Craftsman 17125455 Operating Instructions Manual

iNDUSTRiALDOVETAILJIG

IMPORTANT:. The fo!lowing router bits are required for use

with this jig-

• 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.

17125455

WARNING:

Beforeoperatingproduct,readthis
manualandfollow all its Safetyand
OperatingInstructions.

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
Assembly of
Assembly of
Assembly of
Assembly of

Assembly of

the Top Clamping Bar to the Dovetail Base .................................... 7

the Front Clamping Bar to the Dovetail Base ............................... 9

the Cam Handles and Pivot Shaft to the Dovetail Base ................ 10

the Front Stop Blocks to the Dovetail Base ................................ 13

the Top Stop Blocks to the Dovetail Base ........................................ 14

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

SAFETY GUIDELINES - DEFINITIONS

This manual contains informa-
tion that is important for you to

know and understand. This
information relates to protect-

ing YOUR SAFETY and

PREVENTING EQUIPMENT

PROBLEMS. To help you rec-
ognize this information, we use
the symbols to the righL

Please read the manual and
pay attention to these sections.

IADANGER I

URGENT SAFETYINFORMATION-A

HAZARDTHATWILLCAUSESERF
OtISINJURYORLOSSOFLIFE

I,AWARNINGI

IMPORTANTSAFETYINFORMA-
TION_A HAZARD THATMIGHT

CAUSESERIOUSINJURYORLOSS
OFLIFE

I CAUTION]

INFORMATIONFORPREVENTING

DAMAGETOEQUIPMENT

[ NoTE]

INFORMATIONTHATYOUSHOULD
PAYSPECIALAITENTIONTO

['_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
Read the owner's manual carefuify Learn its

application and limitations as welt as the specific potential
hazards peculiar to this tool

2. Ground all tools (unless double insulated)
If tool is equipped with an approved three-conductor cord

and a three-prong grounding type plug, it should be
plugged into a three hole electrical receptacle If adapter is
used to accommodate a two-hole receptacle, the adapter
wire must be attached
to a known ground (usually the screw securing

receptacle cover plate) Never remove third prong
Never connect green ground wire to a terminal

3. Keep guards in place
Maintain in working order, and in proper adjustment and

alignment

4. Remove adjusting keys and wrenches
Form a habit of checking to see that keys and adjusting

wrenches are removed from tool before turning it ON

5, Keep work area clean

Cluttered areas and benches invite accidents

Ftoor must not be slippery due to wax or sawdust

6. Avoid dangerous environment
Do not use power tools in damp or wet locations

or expose them to rain Keep work area well lighted

Provide adequate surrounding work space

7. Keep children away

All visitors should be kept a safe distance from work
area

8. Make workshop child-proof

Use padlocks, master switches, or remove starter keys

9. Do not force tools
Do not force tool or attachment to do a job it was
not designed to perform

10. Use the right tool

They wifl do the job better and safer at the rate
for which they were designed

11. Wear correct apparel
Do not wear loose clothing, gloves, neckties or

jewelry (rings, wristwatches) that may get caught

in moving parts Nomstip footwear is recommended Wear
protective hair covering to contain long hair Roll long
sleeves above the elbow

12. Use safety goggles (Head Protection)

Wear safety goggles (must comply with ANSI Standard

Z87 1) at all times A_so, use face or

dust mask, if cutting operation is dusty, and ear

protectors (plugs or muffs) during extended periods of

operation

13, Secure work
Use clamps or a vise to hold work when practical it's safer
than using your hands, and both hands
are free to operate tool

14. Do not overreach
Keep proper footing and balance at all times

15. Maintain tools with care
Keep tools sharp and clean for best and safest

performance Follow instructions for lubricating
and changing accessories

16. Disconnect tools before servicing
Before servicing, when changing accessories
such as blades, bits, cutters, etc

17. Avoid accidental starting
Make sure swilch is in OFF position before plugging in

18. Use recommended accessories

Consult the owner's manual for recommended accessories
and follow the instructions The use
of improper accessories may cause hazards

19, Never stand on tool

Serious injury could occur if the tool is tipped or ff the cut_

ring _oot is accidentally contacted DO NOT store materi-
als above or near the tool making it

necessary to stand on the toot to reach them

20. Check damaged parts

Before further use of the Iool, any guard or other

part that is damaged should be carefully checked to

ensure that it will operate properly and perform its

intended function Check for alignment of moving

parts, binding of moving parts, breakage of parts,

mounting, and any other conditions that may affect

its operation A guard or any other part that is

damaged should be properly repaired or replaced

21. Direction of feed

: Feed work into a blade or Cutter AGAINST the

direction of rotation of the blade or cutter only

22. Never leave tool running unattended
Turn power OFF DO NOT leave tool until it comes
to a comptele stop

23. Keep hands away from cutting area

24. Store idle tools
When not in use, tools should be stored in dry,

high or locked-up place - out of reach of children

25. Do not abuse cord
Keep cord away from heat, oil and sharp edges

26. Outdoor extension cords
When tool is used outdoors, use only extension

cords suitable for use outdoors and so marked

27. Never use in an explosive atmosphere
Normal sparking of the motor could ignite fumes,
flammable liquids, or combustible items

28. Drugs, alcohol, medication
DO NOT operate tool while under the influence
of drugs, alcohol, or any medication

Read and Understand this instruction book

completely BEFORE using this product

1 Always wear eye protection that complies with

ANSI Standard Z87 1
2 Noise levels vary widely To avoid possible hearing

damage, wear ear plugs or muffs when using the
Dovetail Jig for hours at a time
3 For dusty operations, wear a dust mask along
with safety goggles
4 Do not use this Dovetail Jig with router bits or
guide bushings other than those specified for the
cuts being made
5 Follow the instructions in your Router Owner's
Manual
6 Vibrations caused by the router during use can

cause fasteners to become loose Before use and
periodically during use, check all fasteners to make
sure thatthey are all are tight and secure
7 Do net use this product until all assembly installa-
tion steps have been completed, and you have read
and understand all safeb/and operational instruc-
tions in this manual, and the Router Owners Manual
8 Make sure that the router bit is properly positioned
in the router so that it does not contact the guide
bushing or the template when cutting
9 The Dovetail Jig must be securely mounted to a

workbench or other stable surface when in use The
front of the base should overhang the front ofthe

workbench by no more than 1/4" to provide clear-
ance when clamping workpieces to the Dovetail Jig
10 Do not use the Dovetail Jig as a work surface
Doing so may cause damage to the Dovetail Jig,
which can cause it to be unsafe to use Aworkbench
should be used for this purpose
11 This product is designed to cut fiat workpieces
Do not cut or attempt to cut workpieces that are
not flat or that are irregularly shaped.
12 This product is to be used for cutting wood work-
pieces only Do not use this product to cut metal
or any other non-wood material.
13 This product has been designed to cut work-
pieces having thicknesses of 3/8" to 1" Do not use
Ior workpieces of any other thicknesses
14 Do not clamp any workpieces to the Dovetail Jig
or make any adjustments to the Dovetail Jig unless
the router has been turned off, the router bit is not
turning, and the Router has been disconnected from
the electrical outlet
15 When setting "the-depth-of-cut" of the router
bit, make sure that the workpiece is clamped to the
Dovetail Jig in such a manner that the router bit
does not cut into the Dovetail base causing dam-
age to it or possible serious injury to you.

16 L'_WARNING_ ALWAYS UNPLUG THE

ROUTER FROM THE ELECTRICAL OUTLET
BEFORE INSTALLING OR REMOVING ROUTER
BITS FROM THE ROUTER AND WHEN ADJUST-

ING THE CUTTING DEPTH OF THE ROUTER BIT;
OR WHEN INSTALLING OR CHANGING GUIDE
BUSHINGS.

17 NEVER LIFT THE ROUTER UPWARDS WHEN

THE ROUTER IS "ON", THE ROUTER BtT IS

ROTATING, AND THE GUIDE BUSHING IS NEAR

OR TOUCHING THE TEMPLATE, BECAUSE THIS
WILL CAUSE THE ROUTER BIT TO CUT INTO
THE TEMPLATE AND DAMAGE IT

• Your Vermont American Industrial Dovetail Jig is an
accessory that is used with Routers allowing you to
make drawers, chests, and similar items requiring
dovetail joints The joints are used to make the front,
back, and sides of the workpiece

• Your Industrial Dovetail Jig comes with two tem-
plates and two guide bushings for making halt-blind
and through or open joints

• Your Industrial Dovetail Jig also comes with a
universal router adapter plate that will permit the

Industrial Dovetail Jig to be used with most popular

routers

• The Dovetail Jig will allow you to make 1"spaced
flush, flush-offset, and 3/8" rabbeted half-blind
dovetail joints

• The Dovetail Jig will also allow you to make t"
spaced open, or through, dovetail joints

• Workpieces up to 16"wide can be accommodated
oWorkpieces with thicknesses between 3f8" and 1"
can be accommodated

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

• Vermont American router bits, #22501 and #22437,
or Magna router bits, #M91113 and #M91016,
WHICH MUST BE PURCHASED SEPARATELY, are
required for making the THROUGH or OPEN joints

• Vermont American router bit, #22500, or
Magna router bit, #M91114, WHICH MUST BE
PURCHASED SEPARATELY, is required for making
the HALF-BLIND ioints

• Your Vermont American Industrial Dovetail Jig
comes with two templates and two guide bushings
Each of the templates has a label, describing the
joint that can be cut with it, along with set-up
information, the router bit and the guide bushing
required, and the the stop block setting for a
particular joint

Refer to Parts List on Page 47

• tn order to simplify handling and to minimize any
damage that may occur during shipping, your

Industrial Dovetail Jig is packaged assembled

• Separate all loose parts from the packing materials
and check each one with the illustrations and list of

parts at the end of this manual to make sure that
all loose parts are present before discarding any
packaging material

.i,A ,,anypartsarem,ss,ngorcannot

be accounted for, do not attempt to assemble, instaIl,
or use the Industrial Dovetail Jig until the missing
parts have been obtained and the product has been
assembled correctly

• Contact customer service at 1-800-742-3869,ext 8359
for missing or replacement parts

ALTHOUGHYOURINDUSTRIALDOVETAILJIG
COMESASSEMBLED,THEFOLLOWINGASSEM-

BLY INSTRUCTIONS ARE BEING INCLUDED FOR
REFERENCE PURPOSES SHOULD IT BECOME
NECESSARY FOR YOU TO DISASSEMBLE AND
REASSEMBLE THE DOVETAIL JIG

PROCEED TO THE SECTION ALIGNMENT OF
THE TEMPLATES AND THEN CONTINUE WITH
THE SECTIONS FOLLOWING ALIGNMENT OF
THE TEMPLATES
THE TEMPLATES MUST BE ALIGNED BEFORE
ANY ROUTING tS TO TAKE PLACE

TOOLS REQUIRED

- A medium sized Phillips screwdSver
° A smafl or medium adjustable wrench

ASSEMBLY OF THE RIGHT SIDE TEMPLATE
SUPPORT TO THE DOVETAIL BASE
1 Ptace the dovetail base topside down on a fiat surface
2 insert one of the 5/16-18 x 2" long round head square

FIGURE 1

neck botts into the slot in the right side of the base
(NOTE: The right side of the base is identified by the
words RIGHT SIDE molded into it )
3 Place a 11/32" t D, x 7/8" OD washer onto the bolt as
shown in Figure 1
4 Thread a 5/16-18 hex nut onto the bolt, as shown, until
it bottoms out against the washer
5 Back off the nut from the washer between 1/4 and 1/2

10_32X 5/8" LONG PANHEAD

MACHINE SCREW

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

!UrpSAlignthenutsothatthecomersofthenu_areverti-
calfyline_JUpasshownNotethealignmentofthehex

pocketinlhetemplatesupportTheboltshouldbefreeto
movesidetoside;ifitdoesnot,loosenthenut1/3turnor
untilthecornersofthenutpointupanddown

6 Assembletherighttemplatesupporttotherightsideof

the dovetail base so that the hex nut lines up and lits into
the hex pocket in the right template support (NOTE: The

right template support has the words RIGHT SIDE molded
into it for identification )
7 Assemble a #t0-32 x 5/8" long panhead machine screw,

a 13/64" I D x 9/16" O D washer, and a #10-32 hex nut to

lhe base as shown to hold the template support in place
Securely tighten thenut and screw : : •
8 The template support should move freely front to back
along the side of the base If it does not, it means that the
5/16-18 hex nut is too tight on the bolt and should be loos-
ened To do this, remove the fasteners assembled in step
7, and remove the template support; repeat steps 4
through 7

ASSEMBLE THE LEFT SIDE TEMPLATE SUPPORT TO
THE DOVETAIL BASE THE SAME AS THE RIGHT SIDE
TEMPLATE SUPPORT WAS ASSEMBLED.

ASSEMBLY OF THE TOP CLAMPING BAR TO
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

the back of the base rests on the surface

[ NOTE ] ALTHOUGH BOTH ENDS OF THE

DOVETAIL BASE ARE SHOWN ASSEMBLED IN THE

FOLLOWING FIGURES, THE ACTUAL ASSEMBLY IS

DONE ONE END AT A TIMEo
5 From the bottom of the base, insert a bolt with bolt sup-

port through the slot in the top of the base so the raised
portion of the bolt support goes into the slot, as shown in

Figure 4

FIGURE 2

FIGURE 3A FIGURE 3B

(_ NYLON

SPRING

RETAINER

COMPRESSION /'J_f

SPRING

SPRING TO
BOTTOM
OUT
AGAINST
SURFACE

FIGURE 4

BOLT 11/

SLOT IN
DOVETAIL BASE DOVETAIL BASE

/ /

SLOT IN
DOVETAIL
BASE k

q

X

\

BOLT AND BOLT
SUPPORT

/

/

FRONT OF DOVETAIL BASE

6 Placean11/32"IDX7/8"ODwasherandthena

5/16"ID X7/8"OD thicknylonwasherovertheboltIt

willbenecessarytoholdtheboilinplacewhenperforming

thisandthefollowingsteps
HELPFULHINTS:Positiontheboltandtheboltsupport
underthenotchintheribasshowninFigure5,tohelp
holdtheboltinplace

7 Placeaspringoverthebolt,asshowninFigure6

8 Placea5/16"IDX7/8"QD thicknylonwasherand
thenan!1/32"ID X7/8"OD washerovertheboiland

pressdownonthespringuntiljusttheendofthebolt
sticksoutpasttheendofthewasher
g Slidetheclampingbaroverthebollsothatthewashers
aresandwichedbetweenthespringandtheinsideofthe

clampingbarasshowninFigure6 NOTE:THESPRING

MUSTPUSHAGAINSTTHETHICKNYLONWASHERS

ANDNOTAGAINSTTHESTEELWASHERS

t0 Placean11/32"tD X7/8"OD thinnylonwasherand

an11/32"ID X7/8"ODwasheroverthebellItwilibe

necessaryforyoutopressdownontheclampingbarwhile

doingthis

11Takeoneoftheclampingknobsandthreaditontothe
boilasshownDONOTTHREADtheknobcompletely
ontothebolt--justenoughsotheknobhoidstheclamping
barinplace

t2 Repeatabovesteps4through10fortheotherendof
theclampingbar

13Assembletheendcapstotheendsoftheclampingbar
bypressingthemin;theyaredesignedtobe"force-fit"into

FIGURE5

j NOTCH

IN RIB

._---- SLOT IN

DOVETAIL
BASE

BOLT AND
BOLT
SUPPORT

the bar in one way only It may be necessary to "tap" them
in by gently hitting them with a rubber mallet or a piece of
wood--since they fit very tlgh|ty into the clamping bar

USE CARE WHEN DOING THIS SO AS NOT TO DAM-

AGE THE END CAPS

USE CARE THAT THE CAPS ARE PROPERLY ALIGNED

AS SHOWN WHEN ASSEMBLING THEM TO THE BAR,,

14. Tighten the clamping knobs onto the bolts so that the
space between the bottom of the clamping bar should be
parallel to the top of the base

15 After completing the above steps your Dovetail Jig
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

\

" !t/32" I.D X 7/8" O D.

CLAMPING BAR DETAIL

SPRING AND
NYLON SPRING
RETAINER FIT
]NSlDE THE
OPEN SIDE OF
THE CLAMPING
BAR
(SEE CLAMPING
BAR DETAIL)

COMPRESSION
SPRING

3 t12"

j/*

BOLT
SUPPORT

// l

//Z-

TOP SURFACE OF
THE DOVETAIL

CLAMPING BAR

•CLAMPING BAR

f_END CAP
L_.! ) OPEN SIDE OF

_-_\/ THE CLAMPING BAR

POINTS TOWARD

"_ THE TOP SURFACE

OF THE DOVETAIL

i BASE

€/1t132" I.D.

_, /X 7/8" O D

/THICK

-_ NYLON
__._WASHER

RIGHT
TEMPLATE
SUPPORT

NYLON SPRING
RETAINER
(RETAINER ABUTS THE

11/32" I,D X 7/8" CLAMPING BAR

O D WASHER __

WASHER .--[ _,

CLAMP,NG AB S.OWNW,THI

END CUT AWAY AND SECTIONED

SO NYLON SPRING RETAINER

PLACEMENT CAN BE SEEN)

COMPRESSION
SPRING

FIGURE7

CLAMPINGBARPARALLELTO
TOPOFBASE

0 0 0

SPACING TO BE

// APPROXIMATELY

t-112"

ASSEMBLY OF THE FRONT CLAMPING BAR TO
THE DOVETAIL BASE

t Assemble the front clamping bar !o the front of the dove-
tail base following the same procedure used Io assemble
the top clamping bar to the dovetail base as shown in

Figure 8 The 5/16-18 X 4-1/2" long round head square
neck bolts are used

FIGURE 8

DOVETAIL

BOLT SUPPORT j7

CLAMPING BAR f

NYLON SPRING /'t"
RETAINER

CLAMPING BAR
(SHOWN WITH END

CUT AWAY AND
SECTIONED SO
NYLON SPRING
RETAINER PLACE r
MENT CAN BE ,.
SEEN) "\,

\.

COMPRESSION

SPRING "__

1/2" BOLT

!1/32' I.D. X 7/8' O.D.

THICK NYLON WASHER

COMPRESSION SPRING

• CLAMPING BAR
END CAP

11132"I,D X 7/8" 0 D.

THIN NYLON WASHER

tt/32" I D X 7/8" O D

\\

\

NYLON
SPRING
RETAINER
(RETAINER
ABUTS THE
CLAMPING

BAR)

CLAMPING KNOB

ASSEMBLYOFTHECAMHANDLESANDPIVOT

SHAFTTOTHEDOVETAILBASE

• After the cam handles and pivot shaft have been assem _
bled to the base, it wil! be possible to accurately position
the templates for close fitting joints

• Note that there are some graduations on both template
supports

• Rotating the cam handle so that the pointer lines up with
one of the graduations permits accurate front-to-back posi-
tioning of the template

• Cam handles are designed to provide infinite template
adjustment

• One graduation equals 1/64" of movement of the tem-
plate

• Rotating the cam handle so that the lever moves toward
the front of the base, causes the template to also move
towards the lront of the base

• Conversely rotating the cam handle so that the lever
moves toward the back of the base, causes the template
to also move Iowards the back of the base also

1 Assemble one of the cam handles to the pivot shaft
using a #10-32 x 5/8" tong panhead machine screw and a
13/64" I D x 9/16" ID washer as shown in Figure 9
2 Use care so that the pivot shaft fits into the hex-shaped
hole in the cam handle The pivot shaft may fit tightly into
the cam handle; this is normal
3 Make sure that the pivot shaft bottoms-out inside the
cam handie
4 Securely tighten the screw
NOTE: THE NEXT TWO STEPS ARE PRE-ASSEMBLY
STEPS.
5 Slide the retainer over the end of the pivot shaft for
about 2" The retainer may fit tightly; this is normal
6 Thread the #10-16 x 1/2" long panhead tapping screw
into the hole in the retainer until it bottoms-out against the
pivot shaft (The screw will fit tightly in the hole ) See
Figure 10

FIGURE 9

13/64"1D X 9/16_'O D WASHER _\

\

#10_32.X5/8" LONG /
PANHEAD MACHINE SCREW

/ CAM HANDLE

/ _ PIVOT SHAFT

J j

<--LT-,:

FIGURE 10

#10-16 X 1/2" LONG PANHEAD TAPPING SCREW

_ RETAINER

/

x\__ PIVOT SHAFT

10

7 LoosenthescrewaboutoneturnRemovetheretainer
fromtheshaftandsetitasidetemporarily

8Assernblethepivotshaftwithcamhandletothebaseby
insertingtheendofthepivotshaftthroughtheholesinthe
righttemplatesupportandthebase
9 MAKESURETHEORIENTATIONOF THE CAM HAN-

DLE IS AS SHOWN IN FIGURE 11

10 Place the retainer at the location shown in Figure 12

and push the pivot shaft through THE ORIENTATION OF

FIGURE 11

CAM HANDLE

PIVOT SHAFT ._

HOLE IN BASE

THE RETAINER RELATIVE TO THE CAM HANDLE WITH
SCREW MUST BE AS SHOWN
NOTE: THE RETAINER MAY FIT TIGHTLY ON THE
PIVOT SHAFT; THIS IS NORMAL,,

11 Continue pushing the pivot shaft through the holes and
the retainer until the end of the pivot shaft extends out of
the teft template support as show in Figure 12

12 Make sure the end of the cam handle fits into the hole
in the base as shown

// RETAINER

RIGHT TEMPLATE

DOVETAIL BASE /

RGURE 12

CAM
HANDLE

HOLE IN BASE

PIVOT SHAFT

i,vo

• ._ ........ HOLE tN

BASE

iA ............../LJJ

11

13Withthecamhandlepushedinagainstthebase,
positiontheretaineragains!thesidewallofthebase,as
showninFigure13Theretainershouldbarelytouchthe
sidewallofthebaseThepurposeoftheretaineristo
preventorminimizetheside-to-sideofthecamhandleand
pivotshaft

14Assembletheothercamhandletotheotherendofthe
pivotshaftusinga13/64"1Dx9/16"ODwasherand
a#10-32X5/8"longpanheadmachinescrew,asshownin
Figure14

15Makesurethatthecamhandlelinesupwiththecam
handleattheotherendofthepivotshaftandthattheend

of the cam handle fits into the hole in the base

16 Tighten the screw securely
17 Rotate one of the cam handles-It should rotate freely

and move the template supports

18 If this does not happen, loosen the screw on the retain-

er and move the retainer away from the side wall slightly

19 Securely retighten the screw

20 If there is too much side-to-side movement (play) of
the cam handles; loosen the screw in the retainer and
move the retainer closer to the side wall of the base

21 Securely retighten the screw

FIGURE 13

_LOF 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

ASSEMBLY OF THE FRONT STOP BLOCKS TO
THE DOVETAIL BASE

1 Assemble the front stop blocks to the front of the dove-
tail base, at each end, using #10-32 x 5/8" long flathead
machine screws, 13/64" I D x 9/16" O D washers, and
#!0-32 hex nuts, as shown in Figure 15
2 Make sure that the open rib portion fits into the slot in

the front of the base The stop block will fit into the slot in
one position only
3 Tighten the screw securely onto the nut
4 Assemble the other front stop block to opposite end of

the dovetail base in the same manner

FIGURE 15

FOR REASONS OF CLARITY, THE FRONT

CLAMPING BAR, KNOBS, BOLTS AND
SPRINGS ARE NOT SHOWN

DOVETAIL BASE

RIGHT _

TEMPLATE ../.,.._ \'_ 7

SUPPORT _____/_\ _ "_

\\

OD WASHER V /i,'_&.

FRONT STOP BLOCK /

,,o 32HExNUT

/L%;f PLATE

_T_// FRONT STOP BLOCK

" #10-32 X 5/8" LONG

FLATHEAD MACHINE

SCREW

FRONT OF DOVETAIL BASE

#t0-,32 X 5/8" LONG FLATHEAD
MACHINE SCREW

t3

ASSEMBLY OF THE TOP STOP BLOCKS TO THE
DOVETAIL BASE

• The top stop blocks are assembled to the top of the
dovetail base in one of two ways depending upon which
style of dovetail joint is to be cut:

a HALF-BLIND FLUSH JOINTS--The "A" on the stop

block faces toward the "middle of the base"
b HALF-BLIND RABBET JOiNTS--The "B" on the

stop block faces toward the "middle of the base"

c THROUGH JOINTS---The "A" on the stop block
faces toward the "middle of the base"

, Since the flush joint is the more commonly used joint, the

following instructions apply to the assembly of the stop

blocks for this style joint

1 Position the dovetait Jig right side up on a flat surface
2 Assemble one of the top stop blocks to the top surface
of the base using a #10-32 x 7/8" long flathead machine

screw, as shown in Figure t6 The screw threads into the
hole in the bottom of the slot

3 Make sure that the "A" faces the "middte of the base"
4 Make sure the open rib portion of the stop block fits into

the slot in the top surface of the base
5 Assemble the remaining top stop block to the opposite

end of the base in the same manner
6 Again make sure that the "A" faces the "middle of the

base"
7 Tighten both screws securely
8 To reposition the stop blocks for rabbet joints, simpty

loosen the screws just enough so that the dbs on the stop
blocks come out of the slot The stop block is then rotated
180 ° to the attemate position, so the "B" faces the middle
of the base, and securefy retighten the screws

FIGURE 16

#10-32 X 7/8" LONG FLAT HEAD \

MACHINE SCREW

\

TOP STOP BLOCK

RIB ON STOP BLOCK ,

\\

#10-32 X 7/8" LONG FLAT

MACHINE SCREW

RIB ON STOP BLOCK

/'

SLOT IN TOP //
OF BASE

SLOT IN TOP
OF BASE

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-

18 bolts at both ends of the dovetail base as shown in
Figure 17.
2 Assemble the clamping knobs onto the bolts as shown

FIGURE 17

5/16-18 X 2" LONG ROUND

HEAD SQUARE NECK BOLT

1t132" I D X 7/8"
OD

3 Thread the clamping knobs onto the bolts so that the

spacing between the washer and the template supports is
approximately 1/2"
4 Set the dovetail base aside for the time being and con-
tinue on with the next section

5/16-18 X 2" LONG ROUND
HEAD SQUARE NECK BOLT

/ CLAMPING

// KNOB

CLAMPING /
KNOB

14

\

1/2" SPACING BETWEEN

WASHER AND TEMPLATE

SUPPORT (BOTH ENDS)

ASSEMBLY OF THE TEMPLATES

• Ptace the template stiffener into the rectangular slot in the

underneath side of the template, as shown in Figure 16
NOTE: THE TEMPLATE FOR cUTTING HALF-BLIND

JOINTS 1S BEING USED AS AN ILLUSTRATION IN THE

FOLLOWING FIGURES.

1 Thread a #8-36 x 3/16" long panhead machine screw
through each of the five holes in the template and into the
threaded holes in the template support, as shown in

Figure 18 and securely tighten all of the screws

NOTE: ON SOME EARLY VERSIONS OF TH1S PROD-

UCT, A SLOTTED BINDING HEAD MACHINE SCREW

HAS BEEN SUBSTITUTED FOR THE PANHEAD SCREW
SPECIFIED FOR ASSEMBLING THE TEMPLATE SUP-

PORTS TO THE TEMPLATES (SEE THE SCREW ILLUS-
TRATION IN FIGURE 18 )
2 Assemble the template brackets to the template using
four #10-32 x 3/8" long panhead machine screws, as
shown in Figure t9

3 MAKE SURE THAT THE TEMPLATE BRACKETS ARE
ASSEMBLED TO THE UNDERNEATH SIDE OF THE

TEMPLATE, AS SHOWN IN FIGURE lg, AND THAT THE
ALIGNMENT OF THE BRACKETS iS ALSO AS SHOWN

IN THE FIGURE

4., IT IS NOT NECESSARY FOR THE SCREWS TO BE
TIGHTENED AT THIS STAGE; THE TEMPLATE BRACK-

ETS SHOULD BE FREE TO MOVE WITH RESPECT TO
THE TEMPLATE OR ELSE IT WILL NOT BE POSSIBLE
TO ALIGN THE TEMPLATE AS DESCRIBED iN THE

NEXT SECTION
5 The assembled template should took like the illustration
in Figure 20
6 Assemble the template stiffener and the template brack-

ets to the TEMPLATE FOR CUTTING THROUGH JOINTS
using the same method described in the preceding steps 1

through 5 Refer to Figure 20

FIGURE 18

\ \ \

!_' _ TEMPLATE STIFFENER

RECTANGULAR SLOT

TEMPLATE

\ \ \

SLOTTED BINDING HEAD
MACHINE SCREW

_--- #8-36 X 3/t6" LONG

\ PANHEAD MACHINE

SCREW

\

\ '\

\

/TEMPLATE BRACKET "_--,o

TEMPLATE

FIGURE 20

15

ALIGNMENTOFTHETEMPLATES

• In order for the Dovetail Jig to function properly, it is
necessary' for the templates to be aligned with respect to

dovetail base The reason for this, is that dovetail cuts are
at both ends of the Dovetail Jig When properly aligned,

the result being all mating comers wi}l always be lined up

• NOTE: THE TEMPLATE FOR CUTTING HALF-BLIND
JOINTS IS BEING USED AS AN ILLUSTRATION IN THE

FOLLOWING FIGURES°

t= With the dovetail base stiB having the 1/2" spacing
between the washer and the template supports (Refer to
Figure 17), assemble the template assembly to the dove-

tail base so that:

a) the slot in the template bracket fits over the bo_t
b) the leg of the template bracket is between the washer
and the template support, and
c) the legs fit into the slots in the template supports, as
shown in Figure 21
d) NOTE: THIS PROCEDURE MUST BE FOLLOWED

WHENEVER THE TEMPLATE iS INSTALLED ON THE
DOVETAIL JIG IT IS MOST IMPORTANT THAT LEG
OF THE TEMPLATE BRACKET ALWAYS BE

BETWEEN THE WASHER AND THE TEMPLATE SUP-
PORT OR ELSE THE TEMPLATE WILL NOT BE
PROPERLY POSITIONED FOR CUTTING ACCURATE
DOVETAILS,

For initia! setup, Allow the legs of the template bracket to
"bottom out" in the slots in the template supports as
shown in Figure 21

• TO REMOVE THE TEMPLATE FROM THE DOVETAIL
JIG, LOOSEN THE CLAMPING KNOBS SO THAT SPAC-
ING BETWEEN THE TEMPLATE BRACKET AND THE
WASHER IS ABOUT 1/2"; GENTLY LIFTTHE TEMPLATE
UPWARD FROM THE DOVETAIL BASE SO THAT THE
TEMPLATE BRACKET CLEARS THE SLOTS IN THE
TEMPLATE SUPPORT AND STORE IN A CONVENIENT
LOCATION
2 Lightly tighten the clamping knobs at both ends of the
base so that the template brackets are he]d in place
against the template supports as shown in Figure 21
3 Move the template from side to side on the templale
brackets so Ihat it is centered with respect to the template
brackets This means that the template and brackets
should took like one of the following figures: Figure 22,
Figure 23 or Figure 24 Move template front-to-back so
that front edge of template is parallel with the front of the
dovetail base In each condition the template and the tem-
plate brackets MUST be symmetrical with each other The
figures do not show the complete Dovetail Jig, but only the
underneath side of the tempJate with template brackets
correctly positioned, in order that the correct positions of

FIGURE 21

jj RtGHTTEMPLATE SUPPORT

BOLT

/ SLOT tN THE TEMPLATE SUPPORT

TEMPLATE BRACKET

SLOT

L

TEMPLATE BRACKET "BOTTOMS-OUT" AGAINST
THIS SURFACE (BOTH ENDS OF DOVETAIL BASE)

16