Sears Craftsman 171.25450 Owner's Manual
ModelNo,
171.25450
CRAFT$1VlAK
INDUSTRIAL
DOVETAIL
FIXTURE
• Assembly
• Operation
iMPORTANT;Thefollowingrouterbitsarerequired
for usewiththis fixture:#25414-1/4-in. Straight Router Bitand
#25415-9/16-in. DovetailRouter Bitwhich are used
for THROUGHor OPENJOINTS.
: #25505 or #26318-1/2-in. DovetailRouterBit which
are usedfor a!l HALFBLINDJOINTS.
Readandfollow
all instructions
carefully.
KEEPTHIS
MANUALFOR
' FUTURE
REFERENCE,
# 83463
Sold by Sears,Roebuckand Co,, Hoffman Estates,IL 60179
, i i
FAILURETO HEEDALLSAFETYANDOPERATINGINSTRUCTIONS
ANDWARNINGSREGARDINGUSEOF THISPRODUCTCANRESULT
IN SERIOUSBODILYINJURY
1) KNOWYOURPOWERTOOL
Readtheowner'smanualcarefully.Learnitsapplicationsand
Iimitatlonsaswell asthespecificpotentialhazardsparticularto
thistool.
2) GROUNDALLTOOLS(UNLESSDOUBLEINSULATED)
Iftoolis equippedwithanapproved3-conductorcordanda3-
pronggroundingtypeplug,itshouldbepluggedintoathreehole
electricalreceptaute.It adapteris usedtoaccommodateatwo-
prongreceptacle,theadapterwiremustbeattachedto known
ground,(usuallythescrewsecuringreceptaclecoverplate).
Neverremovethirdprong.Neverconnectgreengroundwireto a
terminal.
3) KEEPGUARDSINPLACE
--in workingorder,andinproperadjustmentandalignment.
4) REMOVEADJUSTINGKEYSANDWRENCHES
Forma habitof checkingtoseethatkeysandadjustingwrenches
areremovedfromtoolbeforeturningit on.
5) KEEPWORKAREACLEAN
Clutteredareasandbenchesinviteaccidents.Floormustnot be
slipperydoeto waxor sawdust.
6} AVOIDDANGEROUSENVIRONMENT
Donot usepowertoolsindamporwetlocationsorexposethornto
rain.KeepworkareawelIlighted.Provideadequatesurrounding
workspace.
7) KEEPCHILDRENAWAY
All visitorsshooktbekeptata safedistancefromworkarea.
B) MAKEWORKSHOPCHILD-PROOF
--with padlocks,masterswitches,or byremovingstarterkeys.
9) DONOTFORCETOOL
It willdothejob betterandsaferatthe rateforwhichitwas
designed.
10)USEAPPROPRIATETOOL
Donotforcetoolor attachmentto doajob forwhichitwasnot
designed.
11)WEARAPPROPRIATEAPPAREL
Donotwearlooseclothing,gloves,necktiesorjewelry(rings,
wristwatches)to getcaughtin movingparts.Nonslipfootwearis
recommended.Wearprotectivehaircoveringtocontainlonghair.
Rolllongsleevesel;Dyetheelbow.
12)USESAFETYGOGGLES(HeadProtection)
WearSafetyGoggles(mustcomptywith ANSIZ87.1) atalltimes.
Also,usefaceordustmaskif cuttingoperationis dusty,andear
protectors(plugsormuffs)duringextendedperiodsofoperation.
13)SECUREWORK
Useclampsora viseto holdworkwhenpractical,it'ssaferthan
usingyourhandandfreesbothhandsto operatetool.
14)DONOTOVERREACH
Keepproperfootingandbalanceatalltimes.
15)MAINTAINTOOLSWITHCARE
Keeptools sharpandc]eanfor bestandsafestperformance.Follow
instructionsfor lubricatingandchangingaccessories.
16)DISCONNECTTOOLSBEFORESERVICING
-when changingaccessoriessuchasblades,bits,cutters,etc.
17)AVOIDACCIDENTALSTARTING
Makesureswitchisin OFFpositionbeforepluggingin.
18)USERECOMMENDEDACCESSORIES
Consulttheowner'smanualfor recommendedaccessories.Follow
theinstructionsthataccompanytheaccessories.Theuseof
improperaccessoriesmaycausehazards.
19)NEVERSTANDONTOOL
Seriousinjurycouldoccur;fthetool Istippedorthecuttingtool is
accidentallycontacted.0o notstorematerialsaboveor nearthetool
thatwouldmakeit necessaryto standon thetoolto reachthem.
20)CHECKDAMAGEDPARTS
BeforefurtheruseofthetooI,aguardor otherpartthatis damaged
shouldbecarefullycheckedto ensurethatitwill operateproperly
andperformitsintendedfunction.Checkfor alignmentof racy(rig
parts,bindingofmovingparts,breakageof parts,mounting,andany
otherconditionsthat mayaffectitsoperation.Aguardorotherpart
thatisdamagedshouldbeproperlyrepairedorreplaced.
21)DIRECTIONOFFEED
Feedworkintoabladeorcutteronlyagainstthedirectionof rotation
ofthe bladeor cutter.
22)NEVERLEAVETOOLRUNNINGUNA'n'ENDED
Turnpoweroff. Donotleavetooluntilit comesto a completestop.
23)KEEPHANDSAWAYFROMCUT(1NGAREA
24)STOREIDLETOOLS
Whennotin use,toolsshouldbestoredindry,highorIocked-up
place---outof reachofchildren.
25)O0HOTABUSECORD
Keepcordawayfrom heat,oil,andsharpedges.
28)OUTDOOREXTENSIONCORDS
Whentoo!isusedoutdoors,useonlyextensioncordssuitablefor
useoutdoors,andso marked.
27)NEVERUSEINANEXPLOSIVEATMOSPHERE
Normalsparkingofthemotorcouldignitefumes,flarnmab;eliquids,
or combustibleitems.
28)DRUGS,ALCOHOL,MEDICATION
Donotoperatetoolwhile undertheinfluenceofdrags,alcohol,or
anymedication.
READANDUNDERSTANDTHISCOMPLETEINSTRUCTIONBOOK
BEFOREUSINGTHISPRODUCT
2
ADDITIONALSAFETYINSTRUCTIONSFORYOUR
INDUSTRIALDOVETAILFIXTURE
1) AlwaysweareyeprotectionthatcomplieswithcurrentANSI
StandardZ78A.
2) Noiselevelsvarywidely.Toavoidpossiblehearingdamage,wear
earpIugsor muffswhenusingtheDovetailFixturefor hoursata
time.
3) Wearadust maskalongwiththesafetygoggles.
4) Donotusethis DovetailFixturewith routerbitsor guide
bushingsotherthanthosespecifiedforthecuts beingmade.
5) FollowtheinstructionsinyourRouterOwnersManual.
6) Vibrationscausedbytherouterduringusecancausefasteners
to becomeloose.Beforeuseandperiodicallyduringusecheckall
fastenerstomakesurethattheyareagtightandsecure.
7) Donotusethis productuntilallassemblyinstallationstepshave
beencompleted,andyouhavereadandunderstandnitsafetyand
operationalinstructionsinthis manual,andtheRouterOwners
ManuaL
8) Makesurethattherouterbitis properlypositionedin therouter
sothatit doesnotcontacttheguidebushingorthetemplatewhen
cutting.
9) TheDovetailFixturemustbesecurelymountedtoaworkbench
or otherstablesurfacewheninuse.Thefrontof thebaseshould
overhangthe frontof theworkbenchbynomerethan1/4"to provide
clearancewhenclampingworkpiecestotheDovetailFixture.
10) DonotusetheDovetailFixtureasaworksurface.Doingsomay
causedamageto theDovetailFixture,whichcancauseitto beunsafe
to use.Aworkbenchshouldbeusedforthispurpose.
11)Thisproductis designedtocutflatworkpieces.Donotcutor
attempttocutworkpiecesthatarenotflat orthatareirregularly
shaped.
12)Thisproductis to beusedforcuttingwoodworkpiecesonly.Do
notusethisproducttocutmetaloranyothernon-woadmaterial.
13)Thisproducthasbeendesignedto cutworkpieceshaving
thicknessesof3/8"to 1".Donotuseforworkpiecesofanyother
thicknesses.
14)DonotclampanyworkpiecestotheDovetailFixtureormakeany
adjustmentsto theDovetailFixtureunlesstherouterhasbeenturned
off,the routerbitisnotturning,andthe Routerhasbeen
disconnectedfromtheelectricaloutlet.
15)Whensetting"lhe-dopth-ot-cut"oftherouterbit,makesurethat
theworkplaceis clampedto theDovetailFixturein sucha.manner
thattherouterbitdoesnotcutinto the Dovetailbasecausing
damagetoit orpassibleseriousinjurytoyou.
16) ALWAYSUNPLUGTHEROUTERFROMTHE
ELECTRICALOUTLETBEFOREINSTALLINGORREMOVINGROUTER
BITSFROMTHEROUTERANDWHENADJUSTINGTHECUTTING
DEPTHOFTHEROUTERBIT;ORWHENINSTALLINGORCHANGING
GUIDEBUSHINGS,
17)NEVERLiFTTHEROUTERUPWARDSWHENTHEROUTERiS
"ON",THEROUTERBITISROTATING,ANDTHEGUIDEBUSHINGiS
NEARORTOUCHINGTHETEMPLATE,BECAUSETHISWILLCAUSE
THEROUTERBITTOCUTINTOTHETEMPLATEANDDAMAGEIT.
INTRODUCTION
o Your Sears/Craftsmanindustrial DovetailFixture is an accessory used with your Routerto allow you to make drawers, chests, and the like
where dovetail joints are used to join the front, back,and sides of the workpiece.
TheDovetail Fixturewig allow you to make1" spaced flush andflush offset and 318"rabbetedhaif-bfind dovetail joints, in addition you can
make1" spaced (or open) dovetail joints.
• Workplace widths up to 16"can beaccommodated.
Workplacethicknesses between318"and1" can beaccommodated,
The Dovetail Basehas six pockets molded into its front which are gauges to aid you in setting the "depth-of-cut" for commonly used
depths: 3/8", 1/2", 5/8", 3/4'1,7/8", and 1".
The Dovetail Fixture comeswith two templates andtwo guide bushings for making bait-blind and through or openjoints.
Sears/Craftsman router bits,#25414 and#25415, WHICH MUST BEPURCHASEDSEPARATELY,are required to makethe THROUGHor
OPENjoints.
Sears/Craftsman router bit, #25505 or #26318, WHICH MUSTBE PURCHASEDSEPARATELY,is required for making the haIf-bIind joints.
• Eachtemplate has a label, describing the joint that can becut, along with set up information, the bit and guide bushing required, and the
stop block setting for a particular joint.
The Dovetail Fixture can be used with al! Sears/Craftsman Routers.
With a separately purchasedSears/Craftsman#25326, Universal Router Adapter,the DovetagFixture can be usedwith many non-
Craftsman Routers, such as, Black & Decker,Makita,and SkiL
UNPACKINGANDCHECKINGCONTENTS
in orderto simplify handIingand to minimize any damagethat may occur during shipping, your Industrial Dovetail Fixtureis packaged
unassembled,
Separateall parts from the packing materials and check eachonewith the igustrations and list of partsat the endof this manuaIto make
sure that ag parts are presentbefore discarding any packaging material.
• Ifany parts aremissing or cannot beaccounted for, do not attemptto assemble,install, or use the industrial DovetailFixture
until the missing parts havebeenobtained and the product has beenassembled correctly.
Contactyour localSearsRetail Outletfor a repIacement product or for the missing parts.
3
ASSEMBLYINSTRUCTIONS
Thefollowingtoolsare requiredforassembly:
1) AmediumsizedPhillipsscrewdriver,
2) Asmallor mediumsizedadjustablewrench.
ASSEMBLYOFTHERIGHTSIDETEMPLATESUPPORTTOTHEDOVETAILBASE
1). Placethedovetailbasetopsidedownonaflatsurface.
2) insertoneof the5/16-18x2"longroundheadsquareneckboltsintothes!otintherightsideofthebase.(NOTE:Therightsideof the
baseis identifiedbythewordsRIGHTSIDEmoldedintoit.)
3) Placea11/32"I.D_x 7/8"O.D.washerontothe boltasshownin Figure1,
4) Threada5/16-18hexnutontothebolt,asshown,untilit bottomsoutagainstthe washer,
5) Backoffthenutfromthe washerbetween1/4 and1/2turns.NighthenutsothatthecornersofthenutareverticallYlineduPasshown.
Notethe alignmentofthe hexpocketinthetemplatesupport.Theboltshouldbefreeto movesidetoside;if it doesnot,loosenthenut1/3
turnor untilthe cornersofthenutpointupanddown.
8) Assembletherighttemplatesupportto therightside ofthedovetailbaseso thatthe hexoutlinesupandf ts intothehexpocketinthe
righttemplatesupport,(NOTE:TherighttemplatesupporthasthewordsRIGHTSIDEmoldedintoitfor identification.)
7) Assemblea#10-32x5/8°tongpanheadmachinescrew,a 13/64"!.D.x 9/16"O.D.washer,anda#10"32hexnutt° thebaseassh°wnt°
holdthetemplatesupportin place.Securelytightenthenut andscrew_
8) Thetemplatesupportshouldmovefreelyfrontto backalongthe sideofthe base,If it doesnot,it meansthatthe5/16-18hexnutis too
tight ontheboltandshouldbeloosened.Todothis, removethefastenersassembledinstepT,andremovethetemplatesupport;repeatsteps
4 through7.
• ASSEMBLE THE LEFT SIDE TEMPLATE SUPPORT TO THE DOVETAIL BASETHE SAME AS THE RIGHT SIDE
TEMPLATE SUPPORT WAS ASSEMBLED
Fig. 1
11/32"LO.XT/8"O.D.WASHER
5/16-18X2"tongROUNDHEAD
SQUARENECKBOLT
DOVETAILBASE
"/8"longPANHEADMACHINESCREW
MUSTLINEUP
_.D.WASHER
?HEXNUT
_ BACKOFDOVETAILBASE
ASSEMBLYOFTHETOPCLAMPINGBARTOTHEDOVETAILBASE
1) Assembleoneoftheboltsupportsto bothofthe 5/16-18X3-1/2"longroundheadsquareneckboltsasshowninFigure2.
2) Alignthesquareontheboltwiththesquareholeinthe boltsupport.Theboltsupportisto =bottom-out"againstthe bolt asshownin
Figure3.
FIG.2 5/16-18X3-1/2"FIG.3
longROUND
HEADSQUARE _-x
,o,,
FIG. 3a
3) Assembleoneofthespringsto eachofthenylonspringretainersbypushingthespringoverthe raisedcylindricalportionof the
springretaineras shownin Figure3aandFigure3b,
4) Positionthedovetailbaseonafiat smoothsurfacesothe backofthebaserestsonthesurface.
NOTE:ALTHOUGHBOTHENDSOFTHEDOVETAILBASEARESHOWNASSEMBLEDINTHEFOLLOWINGFIGURES,THEACTUALASSEM-
BLYIS DONEONEENDATATIME.
5) Fromthebottomofthe base,inserta boltwithboltsupportthroughtheslotin thetop ofthebasesothe raisedportionof thebolt
supportgoesinto theslot,asshowninFigure4,
Fig, 4 SLOTIN SLOTIN
DOVETAIL DOVETAILEASE DOVETAIL BOLTANDBOLT
EASE / BASE
BOLTAND
BOLTSUPPORT
FRONTOFDOVETAILBASE
6) Placea5/16"I.D.X7/8"O.D.thick nylonwasheroverthe boltso thatthecountersinkfacesawayfromthe dovetailbaseasshownin
Figure6. It will benecessaryfor youto holdthe boltin placewhenperformingthis andthefollowingsteps.
HELPFULHINTS:Positionthe boltandtheboltsupportunderthenotchin theribas shownin Figure5, to helpholdtheboltin place,
Fig. 5 _ NOTCHINRIB
SLOTINDOVETAILBASE
BOLTANDBOLTSUPPORT
7) Placeaspringandspringretainer,assembledinstep3, overtheboltsothespringfitsintothecountersinkinthethickwasherasshown
InFigure6.
8) Pressdownonthespringretaineruntiljusttheendofthebolt sticksoutpasttheendofthe springretainer.
9) Slidetheclampingbaroverthebolt sothatthespringretainerabutstheinsideoftheclampingbarasshownin figure6.NOTE:THE
SPRINGRETAINERMUSTPUSHAGAINSTTHECLAMPNGBAR.
10)Placean11/32"I.D.X7/8"O.D.thin nylonwasherandan 11/3Z I.D.X7/8"O.D.washeroverthe bolt.It will benecessaryfor youto
pressdownonthe dampingbarwhiledoingthis.
11)Takeoneoftheclampingknobsandthreaditontothe boltasshown.DONOTTHREADtheknobcompletelyontothebolt--just enough
sothe knobholdsthe clampingbarinplace.
CLAMPING
FIG. 6 KNOB
SPRINGAND
NYLONSPRING
RETAINERFIT
INSIDETHEOPEN
SIDEOFTHE
CLAMPINGBAR
(SEECLAMPING
BARDETAIL)
SPRING
31/2"BOLT
BOLl
SUPPORT
12)Repeatabovesteps4through11for theotherendof theclampingbar.
13)Assembletheendcapstotheendsoftheclampingbarby pressingthemin; theyaredesignedto be"force-fit"intothebarin oneway
only.It maybenecessaryto "tap"themin bygentlyhittingthemwitha rubbermatletora pieceofwood--sincetheyfit verytightlyintothe
clampingbar,USECAREWHEN DOINGTHISSOAS NOT TO DAMAGE THEEND CAPS,
USECARETHATTHECAPSAREPROPERLYALIGNEDAS SHOWN WHEN ASSEMBLINGTHEM TO THEBAR.
tf/32"LD.X 7/B"O.D.WASHER
11/32"LD.X T/8"O.D.
THINNYLONWASHER
CLAMPINGBAR
\
Assembleclampingbar,knobs,endcaps on bothends asshown
CLAMPINGBARDETAIL
11/32"LD.X7/8"O.D. (RETAINERABUTSTHE
CLAMPINGBARENDCAP
WASHER LAMPING SAR)
OPENSIDEOFTHECLAMPING
BARPOINTSTOWARDTHETOP
SURFACEOFTHEDOVETAILBASE
11/32"LD.X 7/8"O,D.
t THICKNYLONWASHER
CLAMPINGBAR(SHOWNWITH /
DOVETAILBASE
/ TOPSURFACEOFTHE
-- RIGHTTEMPLATE
SUPPORT
ENDCUTAWAYANDSECT!ONED /
SONYLONSPRINGRETAINER /
PLACEMENTCANBESEEN) /
COMPRESSION
SPRING
NYLONSPRINGRETAINER
/
fig.7
CLAMPINGBARPARALLELTO
TOPOFBASE
0 0 0
14)Tightentheclampingknobsontothe boltssothatthespacebetweenthebottomoftheclampingbarandthetop of thebaseisabout
1 1/2".Theciampingbarshouldbeparallettothe topofthe base.
15)AftercompletingtheabovestepsyourDovetailFixtureshouldlookliketheillustrationin Figure7.
J SPACINGTOBE
APPROXIMATELY
1-1/2"
6
ASSEMBLYOFTHEFRONTCLAMPINGBARTOTHEDOVETAILBASE
1) Assemblethe front clampingbarto the dovetailbasefollowingthesameprocedureusedto assemblethetop clampingbartothedove-
tail baseasshownin Figure8.The5/16-18X4-1/2"longroundheadsquareneckboltsareused,
Fig. 8
BOLT
0
4 I/2" BOLT / ""
11/32"1.D.X7/8"O.D,
THICKNYLONWASHER
COMPRESSIONSPRING
CLAMPINGBAR
ENDCAP
1!/32"LD.X7/B"O.D,
RETAINER THINNYLONWASHER
CLAMPINGBAR
(SHOWNWITH
ENDCUTAWAY
ANDSECTIONED
SONYLONSPRING
RETAINERPLACE-
MENTCANBE
SEEN)
COMPRESSION
SPRING
NYLONSPRING
RETAINER
(RETAINER
ABUTSTHE
CLAMPINGBAR)
11/32"I.D.X 7/8"O.D.WASHER
ASSEMBLYOFTHECAMHANDLESAND PIVOTSHAFTTOTHEDOVETAILBASE
Afterthecamhandlesandpivotshafthavebeenassembledto thebase,it willbepossibleto accuratelypositionthetemplatesfor close
fittingjoints,
Notethattherearesomegraduationsonbothtemplatesupports.
• Rotatingthecamhandlesothat thepointerlinesupwithoneofthegraduationspermitsaccuratefront-to-backpositioningofthe
template.
• Camhandlesaredesignedto provideinfinitetemplateadjustment.
Onegraduationequals1/64"of movementof thetemplate.
• Rotatingthecamhandlesothat thepointerlevermovestowardthefrontof thebase.causesthetemplateto alsomovetowardsthefront
ofthe base.
• Converselyrotatingthecamhandlesothatthepointerlevermovestowardthe backofthe base,causesthetemplateto alsomove
towardsthebackofthe basealso.
1) Assembleoneofthe camhandlestothepivotshaftusinga #10-32x 5/8"longpanheadmachinescrewanda 13/64"I.D.x9/16"LD.
washer,asshownin Figure9,
2) Usecareso thatthe pivotshaftfitsintothehex-shapedholein thecamhandle.Thepivotshaftmayfit tightly intothecamhandle;
this isnormal.
3) Makesurethatthepivotshaftbottoms*outinsidethecamhandle.
Fig. 9
/ CAMHANDLE
13/64"t.D.X9/16°0.O,WASHER--_,,,,_ _ PIVOTSHAFT
7
4) Securelytightenthe screw,
NOTE:THENEXTTWOSTEPSAREPRE-ASSEMBLYSTEPS.
5) Sgdetheretainerovertheendof thepivotshaftfor about2".Theretainermayfit tightly;thisis normal
6) Threadthe#1_`16x1/2"_ngpanheadtappingscrewint_theh_eintheretainerunti_itbott_ms-_tagain_tthepiv_tsha_.(Thescrew
willfit tightlyinthehole.)SeeFigure10.
Fig. 10
_ #!0-16X 1/2"LONGPANHEADTAPPINGSCREW
7) Loosenthescrewaboutoneturn.Removethe retainerfromtheshaftandsetit asidetemporarily.
8) Assemblethe pivotshaftwithcamhandleto the basebyinsertingtheendof thepivotshaftthroughthe holestntherighttemplate
supportandthebase.
9) MAKESURETHEORIENTATIONOFTHECAMHANDLEISASSHOWNINFIGURE11.
10)PlacetheretaineratthelocationshowninFigure12endpushthepivotshaftthrough.THEORIENTATIONOFTHERETAINERRELAT]VE
TOTHECAMHANDLEWITHSCREWMUSTBEASSHOWN.
NOTE:THERETAINERMAYFITTIGHTLYONTHEPIVOTSHAFT;THISISNORMAL.
Fig. 11
DOVETAILBASE
11)Continuepushingthepivotshaftthroughtheholesandtheretaineruntilthe endofthepivotshaftextendsout ofthelefttemplatesupport
asshowin Figure12.
12)Makesuretheendof thecamhandlefits intothe holein thebaseasshown,
Fig. 12
PIVOT,
HOLEINBASE,
CAM
HANDLE _"
13)Withthecamhandlepushedin againstthebase,positionthe retaineragainstthesidewallofthebase,asshownin Figure13.Theretainer
shouldbarelytouchthesidewall ofthe base.Thepurposeof the retaineristopreventor minimizetheside-to-sideofthecamhandleand
pivotshaft.
PtVOTSHAFT
SUPPORT
Fig. 13
RVOTSHAFT
-SIDEWALLOFBASE
9
14)Assembletheothercamhandleto theotherendofthepivotshaftusinga13/64"I,D.x 9/16"O.D,washeranda#10-32X 5/8"long
penheadmachinescrew,asshownin Figure14.
15)Makesurethatthecamhandlelinesupwiththecamhandleattheotherendofthe pivotshaftandthattheendofthecamhandlefitsinto
theholein thebase.
16)Tightenthe screwsecurely, LEFTTEMPLATESUPPORT
Fig. 14
/_ #10-32X5/8"LONG
PANHEADMACHINE
SCREW
_" DAMHANDLE
17)Rotateoneofthecamhandtes-ltshoutdrotatefreelyand movethetemplatesupports,
18)Ifthis doesnothappen,loosenthescrewontheretainerandmovetheretainerawayfrom thesidewallslightly,
19)Securelyretightenthescrew.
20)If thereistoomuchside-to-sidemovement(play)ofthecamhandles;loosenthescrewin theretainerandmovetheretainerc/osertothe
sidewaltof thebase.
21)Securelyretightenthescrew,
ASSEMBLYOFTHEFRONTSTOPBLOCKSTOTHEDOVETAILBASE
1) Aseemblethefrontstopblockstothefront ofthedovetailbase,ateachend,using#10-32x 5/8"longflatheadmachinescrews,13/64_
I.D.x 9/16"O.D.washers,and#!0-32 hexnuts,asshownin Figure15.
2) Makesurethattheopenrib portionfits intotheslotin thefrontofthe base.Thestopblockwglfit intotheslotin onepositiononly,
3) Tightenthescrewsecurelyontothenut.
4) Assembletheotherfrontstopblocktooppositeendo1thedovetagbaseinthesamemanner.
Fig. 15
FORREASONSOFCLARITY,THEFRONT
CLAMPINGBAR,KNOBS,BOLTSAND
SPRINGSARENOTSHOWN
WASHER
DOVETAILBASE\
SLOT_
#10_32XB/8OLONG
FLATHEADMACHINE
SCREW
SUPPORT
#10-32HEX
13/64_LD.X9/16°O.D/
WASHER J
FRONTSTOPBLOCI_
_ FRONTOFDOVETAtLBASE
5/8"LONGFLATHEAD
MACHINESCREW
10
ASSEMBLYOFTHETOPSTOPBLOCKSTOTHEDOVETAILBASE
• Thetopstopblocksareassembledto thetopofthedovetailbasein oneoftwowaysdependinguponwhichstyleofdovetailjointis
to becut:
a) HALF-BLINDFLUSHJOINTS--The"A" onthestopblockfacestowardthe"middleofthebase".
b) HALF-BUNDRABBETJOINTS_The"B"onthestopblockfacestowardthe"middleofthebase".
c) THROUGHJOINTS--The"A" onthestopblockfacestowardthe"middleofthebase".
• Sincetheflushjointis themorecommonlyusedjoint,thefollowinginstructionsapplytotheassemblyofthe stopblocksforthis
stylejoint.
1) Positionthedovetailfixturerightsideuponaflat surface.
2) Assembleoneofthetopstopblockstothetopsurfaceofthe baseusinga#10-32x 7/8"longflatheadmachinescrew,as shownin
Figure16.Thescrewthreadsintotheholeinthe bottomofthesIot.
3) Makesurethatthe "A"facesthe"middleofthebase".
4) Makesuretheopenribportionof thestopblockfits intotheslot in thetopsurfaceofthebase.
Fig. 16 RfBONSTOPBLOCK_
#10_32X 7/8_LONG \
MACHINESCREW
#t0-32X7/8"L'ONGFLAT
HEADMACHINESCREW
TOPSTOPBLOCK
SLOTINTOP/
OFBASE
SLOTINTOP
OFBASE
MIDDLEOFTHEBASE
5) Assembletheremainingtopstopblockto theoppositeendofthebaseinthesamemanner.
6) Againmakesurethatthe"A" facesthe"middleofthebase"
7) Tightenbothscrewssecurely.
8) Torepositionthestopblocksforrabbetjoints,simplyloosenthescrewsjustenoughso thattheribsonthe stopblockscomeoutofthe
slot,Thestopblockisthenrotated180° tothealternateposition,sothe"B"facesthe middleofthebase,andsecurelyretightenthescrews.
ASSEMBLYOFTHECLAMPINGKNOBSTOTHEDOVETAILBASE
1) Assemb_e1_/32"_D.x 7/8"____was_ers_ntot_e_/1_-18b_itsat b_thends_ft_ed__etai__aseassh__nin Figure17_
2) Assemblethe clampingknobsontothe boItsasshown.
3) Threadtheclampingknobsontotheboltsso thatthespacingbetweenthewasherandthetemplatesupportsisapproximately1/2".
4) Setthe dovetailbaseasideforthetimebeingandcontinueon withthenextsection.
ASSEMBLYOFTHETEMPLATES
/ 5/16-18X2"longROUND
Fig. 17 / HEADSQUARENECK
BOLT
5/t6-t8X2°tongROUND
HEADSQUARENECKBOLT\
\
11/32"I.D.XT/8"
// O.D,WASHER
KNOB
CLAMPING/
KNOB
11
!/2"SPACING8ETWEFNWASHERAND
TEMPLATESUPPORT(BOTHENOS)
•Placethetemplatestiffenerintotherectangularslotin theunderneathsideofthetemplate,asshowninFigure18.
NOTE:THETEMPLATEFORCUTTINGHALF-BLINDJOINTSISBEINGUSEDASANILLUSTRATIONINTHEFOLLOWIHGFIGURES.
1) Threada #8-36x3/16"longpanheadmachinescrewthrougheachofthe fiveholesinthetemplateandintothethreadedholesin the
templatesupport,asshowninFigure24andsecurelytightenallofthescrews.
Fig. 18 _ TEMPLATESTIFFENER
\ _ _ _ J jRECTANGULARSLOT
TEMPLATE
_ _ MACHINESCREwSLOTTEDBINDINGHEAD_ _ MA#&3gX3!!6"t°ngPANHEADcHINESCREW
NOTE:ONSOMEEARLYVERSIONSOFTHISPRODUCT,ASLOTTEDBINDINGHEADMACHINESCREWHASBEENSUBSTITUTEDFORTHE
PANHEADSCREWSPECIFIEDFORASSEMBLINGTHETEMPLATESUPPORTSTOTHETEMPLATES.(SEETHESCREWILLUSTRATIONIN
FIGURE18),
2) Assemblethetemplatebracketsto thetemplateusingfour#10-32x3/8°longpanheadmachinescrews_asshownin Figure19.
3) MAKESURETHATTHETEMPLATEBRACKETSAREASSEMBLEDTOTHEUNDERNEATHSIDEOFTHETEMPLATE,ASSHOWNIN
FIGURE19,ANDTHATTHEAL]GNMENTOFTHEBRACKETSIS ALSOASSHOWNINTHEFIGURE.
4) ITISNOTNECESSARYFORTHESCREWSTOBETIGHTENEDATTHISSTAGE;THETEMPLATEBRACKETSSHOULDBEFREETOMOVE
WITHRESPECTTOTHETEMPLATEORELSEITWILLNOTBEPOSSIBLETOALIGNTHETEMPLATEASDESCRIBEDINTHENEXTSECTION.
5) TheassembledtemplateshouldlookliketheillustrationinFigure20.
Fig. 19
#10-32X3/8"tongPANHEADMACHINESCREW
TEMPLATE
'\
_- TEMPLATEBRACKET....
6) AssemblethetemplatestiffenerandthetemplatebracketstotheTEMPLATEFORCUTTINGTHROUGHJOINTSusingthesamemethod
describedintheprecedingsteps1through5,Referto Figure20.
Fig. 20
lg
ALIGNMENTOFTHETEMPLATES
Inorderfor the DovetailFixturetofunctionproperly,it isnecessaryfor thetemplatestobealignedwithrespecttodovetailbase.The
reasonforthis, isthatdovetailcutsareat bothendsoftheDovetailFixture.Whenproperlyaligned,theresultbeingall matingcorners
willalwaysbelinedup.
NOTE:THETEMPLATEFORCUTTINGHALF-BLINDJOINTSISBEINGUSEDASANILLUSTRATIONINTHEFOLLOWINGFIGURES,
1) Withthedovetailbasesti!lhavingthe1/2"spacingbetweenthewasherandthetemplatesupports(Referto Figure17),assemblethe
templateassemblyto thedovetailsothat:
a) theslotin thetemplatebracketfitsoverthebolt,
b) thelegofthe templatebracketis betweenthewasherandthetemplatesupport,and
c) thelegsfit intotheslotsinthetemplatesupports,asshownin Figure21.
d) NOTE:THISPROCEDUREMUSTBEFOLLOWEDWHENEVERTHETEMPLATEISINSTALLEDONTHEDOVETAILFIXTURE.ITISMOST
IMPORTANTTHATLEGOFTHETEMPLATEBRACKETALWAYSBEBETWEENTHEWASHERANDTHETEMPLATESUPPORTORELSETHE
TEMPLATEWILLNOTBEPROPERLYPOSITIONEDFORCUTTINGACCURATEDOVETAILS.Forinitialsetup,Allowthelegsofthe template
bracketto "bottomout" intheslotsinthe tempiatesupportsasshownin Figure21.
Fig. 21
WASHER
BOLT_
TEMPLATEBRACKET
SLOTIN THETEMPLATEBRACKET
_ RtGHTTEMPLATESUPPORT
j SLOTINTHETEMPLATESUPPORT
0
"_TEMPLATEBRACKET"BOTTOMS-OUT"AGAINSTTHIS
SURFACE(BOTHENDSOFDOVETAILBASE)
TOREMOVETHETEMPLATEFROMTHEDOVETAILFIXTURE,LOOSENTHECLAMPINGKNOBSSOTHATSPACINGBETWEENTHE
TEMPLATEBRACKETANDTHEWASHERISABOUT1/2";GENTLYLiFTTHETEMPLATEUPWARDFROMTHEDOVETAILBASESOTHATTHE
TEMPLATEBRACKETCLEARSTHESLOTSINTHETEMPLATESUPPORTANDSTOREINACONVENIENTLOCATION,
2) LightIytightentheclampingknobsat bothendsofthebasesothatthetemplatebracketsareheldin placeagainstthetemplatesupports
asshowninFigure21.
3) Movethetemplatefrom sideto sideonthetemplatebracketssothatitis centeredwith respecttothe templatebrackets,Thismeansthat
thetemplateandbracketsshouldlookIikeoneofthefollowingfigures:Figure22,Figure23,or Figure24,Movetemplatefront-to-backsothat
front edgeoftemplateisparallelwith thefrontofthe dovetailbase.IneachconditionthetemplateandthetemplatebracketsMUSTbe
symmetricalwith eachother.Thefiguresdonot showthecompletedovetailfixture,butonlytheunderneathsideofthetemplatewithtemplate
bracketscorrectlypositioned,in orderthatthecorrectpositionsofthe partscanbeseenclearly.
]3
Fig. 22
TEMPLATE
_"DISTANCEBETWEENTHESESURFACES
MUSTBEEQUALATBOTHENDS
I
TEMPLATEBRACKET
CONDITIONONE."TEMPLATEBRACKETSPROTRUDEBEYONDTEMPLATES
Fig. 23
.24
j TEMPLATE
J
F
THESESURFACESMUST
BEEQUALATBOTHENDS
o
_0 0 TEMPLATEBRACKET
CONDITIONTWO;TEMPLATEPROTRUDESBEYONDTEMPLATESBRACKETS
MUSTBEEQUALATBOTHENDS
CONDITIONTHREE.TEMPLATEEVENWITHTEMPLATEBRACKETS
o 0
0
TEMPLATEBRACKET
14
4) Afterthetemplatebracketshavebeencorrectlypositionedonthetemplatesecurelytightenthefourscrewsholdingthetemptatebrackets
to thetemplate.
5) Removethetemplateassemblyfromthebaseandsetit asidefornow.
6) Aligntheothertemplateassemblyin thesamemanner,
ITSHOULDBENOTEDTHATYOUMAYFIND,THATAFTERMAKINGSOMESAMPLECUTS,SLIGHTADJUSTMENTSMAYBEREQUIRED.
HOWTOMAKETHESEADJUSTMENTSIS EXPLAINEDINTWOOFTHEFOLLOWINGSECTIONS:"MAKINGADJUSTMENTSFORHALFBLIND
JOINTS"or "MAKINGADJUSTMENTSFOROPEN(THROUGH)JOINTS".
7) Removethetemplateassemblyfromthebaseandsetit asidefornow.(Figure25 below,isanexampleof INCORRECTLYpositioned
templatebrackets,)
CKET
BEYONDTHETEMPLATE
BRACKET
0
o
!o 0
THETEMPLATEBRACKETEXTENDS
tEMPLATE
CONDITIONFOUR:THISCONDITIONISNOTCORRECT---
TEMPLATEBRACKETEXTENDSBEYONDTHETEMPLATEAND
THETEMPLATEEXTENDSBEYONDTHETEMPLATEBRACKET
• StMPLYMAKESUREBRACKETSAREPOSITIONEDTHESAMEATEACHEND
ASSEMBLYOFA GUIDEBUSHINGTOTHEROUTER
ALWAYSMAKESURETHATTHEROUTERIS "TURNEDOFF"ANDTHATTHEELECTRICALCORDHASBEENUNPLUGGED
FROMTHEELECTRICALOUTLETBEFOREASSEMBLINGAGUIDEBUSHINGTOTHEROUTERORMAKINGANYADJUSTMENTSOR
CHANGINGROUTERBITSINTHEROUTER.
REMOVEANYROUTERBITFROMTHEROUTERBEFOREPROCEEDINGWITHTHEASSEMBLYOFA GUIDEBUSHINGTOTHEROUTER.
Assembly for Sears routers with three hole baseplates:
1) Placethe'routerupsidedawnonaflat surfaceandremoveanyguidebushingthatmaycurrentlybeinthe router,
2) Placetheguidebushingrequiredforthetypeof dovetagjoint to becutundertherouterbaseplateasshownin Figure26.
Fig. 26
10-32X3/8°LONGFLATHEAD
MACHINESCREW
(1/2"DIAMETERSHOWN)
NOTETHEORIENTATIONOF"
THEGUIDEBUSHING
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