Please read this Owner's Manual before
use and keep it at hand for reference.
In the few years
since its first appearance
in woodworking shops
around the globe, INCRA JIG
has quickly established itself as the
finest and most versatile woodworking
system available. At the top of its list of
features has always been its unparalleled
positioning accuracy. As a fence system, INCRA
JIG’s amazing precision allowed precise fence
placement to within a few thousandths of an inch. As a
joint making machine, these same positioning capabilities
permitted an endless variety of box joints, half blind and through
dovetails to be created. And with decorative joints like the exquisite
INCRA Double Dovetail, INCRA JIG made the impossible quite
possible.
Your new INCRA JIG ULTRA represents the next generation in the evolution
of this remarkable tool, combining all of the considerable attributes of its
forerunners, the Original INCRA JIG and the INCRA JIG PRO, with many exciting new
features like integral micro adjusting, velvet smooth tracking and superior strength.
INCRA JIG ULTRA is the ultimate in convenience and function for today’s woodworker.
INCRA JIG ULTRA
(shown with available
INCRA PRO Fence)
Note: If you have purchased
the ULTRA-TS Tablesaw Fence
System it is only necessary to
read pages 2, 3, 6 and 7 of this
Owner's Manual.
CONTENTS
Safety . . . . . . . . . . . . . . . . . . 2
Be sure to read and follow these
important safety instructions before using
the INCRA JIG ULTRA.
System Description . . . 3
A brief description of the various features
and components. If you are already
familiar with how to use an INCRA JIG,
this section may be all you'll need to get
your INCRA JIG ULTRA up and running.
Set Up . . . . . . . . . . . . . . . . . . 4
Covers attaching a plywood base and the
INCRA Fence to the INCRA JIG ULTRA.
Operation . . . . . . . . . . . . . . 6
Describes how to use the carriage clamp
and micro adjusting feature.
Applications . . . . . . . . . . 8
Shows how to set up and gives ideas for
using INCRA JIG ULTRA on various
stationary tools.
Router Table . . . . . . . . . . . . . . . . .8
Zeroing . . . . . . . . . . . . . . . . . . . .8
Centering . . . . . . . . . . . . . . . . . .9
Table Saw . . . . . . . . . . . . . . . . . .10
Zeroing . . . . . . . . . . . . . . . . . . .10
Drill Press . . . . . . . . . . . . . . . . . .11
Joint Making . . . . . . . . . 12
A step-by-step approach to making box
joints and half blind dovetails
Box Joints . . . . . . . . . . . . . . . . . .12
Half Blind Dovetails . . . . . . . . . . .13
Trouble Shooting . . . . . 16
We don't think you'll ever have to look at
this section, but if you do, you'll find a
quick answer to your question.
Adjustments . . . . . . . . . . 18
Instructions for customizing and fine
tuning the ULTRA to suit your individual
preferences.
Warranty . . . . . . . . . . . . . 20
Spare Parts . . . . . . . . . . . 20
INCRA JIG ULTRA
SAFETY
Important safety instructions for using the INCRA JIG ULTRA.
Before using the INCRA JIG ULTRA, read and follow all of the
instructions and safety information in this manual.
When using INCRA JIG ULTRA in conjunction with any
other tool, first read and follow all instructions and safety
information in that tool’s owner’s manual.
When INCRA JIG ULTRA is mounted to a wooden base or
table surface, make sure that all six mounting screws are
securely tightened and the INCRA JIG ULTRA is firmly held
in place.
When using the INCRA JIG ULTRA with a wooden base,
always be sure that the base is securely clamped, screwed
or otherwise fastened to the work surface before making
a cut.
Always turn off the power and make sure that the bit or
blade is fully stationary before moving the INCRA JIG
ULTRA to any new setting.
Always keep both hands behind the fence when moving
INCRA JIG ULTRA to a new setting.
Before making a cut, always make sure that the carriage
clamp is fully engaged and the jig is securely locked in place.
When using INCRA JIG ULTRA with other tools, make sure
that all safety guards and other safety equipment supplied by
the manufacturer of that tool are securely in place and
functional. Never let INCRA JIG ULTRA interfere with
another tool’s safety equipment.
Use appropriate safety devices. Keep hands clear of the bit
or blade. Always use a push stick, rubber soled push block,
or other safety device to keep your hands safely away from
the cutting tool.
Wear safety glasses, hearing protection and follow all normal
shop safety practices.
DO NOT alter or modify the INCRA JIG ULTRA in an attempt
to use it with non-INCRA accessories.
The INCRA JIG ULTRA is designed to be used with genuine
INCRA Fence Systems only. DO NOT attempt to use the
ULTRA with other non-INCRA fence systems as this may
present a safety hazard.
2
SYSTEM DESCRIPTION
Positioning Control
1
INCRA JIG ULTRA obtains its great accuracy and
repeatability from the precision cast saw-toothed
positioning racks which position the jig in exact
increments of 1/32". Standard 1/32" (blue) racks are
supplied with each INCRA JIG ULTRA. Metric (green)
racks with a tooth spacing of one millimeter and a metric
scale are available as an option. (See order information
at the back of this manual.)
2
Carriage
The reinforced square tube design of the carriage
provides the ultimate in strength and support for your
fence. The carriage rides on self-lubricating UHMW
guide bearing surfaces in the base to provide a velvet
smooth glide to your next INCRA JIG ULTRA setting.
Primary Sliding Scale
3
After setting up your INCRA JIG ULTRA, and “zeroing”
(see pages 8 and 10) to the bit or blade, slide this scale
to read 0" under the hairline cursor. Use this scale as
the primary source for readout of fence to bit or blade
distance.
Auxiliary Scale Slots
4
Four auxiliary scale slots are provided to allow additional
setups and cutting operations to take place without
altering the primary scale position. Simply slide the
supplied
reference. These extra slots are great for advanced
joinery requiring the use of the INCRA templates. You
can even leave your most frequently used joinery
templates from the optional
Guide & Template Library
Fence Mounting Bracket
5
This bracket provides a quick and easy means to attach
the INCRA Pro Fence System.
1
/32" “floating” scale into position as needed for
INCRA Master Reference
permanently installed.
Micro Adjust Lever
9
After pushing the carriage clamp down to the “unlocked”
position, push the micro adjust lever down to place the
INCRA JIG ULTRA into the “micro adjust mode”. After
micro adjusting your fence position, simply reset the
micro adjust lever and then pull the carriage clamp up
into the “locked” position before making your next cut.
10
Micro Adjusting Knob
When in the “micro adjust mode”, use this knob to finetune the position of your fence in one thousandth of an
inch increments. A hair line cursor and easy-to-read
scale give a clear readout of your fence movement.
Turning the knob clockwise moves the fence closer to
the bit or blade. Turn it counterclockwise and the fence
moves away from the cutter. Each full turn of the knob
moves the fence 1/32". Micro adjust range is plus or
minus 1/4", for a full 1/2" of vernier travel.
Micro Adjust Scale With Zeroing
11
Feature
Large easy-to-read numbers make fine-tuning your fence
position a snap, and once you’ve micro adjusted and
pulled the carriage clamp up into the “locked” position,
you can re-zero the scale if you desire. Just rotate the
scale (not the knob) gently with your fingers to return the
zero on the scale to its original position under the cursor.
12
Micro Adjust Range Scale
Your INCRA JIG ULTRA has a micro adjustment range of
plus or minus 1/4". By sighting through this scale to the
left end of the micro adjusting knob, this feature tells you
how far you have micro adjusted away from the midrange (0") position and which way you’ve gone. The
scale is marked off in 1/32" increments.
Base
6
Screw the base to a user-supplied piece of 3/4" plywood
and clamp to the stationary tool of your choice. The base
provides strong support for the carriage and is the control
center for most of the INCRA JIG ULTRA’s features.
Hairline Cursor
7
The large hairline cursor provides a clear visual
reference of the fence location and spans all five scale
slots. The factory placement of the cursor can be shifted
to the rear of the base for use on smaller router tables
and table saws. (See Fig. 12 on page 8.)
Carriage Clamp
8
By pushing the carriage clamp down into the “unlocked”
position, the carriage is free to glide effortlessly to the
next setting. Pull the clamp handle up into the “locked”
position and the carriage is locked solidly in place, ready
for your next cut.
INCRA JIG ULTRA Miscellaneous Hardware
Jig Mounting Hardware
4 ea. #10 x 7/8" phillips pan head wood screw
4 ea. #10 flat washer
2 ea. #10 x 3/4" phillips flat head wood screw
3 ea. 6" x 7/8" x .005" clamping shim (clear)
1 ea. Owner's manual
1 ea. Warranty card
3
SET UP
FIG. 1
Attach the ULTRA to
3
/4" plywood base
Approximate
center
of plywood
Align center
holes with
approximate
center of
plywood length
#10 x 3/4" phillips flat
head wood screw
#10 x 7/8" phillips pan
head wood screw
#10 washer
Plywood
base
Although the clamping pressure has been factory
adjusted, you may wish to fine tune the pressure to
suit your own individual preference. If so, refer to the
instructions for adjusting the clamping pressure on
page 18.
Attach INCRA JIG ULTRA to a
1
3
/4" plywood base
Begin with a piece of 3/4" plywood (or hardwood) that is 9"
wide. The length of the plywood should match the width of
your table saw or router table. Clamp the plywood to a flat
surface using (2) C-clamps. Push the carriage clamp down
into the “unlocked” position and carefully slide the carriage out
of the base. Align the center mounting holes in the base with
the approximate center of the plywood as shown in Fig. 1.
NOTE:DO NOT alter the position of the carriage clamp or the
micro adjust lever when carriage is slid out of the base.
3
/4"
Align the front end of the base with the edge of the plywood as
shown and secure in place through the four slotted holes using
7
the supplied #10 x
/8" phillips pan head wood screws and #10
washers. Use the (2) #10 x 3/4" phillips flat head screws
through the two indicated center holes in the middle of the
base. DO NOT use washers on these two screws. The flat
head screws are required in order to provide adequate
clearance between the screws and the ULTRA's carriage.
Attach the INCRA Pro Fence
2
Carefully slide the carriage all the way into the base
and pull the carriage clamp up into the “locked” position.
Before mounting your INCRA PRO Fence you'll need to
determine which fence style you own. The original INCRA
PRO Fence has through holes drilled in the face for mounting
the INCRA racks. The new INCRA PRO Fence has no through
holes, and instead uses a T-slot for mounting the racks. Now
follow the instructions given below for the fence style you have.
FIG. 2
Mounting the
original INCRA
PRO Fence
Original
INCRA PRO
Fence
Spacer plate
Fence mounting
bracket
*Spacer plate
Detail 2a
Thick (gold)
washers
Raised rim on
rectangular nut
faces the fence
*#10-32 x 1 1/4"
phillips pan
head screw
*Use two thick
(gold) 5/8" O.D.
washers on each
screw
Mounting the
Original INCRA PRO Fence
Insert the #10-32 x 1 1/4" phillips pan head screws
through the two thick (gold) washers then through
the holes on the back of the fence mounting bracket
and spacer plate. See Fig. 2. Loosely attach the
two rectangular nuts. The raised rim on the
rectangular nut should face the fence. Now slide the
fence onto the rectangular nuts so that the nuts are
captured in the T-slot on the back of the fence. See
Detail 2a. Position the fence so that the carriage is
approximately centered on the fence length and
tighten the two mounting screws.
* NOTE: The spacer plate, #10-32 x 1 1/4" screws and
the two extra gold washers are NOT included when thenew style fence is packaged with the ULTRA.
4
FIG. 3
Mounting the new style
INCRA PRO Fence
Fence
mounting
bracket
New style
INCRA PRO Fence
Detail 3a
Thick (gold)
washer
Thick (gold) 5/8"
O.D. flat washer
Thin (silver)
5
/8" O.D. flat washer
#10-32 x 1 1/8"
phillips pan
head screw
Mounting to the
new style INCRA PRO Fence
Insert the #10-32 x 1 1/8" phillips pan head screws
through the thick (gold) washers then through the holes
on the back of the fence mounting bracket. Place a thin
(silver) washer on each screw then loosely attach the
rectangular nut. See Fig. 3. The raised rim on the
rectangular nut should face the mounting bracket. Now
slide the fence onto the thin washer and rectangular nut
so that both are captured in the T-slot on the back of the
fence. Make sure the washer is captured in the T-slot
provided as shown in Detail 3a. Position the fence so
that the carriage is approximately centered on the fence
length and tighten the two mounting screws.
NOTE: The spacer plate shown in mounting the original
INCRA Fence in Fig. 2 is not needed for mounting the
new style fence.
Thin washer
captured here
Raised rim on rectangular nut
faces the mounting bracket
To achieve a silky smooth carriage motion, it is important that your table surface is flat and smooth, and that the
carriage is installed parallel to it. If you find that your carriage tends to bind slightly during some portion of its
travel, the following additional step should take care of it. Simply place 3 or 4 pieces of paper under the infeed end of
the fence before tightening the screws in the final step of the fence mounting procedure described above, and then
remove the paper. If the problem still persists, either add a few more pieces of paper, or place the paper under the
other end of the fence before tightening.
Initial alignment for the
3
primary scale
NOTE: Before installing or sliding a scale or template in any of
FIG. 4
Initial primary
scale alignment
Carriage clamp in locked position
the five scale slots on the carriage, the carriage clamp must be
pulled up into the “locked” position.
Before continuing to the operations section of this owner’s
manual, it is a good idea to set a preliminary alignment
between the primary or center scale and the hairline cursor.
Your INCRA JIG ULTRA should still be in the closed position.
(In the closed position, the fence mounting bracket should be
1
about
/4" from the front end of the base.) The carriage clamp
Fence
mounting
bracket
should be pulled up into the “locked” position. Slide the
primary scale in the center scale slot to position 16 1/4" directly
under the hairline cursor. (See Fig. 4) Your new INCRA JIG
ULTRA is now ready for operation.
IMPORTANT: Whenever moving the INCRA JIG ULTRA’s
carriage and fence during cutting operations, always locate the
carriage so that the mark on the scale or template is aligned
directly under the hairline cursor before locking the carriage
Base
Slide primary scale
to read 16 1/4" here
clamp in place.
1
/4" approx.
5
OPERATION
FIG. 5
Moving the fence to
a new position
First:
Push carriage clamp
down to unlock carriage
Second:
Grasp the fence
mounting bracket
and slide fence to a
new position
Third:
Pull carriage clamp up
to lock carriage
Moving to a New Scale Setting
To use your INCRA JIG ULTRA, clamp the plywood base to
the stationary tool of your choice. (See the APPLICATIONS
section beginning on page 8 for specific setup recommendations for the router table, table saw, and drill press.) Moving
the fence to any new position is simple. First, push the
carriage clamp down to “unlock”, then grasp the fence
mounting bracket as shown in Fig. 5 and slide the fence to
the new position. Remember, whenever moving the INCRA
JIG ULTRA’s carriage and fence to any new position, always
align the mark on the scale or template directly under the
hairline cursor before locking the carriage clamp in place.
To secure the carriage at the new scale location, simply pull
the carriage clamp handle up into the “locked” position.
When moving the carriage, take care not to accidentally
slide the scale in its slot.
CAUTION: For your safety, keep both hands behind the fence
when moving to any new scale position.
FIG. 6
Re-zeroing the
micro adjust scale
Rotate the scale ONLY
(not the knob)
Micro Adjusting
The micro adjust feature of your new INCRA JIG ULTRA
allows for precise positioning of the fence to any location
between the 1/32" tooth spacing of the INCRA racks. You’ll find
this feature extremely handy the next time you want to widen a
mortise by a few thousandths of an inch at the router table or
for shaving a “hair” off the width of a tenon cut at the table saw
for a great fitting mortise and tenon joint. Use the micro
adjuster when cutting grooves to accept inlay strips for a
flawless fit, or to loosen up a tight fitting box joint cut with an
undersized bit. You’ll find it extremely useful when “zeroing”
the fence to the bit or blade or for “centering” the cutter on your
workpiece when setting up for joinery operations. Let’s use a
“hands on” step-by-step approach to getting acquainted with
and using the various components of this important feature.
NOTE:Before you micro adjust your fence position, you will
usually want to make sure that the micro adjust scale reads “0”
under the cursor. To adjust, simply rotate the scale (not the
knob) with your fingers. See Fig. 6. Now let’s micro adjust the
fence forward
1
/64". See Fig. 7 as you follow the steps.
6
FIG. 7
Micro adjusting
First:
Push carriage
clamp down to
"unlock"
Second:
Push micro adjust
lever down
Fourth:
Reset micro adjust
lever, and then pull
carriage clamp up
to lock carriage
back in place
Third:
Turn micro adjusting
knob to fine tune
fence position
“Unlock” the carriage clamp
1
Push the carriage clamp handle down to “unlock” the
carriage.
Engage the micro adjust lever
2
Push the micro adjust lever down to place the INCRA
JIG ULTRA into the micro adjust mode.
Micro adjust the fence position
3
Turn the micro adjust knob clockwise 1/2 turn until you
see the 1/64" mark appear under the hairline cursor.
“Lock” the carriage clamp
4
Reset the micro adjust lever, and then pull the carriage
clamp handle up to lock the carriage back in place.
You have successfully moved the fence forward
turning the micro adjusting knob counterclockwise in Step 3,
you can move the fence backward and the range scale on the
cursor lets you know at a glance which way you’ve just moved.
Simply sight through the range scale to the left end of the
micro adjusting knob. See Fig. 8. When the knob aligns with
the “0” on the scale, you are at mid-range. From this position,
you can micro adjust a full 1/4" in either direction. The scale is
marked in 1/32" increments.
IMPORTANT: Do not turn the micro adjusting knob with the
carriage clamp in the “locked” position. The carriage clamp
must always be “unlocked” and the micro adjust lever pushed
down before micro adjusting the fence position.
1
/64". By
FIG. 8
Range Scale
Sight through the scale to the left end
of the knob. This illustration depicts
the micro adjuster at exactly mid-range.
At the end of each day, you might want to micro
adjust back to mid-range on the range scale. This
ensures that you’ll have plenty of micro adjusting
range the next time you begin a project.
Left end
of micro
adjusting
knob
7
APPLICATIONS
FIG. 9
INCRA JIG ULTRA
on the router table
FIG. 10
Router table top
(suggested dimensions)
12"
12"
FIG. 11
"Zeroing" the bit
to your fence
24"
20"
32"
Second:
Press micro adjust lever down
and turn micro adjusting knob
until the gap between the
fence and bit disappears
INCRA JIG ULTRA on the Router Table
INCRA JIG ULTRA is unsurpassed for making dovetails on the router
table. Just about any dovetail is possible - sliding, half blind, or through both equally spaced and variably spaced. Even imaginative joints like the
INCRA Double Dovetail can be made. But INCRA JIG ULTRA is much
more than a dovetail jig. You can also make perfect box joints with any pin
spacing imaginable. And with INCRA JIG ULTRA’s precise positioning
capabilities, geometric patterns for such things as trivets or decorative
panels are both easy and fun. If you are interested in making precise,
intricate models, you’ll find that INCRA JIG ULTRA is just what you have
been looking for. In general, any operation on the router table requiring a
fence will be accomplished with much greater accuracy, speed, and ease
using INCRA JIG ULTRA.
3
To use INCRA JIG ULTRA on your router table, position the
/4" plywood
base on your router table top as shown in Fig. 9. The fence should always
be on the right hand side of the router bit as seen from the operator’s side
of the table. If you do not yet own a router table top, the dimensions shown
in Fig. 10 will produce a comfortable table size which allows enough room
to use the full range of your INCRA JIG ULTRA.
“Zeroing” the bit to your fence
If you wish to set the fence to bit distance equal to zero, release the
carriage clamp and slide the fence as close as possible to the router bit.
Place the INCRA JIG ULTRA in the micro adjust mode as described on
page 7, Steps1 and 2. With the router turned off and unplugged, sight
down the fence as shown in Fig. 11 and turn the micro adjusting knob. As
you turn the knob, the gap between the fence and the cutting wing of the bit
will get smaller. Continue turning the knob until the gap of light disappears.
When this happens, the bit will be “zero” distance from the fence. Check tomake sure that the bit is safely centered on the fence notch. Return
the carriage clamp to the “locked” position and slide the primary scale to
position the 0" mark directly under the cursor.* You have now positioned
your fence so that all of your cuts will be made relative to the edge of your
stock. (Example: By setting your INCRA JIG ULTRA to a scale reading of
1" and making a cut, you will produce a groove 1" from the edge of your
stock.) If you wish, you can return the micro adjust scale to a “0” reading by
rotating the scale (not the knob) to position the “0” mark under the micro
adjust cursor. (See Fig. 6, page 6.)
* On some smaller router tables you may find that the 0" mark on the scale
does not reach the cursor. To remedy this, simply move the hairline cursor
to the rear of the base as shown in Fig. 12. This allows the 0" mark on the
scale to easily reach the hairline cursor.
First:
"Unlock"
carriage
clamp and
slide fence
up to the bit
Third:
"Lock" carriage clamp
Fourth:
Slide primary scale to
read 0" under the
hairline cursor
FIG. 12
Alternate cursor
placement
8
Move
cursor to
rear of base
for use on
smaller
tables
In addition
to the manual
"centering" method
described on pg. 9,
you can automatically
center your work
using the INCRA
Auto-Center
(available from your
INCRA Dealer).
It instantly centers
ANY board up to
16" in width.
FIG. 13
Align board with bit
FIG. 14
Set initial fence position
FIG. 15
Rout test groove
Mark
center
of board
Center of
board aligned with
approximate center of bit
First:
"Unlock"
carriage clamp
Third:
"Lock" carriage clamp back in place
FIG. 16
Small gap between
bit and one side of
groove
“Centering” the bit on your
workpiece
Making a series of cuts relative to the center rather than the
edge of the workpiece is often quite useful when producing
symmetrical pieces. “Centering” is always used when setting
up your INCRA JIG ULTRA for joint making. Let’s use a hands
on step-by-step approach to understanding this important
setup technique. Follow along and you’ll learn how to “center”
a 3/8" straight bit on a piece of stock 3 3/4" wide.
Begin by cutting a piece of
long. Install a 3/8" straight bit and set the depth of cut to 3/8".
Align board with bit
1
Mark the center of the board’s width on one end and
place the board face down on the router table with the
center of the board aligned with the approximate center of the
bit. See Fig. 13.
Set initial fence position
2
“Unlock” the carriage clamp and slide the fence up to
the edge of the board then “lock” the carriage clamp
back in place. See Fig. 14. Make sure the center mark on the
board is still aligned with the approximate center of the bit.
Rout the test groove
3
Turn on the router and, using a good rubber soled
push block, cut a groove along the entire length of the
board. See Fig. 15. Now turn the stock end-for-end with the
groove still face down, and make a second pass over the bit.
This second pass should widen the groove slightly (unless you
are already perfectly centered!) Make sure you have turned
the stock end for end before making the second pass. (This
places the center mark at the back of the board.)
Fine tune the fence position
4
With the router unplugged, turn the bit to its widest cut
angle when viewed from the infeed side of the table.
Place the board against the fence with the bit just inside the
3
/4" thick stock to 3 3/4" wide by 6"
Second:
Slide fence up to
edge of board
First:
Rout a groove
along entire
length of
stock
Second:
Turn stock end-for-end
and make a second
pass over the bit
FIG. 17
Micro adjust fence
to place bit in the
middle of groove
groove cut in Step 3. There should be a small gap between
the edge of the bit and one side of the groove. See Fig. 16.
Now all that is needed is to micro adjust the fence position
so that with the board against the fence, the bit is in the center
of the groove. To do this, simply “unlock” the carriage clamp
and press the micro adjust lever down, then turn the micro
adjusting knob until there appears to be an equal gap on both
sides of the bit. See Fig. 17. “Lock” the carriage clamp back
in place. You have now successfully found the center of the
3
3
/4" wide board with your router bit. If you were setting up for
joint making on this width of stock, you would now slide a
joinery template from the optional Master Template Library into
one of the auxiliary scale slots. By positioning the template to
place the preselected “center cut” mar k directly under the
hairline cursor, you would be ready to cut a perfectly centered
joint. In fact, if you’ll turn now to page 12, you’ll learn how to
use the center you’ve just found to produce a box joint and a
half blind dovetail on 3 3/4" wide stock.
described above, slide the extra 1/32" “floating”
scale to position the 1 7/8" mark directly under the
hairline cursor.* Now the center of any board can be
found quickly by using this scale.
Example: If you want to locate the bit in the center of a
4" wide board, simply “unlock” the carr iage clamp and
move the carriage to position the 2" mark on this scale
directly under the hairline cursor (4" ÷ 2 = 2"). Now lock
the carriage in place. You might still want to make the
test cuts described in Step 3 above since your actual
stock width might be slightly more or less than a true 4"
measurement.
*On some smaller router tables you may find the 1
mark will not reach the hairline cursor. To remedy this,
simply move the hairline cursor to the rear of the base.
See Fig. 12 on page 8.
9
Equal gap on
both sides of bitSmall gap
After centering on the 3 3/4" wide board as
7
/8"
FIG. 18
INCRA JIG ULTRA
on the table saw
NOTE: Blade guard omitted for clarity
INCRA JIG ULTRA on the
Table Saw
Another way of making box joints is to use INCRA JIG
ULTRA as an incremental fence or stop block on the table saw.
Its usefulness on this machine is also evident in its ability to
cut uniform thin strips off the outside edge of the board. Or, if
you ever need to cut a precisely spaced series of grooves,
INCRA JIG ULTRA at the table saw will handle it with ease.
Have you ever tried to exactly duplicate a cut after moving your
old fence system? With INCRA JIG ULTRA on your table saw,
duplication becomes effortless. No more trial and error cuts.
In fact, you’ll not find a more accurate table saw fence on the
market today.
To use INCRA JIG ULTRA on your table saw, position the
3
/4" plywood base on your tabletop as shown in Fig. 18 and
follow the instructions below for zeroing the fence to the blade.
If you wish to cover the notch on your INCRA fence, mount a
wooden auxiliary fence as described on page 7 of your INCRA
PRO Fence System Owner’s Manual. Or, if you prefer, a
notchless version of the INCRA PRO Fence is available. (See
order information at the back of this manual.)
FIG. 19
Zeroing the fence
to the blade
Fence is zero distance
from the blade
Scale reads
0" here
“Zeroing” the fence to the blade
With the motor unplugged, raise your table saw blade to
about 2". Loosen the C-clamps that secure the wooden base
to your table saw. “Unlock” the carriage clamp and slide the
fence up to the blade then “lock” the carriage clamp back in
place. Carefully position the entire assembly so that the fence
is centered on the tabletop and “kissing” the blade. See Fig. 19.
Be gentle when positioning the fence adjacent to the blade so
that you don’t deflect the blade. Clamp the plywood base to
the tabletop with the (2) C-clamps, being careful not to shift the
base. Now slide the middle “primar y” scale to position the 0"
mark directly under the cursor. You have now positioned the
fence parallel to the blade and set the fence to blade distance
at zero.
On some table saws you may find the 0" mark will not
reach the hairline cursor. To remedy this, simply move the
hairline cursor to the rear of the base. See Fig. 12 on page 8.
Once you have “zeroed” the INCRA JIG
ULTRA on your table saw, glue and screw a
1" x 2" piece of hardwood to the underside of
the plywood base adjacent to the right edge of the
table saw. See Fig. 20. The 1" x 2" should be
about as long as the plywood base. Make sure it is
butted up against the right edge of the table saw
before screwing in place. Now, should you need to
remove the INCRA JIG ULTRA from the table saw,
you can quickly reinstall it in the exact position as
before by butting the 1" x 2" against the right edge
of the saw and clamping the plywood base in place.
FIG. 20
Alignment strip
1" x 2"
wood strip
10
INCRA JIG ULTRA on the
Drill Press
Another common tool that is greatly enhanced by INCRA
JIG ULTRA is the drill press. Used as a variable stop block, it
gives you precise, single axis positioning control. When
INCRA JIG ULTRA is used in conjunction with the INCRA Pro
Fence and INCRA Stop you have an ultra-accurate x-y
positioner. See Fig. 21. You can quickly, easily and accurately
locate and drill any 2-dimensional array of holes by simply
moving the INCRA JIG ULTRA and the INCRA Stop to the
desired settings. A cribbage board is a good example of a
project that requires this ability. And since you can locate any
hole to within a few thousandths of an inch, INCRA JIG ULTRA
on the drill press is great for making perfect dowel joints.
FIG. 21
INCRA JIG ULTRA
on the drill press
For more information on using INCRA
tools on the router table, table saw and
drill press, pick up the new book, INCRAJIG Projects and Techniques, available
from your local INCRA dealer.
11
JOINT MAKING
FIG. 22
Equally spaced
3
/8" box joint
/4"
3
3
FIG. 23
Make the cuts on the
top half of Fig. 22
Make cuts at the following scale
settings (use floating scale):
3
/8", 1 1/8", 1 7/8", 2 5/8", 3 3/8"
FIG. 24
Make the cuts on the
bottom half of Fig. 22
Make cuts at the following scale
settings (use floating scale):
0", 3/4", 1 1/2", 2 1/4", 3", 3 3/4"
NOTE: If y ou have purchased the INCRA Master Reference Guide &
/8"
3
3
/8"
5
2
/8"
7
1
/8"
1
1
/8"
3
Template Library, it is not necessary to read this section on joint making.
You'll find the Reference Guide covers this topic completely.
Three important operations take place when using your INCRA JIG
ULTRA for joinery at your router table:
1. Setting the router bit depth of cut
2. “Centering” the bit on your workpiece
3. Cutting the joint
Again we will use a step-by-step approach to make using and
understanding these operations easy. Let’s start with a box joint.
Box Joints
/4"
3"
Wooden
handscrew
clamp
Wooden
handscrew
clamp
1
2
/2"
1
1
/4"
3
You’ll want to begin this exercise by cutting your stock to length and
0"
width. Use 3/8" thick stock and cut (4) boards to 3 3/4" wide x 6" long.
The joint you will be making is an equally spaced 3/8" box joint so you’ll
also need a 3/8" straight bit.
Set the depth of cut
1
Install the 3/8" straight bit in your router table and set the depth of
cut to slightly greater than the thickness of your stock.
“Center” the bit on your stock width
2
Use the “centering” method described on page 9 to find the
center of the board. After you have found the center, slide the
extra 1/32" floating scale to position the 1 7/8" mark directly under the
hairline cursor. On some smaller router tables you may find the 1 7/8"
mark will not reach the hairline cursor. To remedy this, simply move
the hairline cursor to the rear of the base. See Fig. 12 on page 8.
Backing
board to
prevent
splintering
Cut the joint
3
Clamp two of your boards to the INCRA Right Angle Fixture with a
backing board as shown in Fig. 23. The backing board is used to
prevent splintering as the bit exits the cut. Make cuts at the scale
locations shown on the top half of the drawing in Fig. 22. Make sure you
are using the floating scale in Step 2. After completing the cuts , flip the
boards end-for-end and repeat the same cuts. Now clamp the remaining
two boards with a backing board to the INCRA Right Angle Fixture as
shown in Fig. 24 and make cuts at the scale locations shown on the
bottom half of the drawing in Fig. 22. “Sneak up” to the first cut (0") in
several light side-by-side passes to avoid splintering the edge of the
stock. (This is just good router table technique.) When you hav e
completed the cuts, flip the boards over and repeat the same cuts .
You have just completed your first INCRA box joint. With a little
practice, it’ s really quite easy. You’ll notice in Steps 2 and 3, we installed
1
and used the
/32" scale to locate the various cuts. When you later begin
using the joinery templates from the optional INCRA Master ReferenceGuide & Template Library, they will be used in the same way. In fact,
the INCRA joinery templates are simply “scales” which have had all the
marks you don’t need left off. Just find the center of your stock, slide the
suggested “center cut” on the template under the hairline cursor, then
make “A” cuts on two of the boards and “B” cuts on the remaining two.
Too tight or too loose?
Backing
board to
prevent
splintering
Check the fit of the pieces. If the joint is too tight or too loose, the
problem is the bit, not the INCRA JIG. An oversized bit will create a
loose fit. An undersized bit will create a tight fit. The best fit will be
found by using a straight bit that is just slightly oversized, which is the
way that most good bits are manufactured. To loosen a tight fitting
joint, you can micro adjust the fence backward about five thousandths
and then re-cut one of the series of cuts. CAUTION: Remember,
whenever cutting with a straight bit, that the bit man ufacturers recommend
that you cut no deeper than the diameter of the bit in a single pass.
12
FIG. 25
Set initial
depth of cut
Position fence so that
about half of the bit is
inside the fence notch
Slightly less
than 1/4"
FIG. 26
Depth of cut - trial cuts
Make cuts at the following scale
settings (use primary scale):
0", 7/8"
Half Blind Dovetails
You’ll want to begin this exercise by cutting some stock to
length and width. Use 1/2" thick stock and cut (6) boards 3 3/4"
wide x 6" long. You will be making an equally spaced half blind
dovetail requiring a 1/2" 14° dovetail bit.
Set the depth of cut
1
Install the 1/2" 14° dovetail bit in your router table and set
the initial depth of cut to slightly less than 1/4". Position
the fence as shown in Fig. 25 so that about half of the bit is
inside the fence notch. Slide the middle “primary” scale to
read 0" under the cursor. (On some smaller router tables you
may find the 0" mark will not reach the hairline cursor. To
remedy this, simply move the hairline cursor to the rear of the
base. See Fig. 12 on page 8.)
Clamp two of your boards to the INCRA Right Angle Fixture
as shown in Fig. 26 and make cuts at scale readings of 0" and
7
/8". Make sure you are reading the middle “primary” scale set
above.
Unclamp the two boards and test the fit by joining them as
shown in Fig. 27. As with any half blind dovetail jig, a little trial
and error is necessary to achieve a snug fitting joint. The fit
can be fine-tuned by adjusting the dovetail bit’s depth of cut.
To tighten the fit, raise the bit up slightly. To loosen the fit,
lower the bit slightly. Just remember this phrase: Heighten to
tighten, lower to loosen. After adjusting the bit height, make
a new set of trial cuts (two cuts
of the boards. After a few adjustments and trial cuts, you’ll
have a perfect fit. If you mar k the good fitting cuts on one of
the boards, you can save this piece to use as a depth gauge
the next time you set up your 1/2" dovetail bit for joinery.
“Center” the bit on your stock
2
width
Use the “centering” method described on page 9 to find
the center of the 3 3/4" wide board with your dovetail bit. After
you have found the center, slide the extra 1/32" floating scale to
position the 1 7/8" mark directly under the hairline cursor.
7
/8" apart) on the opposite end
FIG. 27
Test the fit
When the fit is too loose, the trial cuts provide a
gauge to let you know how much to raise the bit.
Just join the trial pieces end to end and gently pull the
two boards to wedge the dovetails together. The gap
that appears is the distance you need to raise your
dovetail bit to achieve a tight fit.
FIG. 28
Gap
Raise this much
Cut the joint
3
13
FIG. 29
Cut the rabbets
FIG. 30
Equally
spaced 1/2"
14° dovetail
Dovetail shaped rabbets
cut on both ends of two
of your boards
Tail Cuts
To create the tails, start by cutting a dovetail shaped rabbet on
both ends of two of your boards. See Fig. 29. The rabbet
needs to be 7/32" wide. See Detail 29a. DO NOT cut the full
width of the rabbet in one pass. Instead use 3 or 4 light side by
Rubber
soled push
block
side passes.
Now clamp the boards to your INCRA Right Angle Fixture
as shown in Fig. 31 and make cuts at the scale locations shown
on the top half of the drawing in Fig. 30. Make sure you are
reading from the floating scale set in Step 2 on page 13. As
Detail
29a
Rabbet
width
always, with good router table technique, “sneak up” to the first cut
1
/8") in sev er al light side b y side passes to avoid splintering the
(
edge of the stock. After completing the cuts, flip the boards over
and repeat the same cuts. Your two tail boards are now complete.
Pin Cuts
Set your INCRA JIG ULTRA to the first scale setting shown on
the BOTTOM half of the drawing in Fig. 30 (9/16"). Position an
7
/32" wide
rabbet
/8"
5
3
/4"
3
2
/8"
7
1
1"
/8"
1
INCRA Stop on the fence with the plastic stop strip as close as
possible to the dovetail bit and clamp in place. (The plastic
stop strip should not be touching the router bit.) See Fig. 32.
The INCRA Stop is used to limit the length of the pin cuts.
Place one of the remaining two boards face down on the
router table as shown in Fig. 33 and make cuts at the scale
locations shown on the BOTTOM half of the drawing in Fig. 30.
Be sure to use a good rubber soled push block as shown.
Make the cuts on only one end of the board for now. After
making the four cuts, check the fit between this pin board and
one of your tail boards. If the tails don’t fit all the way into the
pins simply lengthen the pin cuts by moving the INCRA Stop
away from the bit. Recut the pin board and again check the fit.
Once you have a flush fit, make the pin cuts on the opposite
end of the board and on both ends of the remaining board.
FIG. 31
Cut the tails
16"
/
3
3
Wooden
handscrew
clamp
"
/16
5
2
/16"
7
1
/16"
9
Clamp two
boards with
rabbets
facing out
as shown
Make cuts at the following scale
settings (use floating scale):
1
/8", 1", 1 7/8", 2 3/4", 3 5/8"
FIG. 32
Stop for pin cuts
Position INCRA Stop
on outfeed side of bit
as close as possible
to cutting wing
FIG. 33
Cut the pins
Rubber
soled
push
block
Make cuts at the following scale
settings (use floating scale):
9
/16", 1 7/16", 2 5/16", 3 3/16"
14
You have just completed your first INCRA half blind
dovetail. You'll notice in the first step you set the depth of cut
by making two cuts 7/8" apart. This spacing works well with a
1
/2" 14° dovetail bit, but larger or smaller diameter bits will
require a different spacing between these two cuts. To help
you determine the proper spacing you'll find a chart on page 3
of the INCRA Master Reference Guide & Template Library.
The chart will give you the proper spacing for the router bit and
template pattern you have selected. You'll also find the proper
spacing listed as "Distance to set depth of cut" under each
template pattern diagram in the back of the INCRA MasterReference Guide & Template Library. Since different
diameter router bits will also require different rabbet widths, the
INCRA Master Reference Guide & Template Library also
gives this information with each joint pattern.
In Steps 2 and 3, you positioned and used a
1
/32" scale to
locate the various cuts for the tail and pin boards. When you
later begin using the joinery templates from the optional
INCRA Master Reference Guide & Template Library, they
will be used in the same way. In fact, you can think of the
joinery templates as “scales” that have had all the marks you
don’t need erased. Just find the center of the stock width you
are using with the router bit, then slide the suggested “center
cut” on the template under the hairline cursor. Each template
has two series of marks, “A” cuts and “B” cuts. Just use one
series for your tail board cuts and the other series for your pins.
After making your first series of pin cuts,
check the fit with one of the tail boards. If the
tail board doesn’t fit all the way into the pin board,
just measure the distance it protrudes. See Fig. 34.
This is the distance you need to move the INCRA
Stop AWAY from the bit to achieve a flush fit.
FIG. 34
PIN BOARD
Move
INCRA
Stop back
TAIL BOARD
this far to
achieve a
flush fit
Pins or Tails?
Looking at an assembled dovetail, it is
often difficult at first glance to tell which
boards are the pins and which boards
are the tails. They each have dovetail
shaped cuts in them, so what makes
them different and where is each used in
a case construction?
To answer the last question, dovetails
are most often used for one of two
different reasons-beauty or strength.
When used to decorate a piece, most
woodworkers prefer to put the tail boards
on the side of the construction most
visible to the viewer. When used for
strength, the tail boards are placed in
the construction so that they are parallel
to the direction of the force being
applied. In drawer constructions, for
instance, the tail boards are always
placed on the sides parallel to the pull
and push motions involved in opening
and closing. This places the pin boards
on the front and back. Wall hung
cabinets should always be built with the
tail boards on the sides, since once the
cabinet is loaded with weight, the force
is downward. This places the pin boards
on the top and bottom. Once you’ve
determined which sides of your
construction will be pins and which will
be tails, use the illustration and the
information in Fig. 35 to ensure the
proper cuts are made on each.
FIG. 35
Pins and Tails
The first and last cuts
on tail boards are
ALWAYS "open cuts".
This means the edges
are cut away
TAILS
Pin boards are cut
FACE DOWN on the
router table
PINS
Pin boards will ALWAYS have
half pins (solid stock) on
the outer edges of the
board
Tails begin with a
dovetail shaped rabbet.
(half blinds only)
Tail boards are always
cut VERTICALLY,
clamped to the INCRA
Right Angle Fixture.
15
TROUBLE SHOOTING GUIDE
We don't think you'll ever have to look at this section, but if you do you'll find a quick answer to your question.
SYMPTOMPROB ABLE CAUSESOLUTION
Carriage clamping pressureCarriage clamp not adjustedAdjust clamping pressure (see page 18).
is too tight or too loose.properly.
LEXAN
to slidepaste wax or, preferably, Top-Cote (available from your
Racks do not mesh properlySawdust on racks.Remove all debris from the racks' teeth with a stiff
when engaging the carriagebrush, such as a toothbrush. (DO NOT attempt to
clamp.clean the racks with solvents of any kind as this may
When the jig is moved to aFence is improperly mounted onIf the fence is mounted too high or too low on the
new position the carriagethe fence bracket.bracket, it can cause resistance when moving from one
does not glide easily.position to another. If this is the case, loosen the
TM
scale is difficultScale slot has become dirty.Remove the scale and clean the slot thoroughly with
INCRA dealer). Then slide the scale back into the slot.
CAUTION: DO NOT allow wet Top-Cote to come into
contact with LEXAN scale or Templates, or any other
plastic material.
damage them.)
Scale mark is not aligned directlySet the jig to mid-position and lock the carriage clamp.
under the hairline cursor.Then position the scale so that the 8" mark is directly
under the hairline. When setting the jig to any new
position, always make sure that the scale mark is
aligned directly under the hairline cursor BEFORE
locking the carriage clamp.
Carriage racks are improperlyRealign the carriage racks as described on page 19.
aligned.
screws holding the fence and realign. See page 4,
Step 2.
Surface of table is not flat.Bumps or dips on the table surface can force the
carriage into non-parallel alignment with the base.
Check your table surface for flatness. This is also
important from a woodworking standpoint because
errors in the surface of the table will translate directly
into errors in your finished work.
Fence is not square to theFence is improperly mounted onIf the fence is mounted either too high or too low on the
table surface at all jigthe fence bracket.fence mounting bracket, it can change the angle of the
positions.fence relative to the table when it is moved from one
position to another. If this is the case, loosen the
screws holding the fence to the bracket and realign.
See page 4, Step 2.
There are several possible causes:If you identify any of these, take steps to correct the
Jig mounting board is not flat,problem. You can also use shims to bring the fence
table is not flat, sawdust betweeninto perfect squareness as per the instructions on
table and mounting board, orpage 5 of your INCRA PRO Fence System owner's
sawdust between the mountingmanual.
board and the jig.
16
SYMPTOMPROBABLE CAUSESOLUTION
Micro adjusting knob will notCarriage clamp is not "unlocked"Carriage clamp must be pushed down to the "unlock"
rotate or is difficult to rotate.position and the micro adjust lever must be pressed
down to place the jig in the micro adjust mode. See
page 7, Steps 1- 4.
Jig is micro adjusted to end of theMicro adjust back to mid-range position as indicated by
forward travel range.the micro adjust range scale. (Turn knob counter-
clockwise until "0" on the scale is aligned with the left
end of the micro adjusting knob.)
Micro adjusting knob rotatesMicro adjust lever not engaged.After "unlocking" the carriage clamp the micro adjust
but no movement of thelever must be pushed down to place the jig in micro
carriage or fence.adjust mode. See page 7, Steps 1- 4.
Jig micro adjusted to end ofMicro adjust jig forward to mid-range as indicated by
backward travel range.the micro adjust range scale. (Turn knob clockwise
until "0" on the range scale is aligned with the left end
of the micro adjust knob.
After placing jig in microMicro adjust range scale notRealign micro adjust range scale. See page 18.
adjust mode, the microproperly aligned.
adjusting knob will not turn
even though the range scale
indicates travel range
available.
Carriage clamp squeaksCarriage clamp pivot pin needsRemove the carriage from the base, then remove the
when clamping orlubrication(6) phillips head wood screws that secure the ULTRA
unclampingbase to your plywood subbase. Turn the ULTRA's
base upside down and you'll see where the carriage
clamp pivot pin passes through the clamp handle.
Apply a thin coat of light grease to the pivot pin using a
small cotton swab then remount the ULTRA base to
your plywood. See page 4, Fig. 1.
1
/8" thick carriage clamp padApply a thin coat of light grease to the carriage
needs lubrication.clamp pad.
MAINTENANCE
In general, just keeping your INCRA JIG clean is all you need to do to keep the tool in tip top shape. Occasionally, remove the
carriage from the base and brush or blow out any sawdust or debris that may have accumulated on the base and the UHMW
guide bearing strips. Use a toothbrush to clean the teeth on the INCRA racks on both the carriage clamp and on the carriage.
17
Realigning the Carriage
Racks
Remove the carriage from the base and loosen the screws
which hold the racks to the carriage so that they slide easily
along the mounting track.
NOTE:DO NOT alter the position of the carriage clamp or
the micro adjust lever when the carriage is slid out of the
base.
Align the end of rack #1 flush with the rear end of the
carriage and tighten the mounting screws. Position the other
racks on the mounting track with their ends approximately
1
1
/2" apart. See Fig. 38. DO NOT tighten the screws for
racks #2 and #3 yet.
Carefully slide the carriage back into the base, taking care
not to change the position of the loose racks. Position the
carriage so that the base is centered approximately between
the ends of racks #1 and #2. See Fig. 39. With the carriage
properly located you should be able to see one of the
mounting screws for each of the two racks. Pull the carriage
clamp up into the "locked " position and the rack on the clamp
will automatically align rack #2 with rack #1. Tighten the
accessible mounting screw on rack #2. Unlock the carriage
clamp and move the carriage forward to tighten the other
mounting screw on rack #2. Now locate the carriage so that
the base is centered approximately between the ends of racks
#2 and #3. Again, "lock" the carr iage clamp to br idge the two
racks and tighten the accessible mounting screws on rack #3.
Then "unlock" the carriage clamp and move the carriage
forward to tighten the remaining screw on rack #3.
NOTE: If you have the longer 24" range INCRA JIG ULTRA,
there will be an additional rack #4. If so, use the same
procedure for aligning and tightening these racks that you
used for racks #2 and #3 described above.
FIG. 38
Realigning the
carriage racks
Rack #1
1 1/2" approx.
Second:
Align this rack flush
with the end of the
carriage and tighten
the screws
FIG. 39
"Bridge" racks
#1 and #2
Rack #1
Racks are bridged when
ONE screw from each rack
can be seen on either end
of base
First:
Loosen the screws that secure the
racks to the mounting track
Third:
Position remaining racks about 1 1/2"
apart. DO NOT tighten the screws
for these racks yet
1 1/2" approx.
"Bridge" racks #1 and #2
by locking carriage clamp
Rack #3
Rack #2
19
SPARE PARTS ORDER LIST
Part #Part DescriptionPrice
IJU-MACURSORMicro adjust cursor (with mounting hardware)$ 4.95
IJU-HLCURSORPrimary hairline cursor (with mounting hardware)$ 6.95
IJU-MMRACKMetric racks - set of 5 racks with 16" long metric scale and mounting$ 6.95
hardware
IJU-MMSCALE16" long metric scale$ 2.95
IJU-32SCALE16" long
IJU-NLFENCE"Notchless" INCRA PRO Fence (28" long)$44.95
IJU-UHMWUHMW bearing strips (for base) set of 3$ 1.95
IJU-SHIMUHMW carriage clamp pad and shims pack$ 1.95
Includes:1 ea.
IJU-24CARR24" range carriage (only), includes racks, scales and$79.95
fence mounting bracket.
TO ORDER:
Send check, money order, or VISA or Master Card number (include expiration date) along with the Part Number, Part
Description, and quantity of each item you wish to order. Add $3.50 for shipping and handling to each order. Texas
residents please add 8.25% sales tax. Please allow 1 to 2 weeks for delivery.
Mail orders to: TAYLOR DESIGN GROUP, INC., Attn. Order Dept., P.O. Box 810262, Dallas, TX 75381
Telephone: (972) 418-4811 • Fax: (972) 243-4277 • Web Site: www.incra.com
Taylor Design Group, Inc. warrants this product for one year from the date of purchase. We will
repair, without charge, any defects due to faulty material or workmanship, or at our option, replace
the product free. Please return the failing part only, transportation prepaid, along with a descr iption
of the problem to the address below. This warranty does not apply to parts which have been
subjected to improper use, alteration, or abuse.
LIFETIME WARRANTY ON POSITIONING RACKS
If an INCRA positioning rack in this tool becomes damaged for ANY reason, Taylor Design Group
will replace it free of charge for as long as you own the tool. Return the damaged rack,
transportation prepaid, and allow 1 to 2 weeks for delivery.
NOTE: Replacements cannot be sent unless damaged racks have been received by Taylor Design.
Made in America by:
TAYLOR DESIGN GROUP, INC. P.O. Box 810262 Dallas, TX 75381