.D.X7/8"O.D.thin nylonwasherandan 11/3Z I.D.X7/8"O.D.washeroverthe bolt.It will benecessaryfor youto pressdownonthe dampingbarwhiledoingthis.

11)Takeoneoftheclampingknobsandthreaditontothe boltasshown.DONOTTHREADtheknobcompletelyontothebolt--just enough

sothe knobholdsthe clampingbarinplace.

CLAMPING

FIG. 6 KNOB

SPRINGAND NYLONSPRING

RETAINERFIT

INSIDETHEOPEN SIDEOFTHE CLAMPINGBAR

(SEECLAMPING BARDETAIL)

SPRING

31/2"BOLT

BOLl SUPPORT

12)Repeatabovesteps4through11for theotherendof theclampingbar.

13)Assembletheendcapstotheendsoftheclampingbarby pressingthemin; theyaredesignedto be"force-fit"intothebarin oneway only.It maybenecessaryto "tap"themin bygentlyhittingthemwitha rubbermatletora pieceofwood--sincetheyfit verytightlyintothe

clampingbar,USECAREWHEN DOINGTHISSOAS NOT TO DAMAGE THEEND CAPS,

USECARETHATTHECAPSAREPROPERLYALIGNEDAS SHOWN WHEN ASSEMBLINGTHEM TO THEBAR.

tf/32"LD.X 7/B"O.D.WASHER

11/32"LD.X T/8"O.D. THINNYLONWASHER

CLAMPINGBAR

Assembleclampingbar,knobs,endcaps on bothends asshown

CLAMPINGBARDETAIL

11/32"LD.X7/8"O.D. (RETAINERABUTSTHE

CLAMPINGBARENDCAP

WASHER LAMPING SAR)

OPENSIDEOFTHECLAMPING BARPOINTSTOWARDTHETOP

SURFACEOFTHEDOVETAILBASE

11/32"LD.X 7/8"O,D.

t THICKNYLONWASHER

CLAMPINGBAR(SHOWNWITH /

DOVETAILBASE

/ TOPSURFACEOFTHE

-- RIGHTTEMPLATE SUPPORT

ENDCUTAWAYANDSECT!ONED /

SONYLONSPRINGRETAINER / PLACEMENTCANBESEEN) /

COMPRESSION

SPRING

NYLONSPRINGRETAINER

fig.7

CLAMPINGBARPARALLELTO TOPOFBASE

J SPACINGTOBE

APPROXIMATELY

1-1/2"

0 0 0

14)Tightentheclampingknobsontothe boltssothatthespacebetweenthebottomoftheclampingbarandthetop of thebaseisabout 1 1/2".Theciampingbarshouldbeparallettothe topofthe base.

15)AftercompletingtheabovestepsyourDovetailFixtureshouldlookliketheillustrationin Figure7.

ASSEMBLYOFTHEFRONTCLAMPINGBARTOTHEDOVETAILBASE

1) Assemblethefront clampingbarto the dovetailbasefollowingthesameprocedureusedto assemblethetop clampingbartothedove-

tail baseasshownin Figure8.The5/16-18X4-1/2"longroundheadsquareneckboltsareused,

Fig. 8

CLAMPINGBAR (SHOWNWITH

ENDCUTAWAY

ANDSECTIONED

SONYLONSPRING RETAINERPLACE-

MENTCANBE

SEEN)

COMPRESSION SPRING

BOLT

4 I/2" BOLT / ""

11/32"1.D.X7/8"O.D,

THICKNYLONWASHER

COMPRESSIONSPRING

CLAMPINGBAR ENDCAP

1!/32"LD.X7/B"O.D,

RETAINER THINNYLONWASHER

11/32"I.D.X 7/8"O.D.WASHER

NYLONSPRING RETAINER

(RETAINER ABUTSTHE

CLAMPINGBAR)

ASSEMBLYOFTHECAMHANDLESAND PIVOTSHAFTTOTHEDOVETAILBASE

Afterthecamhandlesandpivotshafthavebeenassembledto thebase,it willbepossibleto accuratelypositionthetemplatesfor close fittingjoints, Notethattherearesomegraduationsonbothtemplatesupports.

• Rotatingthe camhandlesothat thepointerlinesupwithoneofthegraduationspermitsaccuratefront-to-backpositioningofthe template.

• Camhandlesaredesignedto provideinfinitetemplateadjustment. Onegraduationequals1/64"of movementof thetemplate.

• Rotatingthe camhandlesothat thepointerlevermovestowardthefrontof thebase.causesthetemplateto alsomovetowardsthefront ofthe base.

• Converselyrotatingthecamhandlesothatthepointerlevermovestowardthebackofthe base,causesthetemplateto alsomove towardsthebackofthe basealso.

1) Assembleoneofthe camhandlestothepivotshaftusinga #10-32x 5/8"longpanheadmachinescrewanda 13/64"I.D.x9/16"LD.

washer,asshownin Figure9,

2) Usecareso thatthe pivotshaftfitsintothehex-shapedholein thecamhandle.Thepivotshaftmayfit tightlyintothe camhandle;

this isnormal.

3) Makesurethatthepivotshaftbottoms*outinsidethecamhandle.

Fig. 9

/ CAMHANDLE

13/64"t.D.X9/16°0.O,WASHER--_,,,,_ _ PIVOTSHAFT

4) Securelytightenthescrew, NOTE:THENEXTTWOSTEPSAREPRE-ASSEMBLYSTEPS.

5) Sgdetheretainerovertheendof thepivotshaftfor about2".Theretainermayfit tightly;thisis normal

6) Threadthe#1_`16x1/2"_ngpanheadtappingscrewint_theh_eintheretainerunti_itbott_ms-_tagain_tthepiv_tsha_.(Thescrew willfit tightlyinthehole.)SeeFigure10.

Fig. 10

_ #!0-16X 1/2"LONGPANHEADTAPPINGSCREW

7) Loosenthescrewaboutoneturn.Removetheretainerfromtheshaftandsetit asidetemporarily.

8) Assemblethepivotshaftwith camhandleto the basebyinsertingtheendofthepivotshaftthroughthe holestntherighttemplate

supportandthebase.

9) MAKESURETHEORIENTATIONOFTHECAMHANDLEISASSHOWNINFIGURE11.

10)PlacetheretaineratthelocationshowninFigure12endpushthepivotshaftthrough.THEORIENTATIONOFTHERETAINERRELAT]VE TOTHECAMHANDLEWITHSCREWMUSTBEASSHOWN.

NOTE:THERETAINERMAYFITTIGHTLYONTHEPIVOTSHAFT;THISISNORMAL.

Fig. 11

DOVETAILBASE

11)Continuepushingthepivotshaftthroughtheholesandtheretaineruntilthe endofthepivotshaftextendsout ofthelefttemplatesupport asshowin Figure12.

12)Makesuretheendof thecamhandlefits intothe holein thebaseasshown,

Fig. 12

PIVOT,

HOLEINBASE,

CAM

HANDLE _"

13)Withthecamhandlepushedin againstthebase,positionthe retaineragainstthesidewallofthebase,asshownin Figure13.Theretainer shouldbarelytouchthesidewall ofthe base.Thepurposeof the retaineristopreventor minimizetheside-to-sideofthecamhandleand

pivotshaft.

PtVOTSHAFT

SUPPORT

Fig. 13

RVOTSHAFT

-SIDEWALLOFBASE

14)Assembletheothercamhandleto theotherendofthepivotshaftusinga13/64"I,D.x 9/16"O.D,washeranda#10-32X 5/8"long penheadmachinescrew,asshownin Figure14.

15)Makesurethatthecamhandlelinesupwiththecamhandleattheotherendofthe pivotshaftandthattheendofthe camhandlefitsinto

theholein thebase.

16)Tightenthe screwsecurely, LEFTTEMPLATESUPPORT

Fig. 14

17)Rotateoneofthecamhandtes-ltshoutdrotatefreelyand movethetemplatesupports,

18)Ifthis doesnothappen,loosenthescrewontheretainerandmovetheretainerawayfrom thesidewallslightly,

19)Securelyretightenthescrew.

20)If thereistoomuchside-to-sidemovement(play)ofthecamhandles;loosenthescrewin theretainerandmovetheretainerc/osertothe

sidewaltof thebase.

21)Securelyretightenthescrew,

/_ #10-32X5/8"LONG

PANHEADMACHINE SCREW

_" DAMHANDLE

ASSEMBLYOFTHEFRONTSTOPBLOCKSTOTHEDOVETAILBASE

1) Aseemblethefrontstopblockstothefront of thedovetailbase,ateachend,using#10-32x 5/8"longflatheadmachinescrews,13/64_ I.D.x 9/16"O.D.washers,and#!0-32 hexnuts,asshownin Figure15.

2) Makesurethattheopenrib portionfits intothe slotin the frontof thebase.Thestopblockwglfit intothe slotin onepositiononly,

3) Tightenthescrewsecurelyontothenut.

4) Assembletheotherfrontstopblocktooppositeendo1the dovetagbaseinthesamemanner.

Fig. 15

SUPPORT

#10-32HEX

13/64_LD.X9/16°O.D/

WASHER J

FRONTSTOPBLOCI_

FORREASONSOFCLARITY,THEFRONT CLAMPINGBAR,KNOBS,BOLTSAND

SPRINGSARENOTSHOWN

DOVETAILBASE\

_ FRONTOFDOVETAtLBASE

5/8"LONGFLATHEAD

MACHINESCREW

SLOT_

WASHER

#10_32XB/8OLONG FLATHEADMACHINE

SCREW

ASSEMBLYOFTHETOPSTOPBLOCKSTOTHEDOVETAILBASE

• Thetopstopblocksareassembledtothetopof thedovetailbaseinoneoftwowaysdependinguponwhichstyleofdovetailjoint is

to becut:

a) HALF-BLINDFLUSHJOINTS--The"A" onthestopblockfacestowardthe "middleofthebase". b) HALF-BUNDRABBETJOINTS_The"B"onthestopblockfacestowardthe"middleofthe base". c) THROUGHJOINTS--The"A" onthestopblockfacestowardthe"middleofthebase".

• Sincetheflushjoint isthemorecommonlyusedjoint,thefollowinginstructionsapplytotheassemblyofthestopblocksforthis stylejoint.

1) Positionthedovetailfixturerightsideuponaflat surface.

2) Assembleoneofthetopstopblockstothetopsurfaceof thebaseusinga#10-32x 7/8"longflatheadmachinescrew,as shownin Figure16.Thescrewthreadsintotheholeinthe bottomofthesIot.

3) Makesurethatthe "A" facesthe "middleofthebase".

4) Makesuretheopenribportionofthestopblockfits intotheslot in thetop surfaceofthebase.

Fig. 16 RfBONSTOPBLOCK_

#10_32X 7/8_LONG \

MACHINESCREW

SLOTINTOP/

OFBASE

5) Assembletheremainingtopstopblocktotheoppositeendofthe baseinthesamemanner.

6) Againmakesurethatthe"A"facesthe"middleofthebase"

7) Tightenbothscrewssecurely.

8) Torepositionthestopblocksforrabbetjoints,simplyloosenthescrewsjustenoughsothatthe ribsonthestopblockscomeoutof the slot,Thestopblockisthenrotated180° to thealternateposition,sothe"B"facesthe middleofthebase,andsecurelyretightenthescrews.

MIDDLEOFTHEBASE

#t0-32X7/8"L'ONGFLAT HEADMACHINESCREW

TOPSTOPBLOCK

SLOTIN TOP OFBASE

ASSEMBLYOFTHECLAMPINGKNOBSTOTHEDOVETAILBASE

1) Assemb_e1_/32"_D.x 7/8"____was_ers_ntot_e_/1_-18b_itsat b_thends_ft_ed__etai__aseassh__nin Figure17_

2) Assembletheclampingknobsontothe boItsasshown.

3) Threadtheclampingknobsontotheboltsso thatthespacingbetweenthewasherandthetemplatesupportsisapproximately1/2".

4) Setthe dovetailbaseasideforthetimebeingandcontinueon withthenextsection.

ASSEMBLYOFTHETEMPLATES

/ 5/16-18X2"longROUND

Fig. 17 / HEADSQUARENECK

BOLT 5/t6-t8X2°tongROUND HEADSQUARENECKBOLT\

CLAMPING/ KNOB

!/2"SPACING8ETWEFNWASHERAND TEMPLATESUPPORT(BOTHENOS)

11/32"I.D.XT/8"

// O.D,WASHER

KNOB

•Placethetemplatestiffenerintotherectangularslotintheunderneathsideofthetemplate,asshowninFigure18. NOTE:THETEMPLATEFORCUTTINGHALF-BLINDJOINTSISBEINGUSEDASANILLUSTRATIONINTHEFOLLOWIHGFIGURES.

1) Threada #8-36x3/16"longpanheadmachinescrewthrougheachofthe fiveholesinthetemplateandintothethreadedholesinthe templatesupport,asshowninFigure24andsecurelytightenallofthescrews.

Fig. 18 _ TEMPLATESTIFFENER

\ _ _ _ J jRECTANGULARSLOT

TEMPLATE

_ _ MACHINESCREwSLOTTEDBINDINGHEAD_ _ MA#&3gX3!!6"t°ngPANHEADcHINESCREW

NOTE:ONSOMEEARLYVERSIONSOFTHISPRODUCT,ASLOTTEDBINDINGHEADMACHINESCREWHASBEENSUBSTITUTEDFORTHE PANHEADSCREWSPECIFIEDFORASSEMBLINGTHETEMPLATESUPPORTSTOTHETEMPLATES.(SEETHESCREWILLUSTRATIONIN FIGURE18),

2) Assemblethetemplatebracketstothetemplateusingfour#10-32x3/8°longpanheadmachinescrews_asshownin Figure19.

3) MAKESURETHATTHETEMPLATEBRACKETSAREASSEMBLEDTOTHEUNDERNEATHSIDEOFTHETEMPLATE,ASSHOWNIN FIGURE19,ANDTHATTHEAL]GNMENTOFTHEBRACKETSISALSOASSHOWNINTHEFIGURE.

4) ITIS NOTNECESSARYFORTHESCREWSTOBETIGHTENEDATTHISSTAGE;THETEMPLATEBRACKETSSHOULDBEFREETOMOVE WITHRESPECTTOTHETEMPLATEORELSEITWILLNOTBEPOSSIBLETOALIGNTHETEMPLATEASDESCRIBEDINTHENEXTSECTION.

5) TheassembledtemplateshouldlookliketheillustrationinFigure20.

Fig. 19

#10-32X3/8"tongPANHEADMACHINESCREW

TEMPLATE

_- TEMPLATEBRACKET....

6) AssemblethetemplatestiffenerandthetemplatebracketstotheTEMPLATEFORCUTTINGTHROUGHJOINTSusingthesamemethod describedintheprecedingsteps1through5,Referto Figure20.

Fig. 20

ALIGNMENTOFTHETEMPLATES

Inorderfor the DovetailFixturetofunctionproperly,it isnecessaryfor thetemplatesto bealignedwithrespectto dovetailbase.The reasonforthis, isthatdovetailcutsareatboth endsoftheDovetailFixture.Whenproperlyaligned,theresultbeingall matingcorners willalwaysbelinedup.

NOTE:THETEMPLATEFORCUTTINGHALF-BLINDJOINTSISBEINGUSEDASANILLUSTRATIONINTHEFOLLOWINGFIGURES,

1) Withthedovetailbasesti!lhavingthe1/2"spacingbetweenthewasherandthetemplatesupports(Referto Figure17),assemblethe templateassemblytothedovetailsothat: a) theslotin thetemplatebracketfitsoverthebolt, b) thelegofthe templatebracketis betweenthe washerandthetemplatesupport,and c) thelegsfit intotheslotsinthetemplatesupports,asshownin Figure21.

d) NOTE:THISPROCEDUREMUSTBEFOLLOWEDWHENEVERTHETEMPLATEISINSTALLEDONTHEDOVETAILFIXTURE.ITISMOST IMPORTANTTHATLEGOFTHETEMPLATEBRACKETALWAYSBEBETWEENTHEWASHERANDTHETEMPLATESUPPORTORELSETHE

TEMPLATEWILLNOTBEPROPERLYPOSITIONEDFORCUTTINGACCURATEDOVETAILS.Forinitialsetup,Allowthelegsofthetemplate bracketto "bottomout" intheslotsinthe tempiatesupportsasshownin Figure21.

Fig. 21

_ RtGHTTEMPLATESUPPORT

WASHER

BOLT_

j SLOTINTHETEMPLATESUPPORT

TEMPLATEBRACKET

SLOTIN THETEMPLATEBRACKET

TOREMOVETHETEMPLATEFROMTHEDOVETAILFIXTURE,LOOSENTHECLAMPINGKNOBSSOTHATSPACINGBETWEENTHE

TEMPLATEBRACKETANDTHEWASHERISABOUT1/2";GENTLYLiFTTHETEMPLATEUPWARDFROMTHEDOVETAILBASESOTHATTHE TEMPLATEBRACKETCLEARSTHESLOTSINTHETEMPLATESUPPORTANDSTOREINACONVENIENTLOCATION,

2) LightIytightentheclampingknobsatbothendsof thebasesothatthetemplatebracketsareheldin placeagainstthetemplatesupports asshowninFigure21.

3) Movethetemplatefrom sideto sideonthetemplatebracketsso thatitiscenteredwithrespecttothe templatebrackets,Thismeansthat thetemplateandbracketsshouldlookIikeoneofthefollowingfigures:Figure22,Figure23,or Figure24,Movetemplatefront-to-backsothat

front edgeoftemplateisparallelwith thefrontofthe dovetailbase.IneachconditionthetemplateandthetemplatebracketsMUSTbe symmetricalwith eachother.Thefiguresdonot showthecompletedovetailfixture,butonlytheunderneathsideofthetemplatewithtemplate

bracketscorrectlypositioned,in orderthatthecorrectpositionsofthe partscanbeseenclearly.

"_TEMPLATEBRACKET"BOTTOMS-OUT"AGAINSTTHIS

SURFACE(BOTHENDSOFDOVETAILBASE)

Fig. 22

TEMPLATE

_"DISTANCEBETWEENTHESESURFACES

MUSTBEEQUALATBOTHENDS

TEMPLATEBRACKET

CONDITIONONE."TEMPLATEBRACKETSPROTRUDEBEYONDTEMPLATES

Fig. 23

.24

j TEMPLATE

THESESURFACESMUST

BEEQUALATBOTHENDS

_0 0 TEMPLATEBRACKET

CONDITIONTWO;TEMPLATEPROTRUDESBEYONDTEMPLATESBRACKETS

MUSTBEEQUALATBOTHENDS

o 0

CONDITIONTHREE.TEMPLATEEVENWITHTEMPLATEBRACKETS

TEMPLATEBRACKET

4) Afterthetemplatebracketshavebeencorrectlypositionedonthetemplatesecurelytightenthefourscrewsholdingthetemptatebrackets

to thetemplate.

5) Removethetemplateassemblyfromthebaseandsetit asidefornow.

6) Aligntheothertemplateassemblyin thesamemanner, ITSHOULDBENOTEDTHATYOUMAYFIND,THATAFTERMAKINGSOMESAMPLECUTS,SLIGHTADJUSTMENTSMAYBEREQUIRED.

HOWTOMAKETHESEADJUSTMENTSIS EXPLAINEDINTWOOFTHEFOLLOWINGSECTIONS:"MAKINGADJUSTMENTSFORHALFBLIND JOINTS"or "MAKINGADJUSTMENTSFOROPEN(THROUGH)JOINTS".

7) Removethetemplateassemblyfromthebaseandsetit asidefornow.(Figure25 below,isanexampleofINCORRECTLYpositioned

templatebrackets,)

CKET

THETEMPLATEBRACKETEXTENDS

tEMPLATE

BEYONDTHETEMPLATE BRACKET

!o 0

CONDITIONFOUR:THISCONDITIONISNOTCORRECT--- TEMPLATEBRACKETEXTENDSBEYONDTHETEMPLATEAND THETEMPLATEEXTENDSBEYONDTHETEMPLATEBRACKET

• StMPLYMAKESUREBRACKETSAREPOSITIONEDTHESAMEATEACHEND

ASSEMBLYOFA GUIDEBUSHINGTOTHEROUTER

ALWAYSMAKESURETHATTHEROUTERIS"TURNEDOFF"ANDTHATTHEELECTRICALCORDHASBEENUNPLUGGED

FROMTHEELECTRICALOUTLETBEFOREASSEMBLINGAGUIDEBUSHINGTOTHEROUTERORMAKINGANYADJUSTMENTSOR

CHANGINGROUTERBITSINTHEROUTER.

REMOVEANYROUTERBITFROMTHEROUTERBEFOREPROCEEDINGWITHTHEASSEMBLYOFA GUIDEBUSHINGTOTHEROUTER.

Assembly for Sears routers with three hole baseplates:

1) Placethe'routerupsidedawnonaflat surfaceandremoveanyguidebushingthatmaycurrentlybeinthe router,

2) Placetheguidebushingrequiredforthetypeof dovetagjointto becutundertherouterbaseplateasshownin Figure26.

Fig. 26

10-32X3/8°LONGFLATHEAD

MACHINESCREW

NOTETHEORIENTATIONOF"

THEGUIDEBUSHING

(1/2"DIAMETERSHOWN)

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