Leigh R9 PLUS User Manual

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Page 1

Router Table & Bench Joinery System

LEIGH R9

PLUS

User Guide

See other side of book for Bench Operation

Router Table Operation

Dedicated Customer Support

1-800-663-8932

Page 2

ROUTER TABLE OPERATION

Your New Leigh R9PLUS Joinery System for Dovetails and Box Joints

R9PLUS Joinery System User Guide

Introduction

Note: There are two user guides in this book. This user guide is for Router Table Operation. Flip the book over for Bench Operation.

The R9PLUS Joinery System was designed to overcome the restrictions of fixed width jigs. Because of its unique “step over” feature, it is possible to rout Through Dovetails and Box Joints on boards of ANY width!

The R9

PLUS

can be used as a template jig with a hand-held router or as a router table template. In either mode, you will be able to rout multiple sizes of perfectly fitting through dovetails and box joints.

Customer Support

If you have any questions that are not answered in this user guide, please call Leigh Customer Support: 1-800-663-8932 in North America or email: [email protected] For support contacts in your country of purchase see the Customer Support section of the Appendix.

Reminder: If at first you don’t succeed, read the instructions!

Important! Inches and Millimeters

Text and illustrations in this English language user guide indicate dimensions in both inches and millimeters, with “inches” first, followed by “millimeters” in square brackets, i.e.

⁄2"x 2"[12x50mm].

Do not be concerned that the inch/millimeter equivalents are not mathematically “correct.” Just use the dimensions that apply to your guides and bits.

Patents Pending

What’s in the Box:

PART NO. QUANTITY PART DESCRIPTION

2000 1 R9PLUS Template 2090 1 User Guide BAG 1 2030 2 Latches 2040 1 Glide 2080 1 Side Stop BAG 2 2010 3 Pin Plates BAG 3 2050 2 Beam Assembly Screws, ¼"-20 x 2¾" 2055 2 Beam Assembly Wing Nuts, ¼"-20 2060 2 Latch Screws, Phillips 10-24 x ¾" 2065 2 Latch Nuts, Nyloc 2070 11 Wood Screws, Phillips Flat Head, No.8 x 1¼" 2075 1 Side stop Screw, Phillips Round Head, No.8 x ¼" BAG 4 e10 1 e10 e-Bush (Guide Bushing) 80-8 1 Dovetail Bit, ½"-8º 160 1 Straight Bit, ½" Two Flute 172-8 1 Collet Reducer, ½" to 8mm 730V 1 Pin Wrench BAG 5 2020 2 Clamp Locators 9505 2 F-Clamps

2000

2090

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ROUTER TABLE OPERATION

R9PLUS Joinery System User Guide

Introduction

e10

172-8

730V

80-8

160

2030 x2

2040

2080

2010

2070 x11

2075

2065 x2

2060 x2

2050 x2

2055 x2

2020 x2

BAG 1 BAG 4

BAG 5

BAG 3

BAG 2

9505 x2

Contents

You will need:

s A wooden beam 1

⁄2"

x 3

⁄2"

x 30".

See jig assembly for optional beam sizes.

s 5

⁄8"[15mm]

MDF for sacrificial backer boards and clamp face boards. See jig assembly for optional sizes.

s A No.2 Phillips screwdriver

s An electric drill, preferably bench or pedestal,

but hand-held will work

s 3

⁄32"

drill bit for pilot holes

s 3

⁄4"

[19mm] Forstner or similar bit for the

clamp holes

s 5

⁄16"

drill bit for the back up board holes,

s A countersink bit

s A router with adaptor for the e10 guide

bushing

Dedicated Customer Support

1-800-663-8932

Chapter 1 Making the Beam 5

Chapter 2 Glossary of Symbols 11

Chapter 3 Using your Jig Safely 13

Chapter 4 Basic Jig Functions 15

Chapter 5 The Leigh e-Bush 17

Chapter 6 Through Dovetail Joint Procedures Concept of Operation 19 Board Width Selection 20 Through Dovetail Joints 21 Half-Pitch Through Dovetail Joints 23 Wide Boards 24

Chapter 7 Box Joint Procedures Concept of Operation 27 Board Width Selection 28 3/8" Box Joints 29 3/16" Box Joints 31 3/4" Box Joints 32 Wide Boards 34

Appendix e-Bush and Adaptors 35 Customer Support 37 R9PLUS Beam Drawing 38

Page 4

ROUTER TABLE OPERATION

R9PLUS Joinery System User Guide

R9PLUS Bit Selection

This chart shows all the bits that can be used on the R9PLUS.

R9PLUS BIT SELECTION

Leigh Bits

D E

A B*

Bit

Diameter

Cutting

Depth

Max.

Diameter

Shank

Length

Overall Length

D B

Angle

Use with

Straight

Bit No.

Use with

e-Bush

Use with

Collet

Reducer

Joint

Type

Introduction

70-8

75-8

80-8*

166*

166C*

140-8

170*

170C*

173*

3/8"

1/4" to

7/16"

1/2"

13/16"

3/16"

3/16" 2 1/2"5/8" 1/4"

5/16"

5/16" 3"7/8" 8mm,

5/16"

3/8" 3"1/8"- 1" 3/8"

8mm

1/2"

8mm

5/8"

8mm

(5/16")

2 1/4" 8º

1 3/4"

2 3/8" 8º

1 3/4"3/8" to

2 9/16" 8º

1 3/4"1/2" to

2 7/8"5/8" 1/4"

1 3/4"

2 3/4" 172-8– – e7

1 3/4"up to1"8mm

1 3/4"

2 3/4" – – e7 172-8

1 3/4"up to1"8mm,

1 3/4" 172-375

140-8

170C

140-8

170C

180C

–

170

e10

170

e10

160 180

– –

e10

– ––

e10

– e7–

–

e10

172-8

172-8e10

172-8

Dovetail

Box

Dovetail

Box

*Bits 80-8 and 160 included with the R9 Plus.

*Spiral upcut bits rout cleaner and faster,

leaving a smoother finish.

R9PLUS Accessory Kit

This kit offers great savings over individual prices. See leighjigs.com

173C*

160*

180*

180C*

3/8" 3"1" 3/8"

1/2"

1/2" 3 1/2"1 1/4" 1/2"

1/2"

1 1/4"

up to

1/2"

172-8

1/2" to 8mm collet reducer 1 1/4" long. For 8mm shank bits.

1 3/4"

1 3/4"up to

1 3/4"

3" –

3 1/2" – – –

–

––

172-375

1/2" to 3/8" collet reducer 1 1/4" long. For 3/8" shank bits.

e10

172-375

––

–

Dovetail

Includes: 70-8

3/8" dovetail bit (for through dovetails)

75-8

7/16" dovetail bit (for through dovetails)

140-8

5/16" straight bit (for half-pitch through dovetails)

e-Bush (for 70-8, 75-8 for half-pitch through dovetails)

166

3/16" spiral upcut bit (for box joints)

173

3/8" spiral upcut bit (for box joints)

Box

Page 5

R9PLUS BENCH OPERATION

CHAPTER 1

Making the Beam

The heart of the R9PLUS Joinery System is the beam. A typical beam, shown below, is 30"[762mm] long. A 30"[762mm] beam can accommodate board widths of up to 18"[457mm]. Beams can be made shorter (minimum 20"[508mm]) or longer, in 10"[254mm] increments. Because of the template’s unique “step over” ability, beams can be made longer to suit any width project. The beam is equally suited to router table or bench operation.

The following instructions will guide you through the beam making process. Care in building the beam will ensure great joinery every time with the R9PLUS. In addition to these instructions, a two page drawing, complete with all dimension information, is provided at the end of the user guide.

Important: Please use this chapter’s step-by-step instructions in conjunction with the technical drawing on pages 38-39 of the Appendix.

Page 6

Important: Please use these step-by-step instructions in conjunction with the technical drawing on pages 38-39 of the Appendix.

Chapter 1

ROUTER TABLE OPERATION

1-1 The beam assembly consists of the main beam

sacrificial backer boardand the clamping surface. The

R9PLUS Joinery System User Guide

1-2



, the

Start with a straight, flat and square 30"[762mm] length

of wood, 11⁄2" x 31⁄2" x 30"[35mm x 89mm x 762mm].

Making The Beam

clamping surface and sacrificial board are made from commonly available 5⁄8"[15mm] MDF (optional 3⁄4"[19mm]). Hardwood or softwood may also be used.

1-3 Cut a piece of MDF 30" long and 2

⁄8" wide [762mm x 54mm]. This will be your clamping surface. Then cut your sacrificial boards 11⁄2" x 30"[35mm x 762mm]. You may want to cut a number of extra sacrificial boards now to use as replacements.

1-4

Lay out the mounting screw holesand clamp holesas per the drawing on pages 38-39. Drill and countersink the screw holes on the clamping surface. Drill the 5⁄16"[8mm] holesin the sacrificial board. This piece can be reversed and flipped four times to use up all four surfaces.

1-5

This procedure is critical to the accuracy of the jig.

Before attaching the MDF boards to the beam, use each pin plate as a drill guide. First, mark a line 41⁄2"[114mm] in from the end of the beam and square it across. Next, stack the clamping surface, sacrificial board and beamnear the edge of the workbench and clamp in place.

1-6

Clamp a pin plate with its wide straight side flush to the flat bench surfaceand its side edge on the line. Using the 2 small holesin the pin plate as a drill guide, drill two

⁄32"[2,5mm] pilot holes 1"[25,4mm] deep.

Page 7

Making The Beam

ROUTER TABLE OPERATION

R9PLUS Joinery System User Guide

Chapter 1

1-7 Use two No.8 x 1

lightly

attach the first pin plate with its left edge flush to the

⁄2"[38mm] wood screws (included) and

marked line.

1-9 Assemble the Latches There are three parts to each

latch assembly: the latch screw, the nyloc nutand the plastic latch . Press the nyloc nut into the hexagon opening in the top of the plastic latch with the white nylon insert facing up. Next, screw in the latch screw from the bottom of the latch. Do not tighten the screw at this time.

1-8 Square a second line across the beam board exactly 7"

[178mm] from the right edge of the first pin plate. Clamp the second pin plate flat on the workbench and against the line. Repeat the drilling and attaching procedure as before.

Repeat this procedure for each successive pin plate.

1-10 Pin Plate “Pin” The template has positioning holes

that allow it to sit perfectly on top of the raised pinof each pin plate.

1-11 Attach the latches to the keyhole slots and turn to engage

the pin plates. Adjust the latch screw tension so that the latches are stiff to turn onto the plates (as seen from underside of template).

A A

1-12

Mount the template on the left pair of pin plates using the

⁄16"[11mm] pin position.

Page 8

Chapter 1

ROUTER TABLE OPERATION

R9PLUS Joinery System User Guide

Making The Beam

1-13 Turn the assembly upside down. Take a piece of the

predrilled sacrificial board and lay it flush on the template.

1-15

Place the clamping surfaceagainst the beam. Be sure the clamp hole layout marksare next to the sacrificial board. Screw the clamping surface to the beam through the countersunk holes.

1-14 Using the two

⁄16"[8mm] holes as drill guides, drill two 5⁄16"[8mm] holes through the beam. Attach the sacrificial board at the left end with a ¼-20 machine screw and wing nut. Then move the template to its second position and install the second screw.

1-16

Clamp Holes Drill all 3⁄4"[19mm] clamp holessquare to the beam, through the clamping surface and beam. Next, drill two holes (as per beam drawing), 5⁄16"[8mm] diameter and

⁄16"[14mm] deep, for the table glide(used for router table

operation only).

[8mm]

[114mm]

[47mm]

x 5/

dia.

[8mm x 8mm]

5/1

1-17 Side Stop Positioning Create layout lines as indicated

above for the sidestop. Note: Be precise. Side stop positioning is very important.

deep

1-18 Using a Brad Point or Forstner bit, counter bore a

⁄16"[8mm] hole, 3⁄8"[9,5mm] deep for the side stop hub. Then, using a 3⁄32"[2,5mm] bit, drill a pilot hole for the side stop mounting screw. Attach the side stop to the beam with the provided No.8 x 11⁄4"[30mm] round head screw.

Page 9

Making The Beam

ROUTER TABLE OPERATION

R9PLUS Joinery System User Guide

90º90

Chapter 1

1-19

The template will now be used to precisely position the pin plates. Slightly loosen all pin plate screwsjust enough so that the pin plates can move side to side. Position the template on the pin plates in the 3⁄8"[9,5mm] position. Set the side stop to the TD Max position.

1-21

Gradually tighten the second pin plate screwsmaking sure the template is not binding on the pins. Move the template to the second position and repeat the procedure with the third pin plate.

1-20 Clamp a square board against the side stop and flush

under the template. Insert the shank of the No.80-8 bit into the 5⁄16"[8mm] hole in the template. Move the template and pin plates laterally until the shank of the bit just touches the edge of the board. Now tighten the first pin plate.

1-22

Optional Hold-down for Bench Use

Notch out the ends of the beam in order to clamp beam assembly to a bench and use in hand-held router mode.

■

Important: The beam may expand or contract with humidity changes. Use the

⁄8"[9,5mm]

ho les to adjus t th e pin pla tes as r equired .

Page 10

1010

Chapter 1

ROUTER TABLE OPERATION

R9PLUS Joinery System User Guide

Making The Beam

Page 11

R9PLUS ROUTER TABLE OPERATION

CHAPTER 2

Glossary of Symbols

Which Way Around Should the Board Go?

The following symbols/icons are used throughout this user guide. They indicate which side of a board faces out (toward you, the operator, when clamped in jig), which faces are in or out when assembled, and which edge goes against the side stop. Dashed line icons indicate the other side of the board.

“Outside” of board

“Inside” of board

“Either side“ of board

1111

“Outside” of board (on other side of board)

“Inside” of board (on other side of board)

“Either side“ of board (on other side of board)

“This edge” against side stop

“This edge” against side stop (on other side of board)

2-1

Icons such as the one above indicate which side of the board faces out (toward you, the operator) when clamped in jig, and which faces are in or out when assembled.

2-2 Box joint boards are clamped against the beam both “face

in” and “face out” for alternate end cuts. With box joints, the same side edge always goes against the side stop.

2-3

Note:

Because through dovetail pin and tail boards face only one way, both side edges are (alternately) used against the side stop.

Page 12

1212

Chapter 2

ROUTER TABLE OPERATION

R9PLUS Joinery System User Guide

Glossary of Symbols

Page 13

1313

Safety is not optional.

Read and follow the recommendations in this chapter.

R9PLUS BENCH OPERATION

CHAPTER 3

Using Your Jig Safely

3-2 Always wear:

ÊUÊ>««ÀÛi`ÊÃ>viÌÞÊ}>ÃÃiÃÆÊ ÊUÊ>Êv>ViÊ>ÃÊÌÊ«ÀÌiVÌÊÞÕÀÃivÊvÀÊ>ÀvÕÊ`ÕÃÌÆÊ ÊUÊi>À}Ê«ÀÌiVÌ°

3-1

Read the owner’s manual that came with your router. It is essential to understand the router manufacturer’s instructions completely.

3-4

Always disconnect the power source from the router when fitting bits or guide bushings, or making adjustments. Before connecting the router to the power source, make sure the bit and collet revolve freely in all the areas you plan to rout, not touching the guidebush or jig.

3-3

! Never drink alcohol or take medications that can cause

drowsiness while operating a router.

Page 14

1414

ROUTER TABLE OPERATION

R9PLUS Joinery System User Guide

Using Your Jig Safely

Chapter 3

3-5

Do not tilt the beam. Keep the beam flat on the router table.

3-6

Chips and sawdust are thrown out at high speed. Always stand and use the beam from the opposite side of the chip and sawdust ejection.

■

Page 15

1515

R9PLUS ROUTER TABLE OPERATION

CHAPTER 4

Basic Jig Functions

Router Table Surface Temp l at e O ri en t at io n Pin Plate Positioning Routing Position Side Stop Clamping Procedure

Note: The images in this user guide show the “action” side of the jig, however the operator stands behind the router table, away from the chips and sawdust thrown off by the router bit.

Router Table Surface

4-1

When using the R9

PLUS

on a router table, be sure there are no height differences between the table and any lift mechanism, guide bushingor bushing adaptor. The template must slide smoothly over the table top.

A A

Templa t e Or i en t at i on

4-2 The engraved side of the template always faces up. Template

positioning holesare for through dovetail pins. Template positioning holesare for through dovetail tails and box joints.

Pin Plate Positioning

4-3

The beam is positioned on the template using the pin plate positioning holesand. Most illustrations will have an inset showing the correct template pin position for the procedure.

Routing Position

4-4 Always begin routing from the left end of the jig when

viewed from the operator’s position.

Page 16

1616

Chapter 4

ROUTER TABLE OPERATION

R9PLUS Joinery System User Guide

Basic Jig Functions

Side Stop

4-5

The side stop is set on one of the five positions, depending on the part or type of joint being routed. The side stop pictured above is in the TD (Through Dovetails) mode.

4-7

Squeeze the tips of the clamp locatorand insert through a clamp hole in the beam. Clamp locators hold the clamp arm firmly in place while the clamp’s screw arm is attached from the opposite side of the beam.

Clamping Procedure

4-6

Each of the F-Clamps included with the R9

PLUS

is fitted with a clamp locator. The clamp locators are pressed onto the clamp arm and should not be removed.

4-8

All boards are clamped against the side stop and flat on the

template. ■

Page 17

1717

R9PLUS BENCH OPERATION

CHAPTER 5

The Leigh e-Bush

Note: Normal tolerances with bits, guide bushings and router runout will generally produce poor fitting joints. The Leigh e10 elliptical guide bushing solves this problem.

Joint Fit Adjustment

5-1 The Leigh e-Bush barrel is elliptical

, unlike plain



circular template guidebushes. When rotated, the effective diameter of the barrel changes, allowing fit adjustments as small as .001"[0.025mm]. The e10 e-Bush is included with the R9

PLUS

5-2

With the e-Bush turned to “10”in the base the active

“diameter” is increased, allowing less side-to-side movement, resulting in smaller sockets and larger pins. Turning the e-Bush to “0”allows more side-to-side router/bit movement and more

wood removal, producing larger sockets and smaller pins, and thus a looser fit.

5-3

Make a small scratch line or permanent ink mark on the router baseplateor guidebush adaptor at the 12 o’clock and 6 o’clock position. This will help you steer the template along and between the guide surfaces.

5-4 All settings for the e-Bush will be aligned to the scratch or

ink marks on the router. The e-Bush will always be set on index mark 5 as a starting point for dovetails and box joints.

Page 18

1818

5-5

Chapter 5

Adjust the e-Bush with the pin wrench. Markings on the

ROUTER TABLE OPERATION

R9PLUS Joinery System User Guide

e-Bush indicate which way to turn it for a looser or tighter fit.

The Leigh e-Bush

5-6 One division of the e-Bush changes the joint glue line by

0.002" [0.050mm]. A perfect fit will be established with one or two test cuts.

5-6

After a good fit is established, record the e-Bush setting

for easy repeatability the next time.

■