VERMONT AMERICAN 23461 User guide
SAFETY
ASSEMBLY INSTALLATION OPERATION PARTS LIST
WARNING:
Before operating product, read this
manual and follow all its Safety and
Operating Instructions.
FRANÇAIS/
ESPAÑOL
®
INDUSTRIAL DOVETAIL JIG
MODEL# 23461
IMPORTANT: The following router bits are required for use
with this jig.
• VA #22437, or MAGNA #M91016, 1/4" Straight Router Bit, and
VA #22501, or MAGNA #M91114, 9/16" Dovetail Router Bit
which are used for THROUGH or OPEN JOINTS.
• VA #22500, or MAGNA #M91113, 1/2" Dovetail Router Bit,
which is used for all HALF BLIND JOINTS.
2
TABLE OF CONTENTS
General Safety Instructions for Power Tools .......................................... 3
Additional Safety Instructions for Industrial Dovetail Jig ...................... 4
Introduction ................................................................................................ 5
Unpacking and Checking Contents .......................................................... 5
Assembly .................................................................................................... 6
Assembly of the Right Side Template Support to the Dovetail Base .............. 6
Assembly of the Top Clamping Bar to the Dovetail Base.................................. 7
Assembly of the Front Clamping Bar to the Dovetail Base .............................. 9
Assembly of the Cam Handles and Pivot Shaft to the Dovetail Base .............. 10
Assembly of the Front Stop Blocks to the Dovetail Base ................................ 13
Assembly of the Top Stop Blocks to the Dovetail Base .................................... 14
Assembly of the Clamping Knobs to the Dovetail Base.................................... 14
Assembly of the Templates .................................................................................. 15
Alignment of the Templates .................................................................................. 16
Assembly of the Adapter Plate to the Router...................................................... 18
Assembly of the Guide Bushing to the Router .................................................. 21
Installation .................................................................................................. 22
Operation .................................................................................................... 24
Styles of Dovetail Joints ...................................................................................... 24
Half Blind Flush Joint ...................................................................................... 24
Half Blind Flush Offset Joint............................................................................ 25
Half Blind Rabbeted Joint ................................................................................ 25
Open or Through Joint .................................................................................... 26
Adjusting the Depth-of-Cut of the Router Bit...................................................... 26
Clamping the Workpieces to the Dovetail Base ................................................ 28
Making Drawers with Half Blind Flush Joints .................................................... 29
Making Drawers with Half Blind Flush Offset Joints.......................................... 35
Making Drawers with Half Blind Rabbeted Joints .............................................. 35
Making Projects with Open (Through) Joints .................................................... 37
Parts List .................................................................................................... 47
3
SAFETY
This manual contains information that is important for you to
know and understand. This
information relates to protecting YOUR SAFETY and
PREVENTING EQUIPMENT
PROBLEMS. To help you rec-
ognize this information, we use
the symbols to the right.
Please read the manual and
pay attention to these sections.
URGENT SAFETY INFORMATION - A
HAZARD THAT WILL CAUSE SERIOUS INJURY OR LOSS OF LIFE
IMPORTANT SAFETY INFORMATION- A HAZARD THAT MIGHT
CAUSE SERIOUS INJURY OR LOSS
OF LIFE
INFORMATION FOR PREVENTING
DAMAGE TO EQUIPMENT
INFORMATION THAT YOU SHOULD
PAY SPECIAL ATTENTION TO
GENERAL SAFETY INSTRUCTIONS FOR POWER TOOLS
Failure to heed all safety and operating instructions and warnings regarding use of this
product can result in serious bodily injury.
WARNING
1. Know your power tool
Read the owner’s manual carefully. Learn its
application and limitations as well as the specific potential
hazards peculiar to this tool.
2. Ground all tools (unless double insulated)
If tool is equipped with an approved three-conductor cord
and a three-prong grounding type plug, it should be
plugged into a three hole electrical receptacle. If adapter is
used to accommodate a two-hole receptacle, the adapter
wire must be attached
to a known ground (usually the screw securing
receptacle cover plate). Never remove third prong.
Never connect green ground wire to a terminal.
3. Keep guards in place
Maintain in working order, and in proper adjustment and
alignment.
4. Remove adjusting keys and wrenches
Form a habit of checking to see that keys and adjusting
wrenches are removed from tool before turning it
ON.
5. Keep work area clean
Cluttered areas and benches invite accidents.
Floor must not be slippery due to wax or sawdust.
6. Avoid dangerous environment
Do not use power tools in damp or wet locations
or expose them to rain. Keep work area well lighted.
Provide adequate surrounding work space.
7. Keep children away
All visitors should be kept a safe distance from work
area.
8. Make workshop child-proof
Use padlocks, master switches, or remove starter keys.
9. Do not force tools
Do not force tool or attachment to do a job it was
not designed to perform.
10. Use the right tool
They will do the job better and safer at the rate
for which they were designed.
11. Wear correct apparel
Do not wear loose clothing, gloves, neckties or
jewelry (rings, wristwatches) that may get caught
in moving parts. Non-slip footwear is recommended. Wear
protective hair covering to contain long hair. Roll long
sleeves above the elbow.
12. Use safety goggles (Head Protection)
Wear safety goggles (must comply with ANSI Standard
Z87.1) at all times. Also, use face or
dust mask, if cutting operation is dusty, and ear
protectors (plugs or muffs) during extended periods of
operation.
13. Secure work
Use clamps or a vise to hold work when practical. It’s safer
than using your hands, and both hands
are free to operate tool.
14. Do not overreach
Keep proper footing and balance at all times.
15. Maintain tools with care
Keep tools sharp and clean for best and safest
performance. Follow instructions for lubricating
and changing accessories.
WARNING
CAUTION
SAFETY GUIDELINES – DEFINITIONS
1. Always wear eye protection that complies with
ANSI Standard Z87.1.
2. Noise levels vary widely. To avoid possible hearing
damage, wear ear plugs or muffs when using the
Dovetail Jig for hours at a time.
3. For dusty operations, wear a dust mask along
with safety goggles.
4. Do not use this Dovetail Jig with router bits or
guide bushings other than those specified for the
cuts being made.
5. Follow the instructions in your Router Owner’s
Manual.
6.Vibrations caused by the router during use can
cause fasteners to become loose. Before use and
periodically during use, check all fasteners to make
sure that they are all are tight and secure.
7. Do not use this product until all assembly installation steps have been completed, and you have read
and understand all safety and operational instructions in this manual, and the Router Owners Manual.
8. Make sure that the router bit is properly positioned
in the router so that it does not contact the guide
bushing or the template when cutting.
9. The Dovetail Jig must be securely mounted to a
workbench or other stable surface when in use. The
front of the base should overhang the front of the
workbench by no more than 1/4" to provide clearance when clamping workpieces to the Dovetail Jig.
10. Do not use the Dovetail Jig as a work surface.
Doing so may cause damage to the Dovetail Jig,
which can cause it to be unsafe to use. A workbench
should be used for this purpose.
11. This product is designed to cut flat workpieces.
Do not cut or attempt to cut workpieces that are
not flat or that are irregularly shaped.
12. This product is to be used for cutting wood workpieces only. Do not use this product to cut metal
or any other non-wood material.
13. This product has been designed to cut workpieces having thicknesses of 3/8" to 1". Do not use
for workpieces of any other thicknesses.
14. Do not clamp any workpieces to the Dovetail Jig
or make any adjustments to the Dovetail Jig unless
the router has been turned off, the router bit is not
turning, and the Router has been disconnected from
the electrical outlet.
15. When setting “the-depth-of-cut” of the router
bit, make sure that the workpiece is clamped to the
Dovetail Jig in such a manner that the router bit
does not cut into the Dovetail base causing damage to it or possible serious injury to you.
4
16. Disconnect tools before servicing
Before servicing, when changing accessories
such as blades, bits, cutters, etc.
17. Avoid accidental starting
Make sure switch is in OFF position before plugging in.
18. Use recommended accessories
Consult the owner’s manual for recommended accessories
and follow the instructions. The use
of improper accessories may cause hazards.
19. Never stand on tool
Serious injury could occur if the tool is tipped or if the cutting tool is accidentally contacted.
DO NOT store materi-
als above or near the tool making it
necessary to stand on the tool to reach them.
20. Check damaged parts
Before further use of the tool, any guard or other
part that is damaged should be carefully checked to
ensure that it will operate properly and perform its
intended function. Check for alignment of moving
parts, binding of moving parts, breakage of parts,
mounting, and any other conditions that may affect
its operation. A guard or any other part that is
damaged should be properly repaired or replaced.
21. Direction of feed
Feed work into a blade or cutter AGAINST the
direction of rotation of the blade or cutter only.
22. Never leave tool running unattended
Turn power OFF. DO NOT leave tool until it comes
to a complete stop.
23. Keep hands away from cutting area
24. Store idle tools
When not in use, tools should be stored in dry,
high or locked-up place – out of reach of children.
25. Do not abuse cord
Keep cord away from heat, oil and sharp edges.
26. Outdoor extension cords
When tool is used outdoors, use only extension
cords suitable for use outdoors and so marked.
27. Never use in an explosive atmosphere
Normal sparking of the motor could ignite fumes,
flammable liquids, or combustible items.
28. Drugs, alcohol, medication
DO NOT operate tool while under the influence
of drugs, alcohol, or any medication.
Read and Understand this instruction book
completely BEFORE using this product.
.
ADDITIONAL SAFETY INSTRUCTIONS FOR THE
INDUSTRIAL DOVETAIL JIG
5
16. ALWAYS UNPLUG THE
ROUTER FROM THE ELECTRICAL OUTLET
BEFORE INSTALLING OR REMOVING ROUTER
BITS FROM THE ROUTER AND WHEN ADJUSTING THE CUTTING DEPTH OF THE ROUTER BIT;
OR WHEN INSTALLING OR CHANGING GUIDE
BUSHINGS.
17. NEVER LIFT THE ROUTER UPWARDS WHEN
THE ROUTER IS “ON”, THE ROUTER BIT IS
ROTATING, AND THE GUIDE BUSHING IS NEAR
OR TOUCHING THE TEMPLATE, BECAUSE THIS
WILL CAUSE THE ROUTER BIT TO CUT INTO
THE TEMPLATE AND DAMAGE IT.
WARNING
INTRODUCTION
• Your Vermont American Industrial Dovetail Jig is an
accessory that is used with Routers allowing you to
make drawers, chests, and similar items requiring
dovetail joints. The joints are used to make the front,
back, and sides of the workpiece.
• Your Industrial Dovetail Jig comes with two templates and two guide bushings for making half-blind
and through or open joints.
• Your Industrial Dovetail Jig also comes with a
universal router adapter plate that will permit the
Industrial Dovetail Jig to be used with most popular
routers.
• The Dovetail Jig will allow you to make 1" spaced
flush, flush-offset, and 3/8" rabbeted half-blind
dovetail joints.
• The Dovetail Jig will also allow you to make 1"
spaced open, or through, dovetail joints.
• Workpieces up to 16" wide can be accommodated.
• Workpieces with thicknesses between 3/8" and 1"
can be accommodated.
• The Dovetail Jig Base has six pockets molded into
its front which are gauges to aid you setting the
“depth-of- cut” for commonly used depths: 3/8", 1/2",
5/8", 3/4", 7/8", and 1".
• Vermont American router bits, #22501 and #22437,
or Magna router bits, #M91113 and #M91016,
WHICH MUST BE PURCHASED SEPARATELY, are
required for making the THROUGH or OPEN joints.
• Vermont American router bit, #22500, or
Magna router bit, #M91114, WHICH MUST BE
PURCHASED SEPARATELY, is required for making
the HALF-BLIND joints.
• Your Vermont American Industrial Dovetail Jig
comes with two templates and two guide bushings.
Each of the templates has a label, describing the
joint that can be cut with it, along with set-up
information, the router bit and the guide bushing
required, and the the stop block setting for a
particular joint.
UNPACKING AND CHECKING CONTENTS
• If any parts are missing or cannot
be accounted for, do not attempt to assemble, install,
or use the Industrial Dovetail Jig until the missing
parts have been obtained and the product has been
assembled correctly.
• Contact customer service at 1-800-742-3869, ext. 8359
for missing or replacement parts.
WARNING
Refer to Parts List on Page 47.
• In order to simplify handling and to minimize any
damage that may occur during shipping, your
Industrial Dovetail Jig is packaged assembled.
• Separate all loose parts from the packing materials
and check each one with the illustrations and list of
parts at the end of this manual to make sure that
all loose parts are present before discarding any
packaging material.
6
ASSEMBLY INSTRUCTIONS
IMPORTANT
ALTHOUGH YOUR INDUSTRIAL DOVETAIL JIG
COMES ASSEMBLED, THE FOLLOWING ASSEM-
BLY INSTRUCTIONS ARE BEING INCLUDED FOR
REFERENCE PURPOSES SHOULD IT BECOME
NECESSARY FOR YOU TO DISASSEMBLE AND
REASSEMBLE THE DOVETAIL JIG.
PROCEED TO THE SECTION ALIGNMENT OF
THE TEMPLATES AND THEN CONTINUE WITH
THE SECTIONS FOLLOWING ALIGNMENT OF
THE TEMPLATES.
THE TEMPLATES MUST BE ALIGNED BEFORE
ANY ROUTING IS TO TAKE PLACE.
ASSEMBLY OF THE RIGHT SIDE TEMPLATE SUPPORT TO THE DOVETAIL BASE
1. Place the dovetail base topside down on a flat surface.
2. Insert one of the 5/16-18 x 2" long round head square
TOOLS REQUIRED
• A medium sized Phillips screwdriver
• A small or medium adjustable wrench
neck bolts into the slot in the right side of the base.
(NOTE: The right side of the base is identified by the
words RIGHT SIDE molded into it.)
3. Place a 11/32" I.D. x 7/8" O.D. washer onto the bolt as
shown in Figure 1.
4. Thread a 5/16-18 hex nut onto the bolt, as shown, until
it bottoms out against the washer.
5. Back off the nut from the washer between 1/4 and 1/2
5/16-18 HEX NUT
11/32" I.D. X 7/8" O.D. WASHER
5/16-18 X 2" LONG ROUND HEAD
SQUARE NECK BOLT
DOVETAIL BASE
10-32 X 5/8" LONG PANHEAD
MACHINE SCREW
RIGHT TEMPLATE SUPPORT
HEXES MUST LINE UP
# 10-32 HEX NUT
BACK OF DOVETAIL BASE
13/64" I.D. X 9/16" O.D. WASHER
FIGURE 1
7
ASSEMBLY
turns. Align the nut so that the corners of the nut are vertically lined up as shown. Note the alignment of the hex
pocket in the template support. The bolt should be free to
move side to side; if it does not, loosen the nut 1/3 turn or
until the corners of the nut point up and down.
6. Assemble the right template support to the right side of
the dovetail base so that the hex nut lines up and fits into
the hex pocket in the right template support. (NOTE: The
right template support has the words RIGHT SIDE molded
into it for identification.)
7. Assemble a #10-32 x 5/8" long panhead machine screw,
a 13/64" I.D. x 9/16" O.D. washer, and a #10-32 hex nut to
the base as shown to hold the template support in place.
Securely tighten the nut and screw.
8. The template support should move freely front to back
along the side of the base. If it does not, it means that the
5/16-18 hex nut is too tight on the bolt and should be loosened. To do this, remove the fasteners assembled in step
7, and remove the template support; repeat steps 4
through 7.
ASSEMBLE THE LEFT SIDE TEMPLATE SUPPORT TO
THE DOVETAIL BASE THE SAME AS THE RIGHT SIDE
TEMPLATE SUPPORT WAS ASSEMBLED.
ASSEMBLY OF THE TOP CLAMPING BAR TO THE DOVETAIL BASE
1. Assemble one of the bolt supports to both of the
5/16-18 X 3-1/2" long round head square neck bolts as
shown in Figure 2.
2. Align the square on the bolt with the square hole in the
bolt support. The bolt support is to "bottom-out" against the
bolt as shown in Figure 3.
3. Assemble one of the springs to each of the nylon spring
retainers by pushing the spring over the raised cylindrical
portion of the spring retainer as shown in Figure 3A and
Figure 3B.
4. Position the dovetail base on a flat smooth surface so
the back of the base rests on the surface.
ALTHOUGH BOTH ENDS OF THE
DOVETAIL BASE ARE SHOWN ASSEMBLED IN THE
FOLLOWING FIGURES, THE ACTUAL ASSEMBLY IS
DONE ONE END AT A TIME.
5. From the bottom of the base, insert a bolt with bolt support through the slot in the top of the base so the raised
portion of the bolt support goes into the slot, as shown in
Figure 4.
5/16-18 X 3-1/2"
LONG ROUND
HEAD SQUARE
NECK BOLT
BOLT
SUPPORT
NYLON
SPRING
RETAINER
COMPRESSION
SPRING
SPRING TO
BOTTOM
OUT
AGAINST
SURFACE
FIGURE 4
FIGURE 2 FIGURE 3
FIGURE 3A FIGURE 3B
SLOT IN
DOVETAIL BASE
DOVETAIL BASE
BOLT
AND
BOLT
SUPPORT
FRONT OF DOVETAIL BASE
BOLT AND BOLT
SUPPORT
SLOT IN
DOVETAIL
BASE
8
6. Place an 11/32" I.D. X 7/8" O.D. washer and then a
5/16" I.D. X 7/8" O.D. thick nylon washer over the bolt. It
will be necessary to hold the bolt in place when performing
this and the following steps.
HELPFUL HINTS: Position the bolt and the bolt support
under the notch in the rib as shown in Figure 5, to help
hold the bolt in place.
7. Place a spring over the bolt, as shown in Figure 6.
8. Place a 5/16" I.D. X 7/8" O.D. thick nylon washer and
then an 11/32" I.D. X 7/8" O.D. washer over the bolt and
press down on the spring until just the end of the bolt
sticks out past the end of the washer.
9. Slide the clamping bar over the bolt so that the washers
are sandwiched between the spring and the inside of the
clamping bar as shown in Figure 6. NOTE: THE SPRING
MUST PUSH AGAINST THE THICK NYLON WASHERS
AND NOT AGAINST THE STEEL WASHERS.
10. Place an 11/32" I.D. X 7/8" O.D. thin nylon washer and
an 11/32" I.D. X 7/8" O.D. washer over the bolt. It will be
necessary for you to press down on the clamping bar while
doing this.
11. Take one of the clamping knobs and thread it onto the
bolt as shown. DO NOT THREAD the knob completely
onto the bolt––just enough so the knob holds the clamping
bar in place.
12. Repeat above steps 4 through 10 for the other end of
the clamping bar.
13. Assemble the end caps to the ends of the clamping bar
by pressing them in; they are designed to be “force-fit” into
NOTCH
IN RIB
SLOT IN
DOVETAIL
BASE
BOLT AND
BOLT
SUPPORT
FIGURE 5
FIGURE 6 Assemble clamping bar, knobs, end caps on both ends as shown
CLAMPING BAR DETAIL
the bar in one way only. It may be necessary to “tap” them
in by gently hitting them with a rubber mallet or a piece of
wood––since they fit very tightly into the clamping bar.
USE CARE WHEN DOING THIS SO AS NOT TO DAMAGE THE END CAPS.
USE CARE THAT THE CAPS ARE PROPERLY ALIGNED
AS SHOWN WHEN ASSEMBLING THEM TO THE BAR.
14. Tighten the clamping knobs onto the bolts so that the
space between the bottom of the clamping bar should be
parallel to the top of the base.
15. After completing the above steps your Dovetail Jig
should look like the illustration in Figure 7.
CLAMPING KNOB
SPRING AND
NYLON SPRING
RETAINER FIT
INSIDE THE
OPEN SIDE OF
THE CLAMPING
BAR
(SEE CLAMPING
BAR DETAIL)
11/32" I.D.
X 7/8" O.D. WASHER
11/32" I.D. X 7/8" O.D.
THIN NYLON WASHER
CLAMPING BAR
CLAMPING BAR
END CAP
OPEN SIDE OF
THE CLAMPING BAR
POINTS TOWARD
THE TOP SURFACE
OF THE DOVETAIL
BASE
11/32" I.D.
X 7/8" O.D.
THICK
NYLON
WASHER
TOP SURFACE OF
THE DOVETAIL
RIGHT
TEMPLATE
SUPPORT
BOLT
SUPPORT
3 1/2" BOLT
COMPRESSION
SPRING
NYLON SPRING
RETAINER
(RETAINER ABUTS THE
CLAMPING BAR)
11/32" I.D. X 7/8"
O.D. WASHER
11/32" I.D. X 7/8" O.D.
THICK NYLON
WASHER
CLAMPING BAR (SHOWN WITH
END CUT AWAY AND SECTIONED
SO NYLON SPRING RETAINER
PLACEMENT CAN BE SEEN)
COMPRESSION
SPRING
9
CLAMPING BAR PARALLEL TO
TOP OF BASE
SPACING TO BE
APPROXIMATELY
1-1/2"
FIGURE 7
ASSEMBLY OF THE FRONT CLAMPING BAR TO THE DOVETAIL BASE
1. Assemble the front clamping bar to the front of the dovetail base following the same procedure used to assemble
the top clamping bar to the dovetail base as shown in
FIGURE 8
CLAMPING BAR
(SHOWN WITH END
CUT AWAY AND
SECTIONED SO
NYLON SPRING
RETAINER PLACEMENT CAN BE
SEEN)
COMPRESSION
SPRING
NYLON
SPRING
RETAINER
(RETAINER
ABUTS THE
CLAMPING
BAR)
4 1/2" BOLT
11/32" I.D. X 7/8" O.D.
THICK NYLON WASHER
COMPRESSION SPRING
CLAMPING BAR
END CAP
11/32" I.D. X 7/8" O.D.
THIN NYLON WASHER
11/32" I.D. X 7/8" O.D.
CLAMPING KNOB
NYLON SPRING
RETAINER
BOLT SUPPORT
DOVETAIL BASE
CLAMPING BAR
Figure 8. The 5/16-18 X 4-1/2" long round head square
neck bolts are used.
10
ASSEMBLY OF THE CAM HANDLES AND PIVOT SHAFT TO THE DOVETAIL BASE
• After the cam handles and pivot shaft have been assembled to the base, it will be possible to accurately position
the templates for close fitting joints.
• Note that there are some graduations on both template
supports.
• Rotating the cam handle so that the pointer lines up with
one of the graduations permits accurate front-to-back positioning of the template.
• Cam handles are designed to provide infinite template
adjustment.
• One graduation equals 1/64" of movement of the template.
• Rotating the cam handle so that the lever moves toward
the front of the base, causes the template to also move
towards the front of the base.
•Conversely rotating the cam handle so that the lever
moves toward the back of the base, causes the template
to also move towards the back of the base also.
13/64" I.D. X 9/16" O.D. WASHER
#10-32 X 5/8" LONG
PANHEAD MACHINE SCREW
CAM HANDLE
PIVOT SHAFT
#10-16 X 1/2" LONG PANHEAD TAPPING SCREW
RETAINER
PIVOT SHAFT
FIGURE 9
FIGURE 10
1. Assemble one of the cam handles to the pivot shaft
using a #10-32 x 5/8" long panhead machine screw and a
13/64" I.D. x 9/16" I.D. washer. as shown in Figure 9.
2. Use care so that the pivot shaft fits into the hex-shaped
hole in the cam handle. The pivot shaft may fit tightly into
the cam handle; this is normal.
3. Make sure that the pivot shaft bottoms-out inside the
cam handle.
4. Securely tighten the screw.
NOTE: THE NEXT TWO STEPS ARE PRE-ASSEMBLY
STEPS.
5. Slide the retainer over the end of the pivot shaft for
about 2". The retainer may fit tightly; this is normal.
6. Thread the #10-16 x 1/2" long panhead tapping screw
into the hole in the retainer until it bottoms-out against the
pivot shaft. (The screw will fit tightly in the hole.) See
Figure 10.
11
7. Loosen the screw about one turn. Remove the retainer
from the shaft and set it aside temporarily.
8. Assemble the pivot shaft with cam handle to the base by
inserting the end of the pivot shaft through the holes in the
right template support and the base.
9 . MAKE SURE THE ORIENTATION OF THE CAM HANDLE IS AS SHOWN IN FIGURE 11.
10. Place the retainer at the location shown in Figure 12
and push the pivot shaft through. THE ORIENTATION OF
THE RETAINER RELATIVE TO THE CAM HANDLE WITH
SCREW MUST BE AS SHOWN.
NOTE: THE RETAINER MAY FIT TIGHTLY ON THE
PIVOT SHAFT; THIS IS NORMAL.
11. Continue pushing the pivot shaft through the holes and
the retainer until the end of the pivot shaft extends out of
the left template support as show in Figure 12.
12. Make sure the end of the cam handle fits into the hole
in the base as shown.
CAM HANDLE
PIVOT SHAFT
RETAINER
HOLE IN BASE
RIGHT TEMPLATE
DOVETAIL BASE
FIGURE 11
FIGURE 12
PIVOT SHAFT
RETAINER
PIVOT
HOLE IN
BASE
LEFT
TEMPLATE
SUPPORT
CAM
HANDLE
HOLE IN BASE
12
13. With the cam handle pushed in against the base,
position the retainer against the side wall of the base, as
shown in Figure 13. The retainer should barely touch the
side wall of the base. The purpose of the retainer is to
prevent or minimize the side-to-side of the cam handle and
pivot shaft.
14. Assemble the other cam handle to the other end of the
pivot shaft using a 13/64" I.D. x 9/16" O.D. washer and
a#10-32 X 5/8" long panhead machine screw, as shown in
Figure 14.
15. Make sure that the cam handle lines up with the cam
handle at the other end of the pivot shaft and that the end
RETAINER
SIDE WALL OF BASE
of the cam handle fits into the hole in the base.
16. Tighten the screw securely.
17. Rotate one of the cam handles–It should rotate freely
and move the template supports
18. If this does not happen, loosen the screw on the retainer and move the retainer away from the side wall slightly.
19. Securely retighten the screw.
20. If there is too much side-to-side movement (play) of
the cam handles; loosen the screw in the retainer and
move the retainer closer to the side wall of the base.
21. Securely retighten the screw.
LEFT TEMPLATE SUPPORT
PIVOT SHAFT
#10-32 X 5/8" LONG
PANHEAD MACHINE
SCREW
13/64" I.D. X 9/16" O.D. WASHER
CAM HANDLE
FIGURE 13
FIGURE 14
13
ASSEMBLY OF THE FRONT STOP BLOCKS TO THE DOVETAIL BASE
1. Assemble the front stop blocks to the front of the dovetail base, at each end, using #10-32 x 5/8" long flathead
machine screws, 13/64" I.D. x 9/16" O.D. washers, and
#10-32 hex nuts, as shown in Figure 15.
2. Make sure that the open rib portion fits into the slot in
the front of the base. The stop block will fit into the slot in
one position only.
3. Tighten the screw securely onto the nut.
4. Assemble the other front stop block to opposite end of
the dovetail base in the same manner.
DOVETAIL BASE
RIGHT
TEMPLATE
SUPPORT
#10-32 HEX NUT
13/64" I.D. X 9/16"
O.D. WASHER
FRONT STOP BLOCK
SLOT
#10-32 X 5/8" LONG FLATHEAD
MACHINE SCREW
FRONT OF DOVETAIL BASE
SLOT
#10-32 HEX NUT
13/64" I.D. X 9/16" O.D.
WASHER
LEFT TEMPLATE
SUPPORT
FRONT STOP BLOCK
#10-32 X 5/8" LONG
FLATHEAD MACHINE
SCREW
FIGURE 15
FOR REASONS OF CLARITY, THE FRONT
CLAMPING BAR, KNOBS, BOLTS AND
SPRINGS ARE NOT SHOWN
14
ASSEMBLY OF THE TOP STOP BLOCKS TO THE DOVETAIL BASE
• The top stop blocks are assembled to the top of the
dovetail base in one of two ways depending upon which
style of dovetail joint is to be cut:
a. HALF-BLIND FLUSH JOINTS—The “A” on the stop
block faces toward the “middle of the base”.
b. HALF-BLIND RABBET JOINTS—The “B” on the
stop block faces toward the “middle of the base”.
c. THROUGH JOINTS—The “A” on the stop block
faces toward the “middle of the base”.
• Since the flush joint is the more commonly used joint, the
following instructions apply to the assembly of the stop
blocks for this style joint.
1. Position the dovetail Jig right side up on a flat surface
2. Assemble one of the top stop blocks to the top surface
of the base using a #10-32 x 7/8" long flathead machine
ASSEMBLY OF THE CLAMPING KNOBS TO THE DOVETAIL BASE
1. Assemble 11/32" I.D. x 7/8" O.D. washers onto the 5/1618 bolts at both ends of the dovetail base as shown in
Figure 17.
2. Assemble the clamping knobs onto the bolts as shown.
screw, as shown in Figure 16. The screw threads into the
hole in the bottom of the slot.
3. Make sure that the “A” faces the “middle of the base”.
4. Make sure the open rib portion of the stop block fits into
the slot in the top surface of the base.
5. Assemble the remaining top stop block to the opposite
end of the base in the same manner
6.Again make sure that the “A” faces the “middle of the
base”.
7. Tighten both screws securely.
8. To reposition the stop blocks for rabbet joints, simply
loosen the screws just enough so that the ribs on the stop
blocks come out of the slot. The stop block is then rotated
180° to the alternate position, so the “B” faces the middle
of the base, and securely retighten the screws.
5/16-18 X 2" LONG ROUND
HEAD SQUARE NECK BOLT
5/16-18 X 2" LONG ROUND
HEAD SQUARE NECK BOLT
11/32" I.D. X 7/8"
O.D. WASHER
CLAMPING
KNOB
CLAMPING
KNOB
11/32" I.D. X 7/8"
O.D. WASHER
1/2" SPACING BETWEEN
WASHER AND TEMPLATE
SUPPORT (BOTH ENDS)
FIGURE 16
FIGURE 17
#10-32 X 7/8" LONG FLAT HEAD
MACHINE SCREW
#10-32 X 7/8" LONG FLAT
HEAD MACHINE SCREW
RIB ON STOP BLOCK
TOP STOP BLOCK
RIB ON STOP BLOCK
SLOT IN TOP
OF BASE
TOP STOP BLOCK
MIDDLE OF THE BASE
SLOT IN TOP
OF BASE
3. Thread the clamping knobs onto the bolts so that the
spacing between the washer and the template supports is
approximately 1/2".
4. Set the dovetail base aside for the time being and continue on with the next section.
15
FIGURE 20
FIGURE 19
FIGURE 18
#10-32 X 3/16" LONG PANHEAD MACHINE
TEMPLATE
TEMPLATE BRACKET
TEMPLATE STIFFENER
RECTANGULAR SLOT
TEMPLATE
#8-36 X 3/16" LONG
PANHEAD MACHINE
SCREW
SLOTTED BINDING HEAD
MACHINE SCREW
ASSEMBLY OF THE TEMPLATES
• Place the template stiffener into the rectangular slot in the
underneath side of the template, as shown in Figure 18.
NOTE: THE TEMPLATE FOR CUTTING HALF-BLIND
JOINTS IS BEING USED AS AN ILLUSTRATION IN THE
FOLLOWING FIGURES.
1. Thread a #8-36 x 3/16" long panhead machine screw
through each of the five holes in the template and into the
threaded holes in the template support, as shown in
Figure 18 and securely tighten all of the screws.
NOTE: ON SOME EARLY VERSIONS OF THIS PRODUCT, A SLOTTED BINDING HEAD MACHINE SCREW
HAS BEEN SUBSTITUTED FOR THE PANHEAD SCREW
SPECIFIED FOR ASSEMBLING THE TEMPLATE SUPPORTS TO THE TEMPLATES. (SEE THE SCREW ILLUSTRATION IN FIGURE 18.)
2. Assemble the template brackets to the template using
four #10-32 x 3/8" long panhead machine screws, as
shown in Figure 19.
3. MAKE SURE THAT THE TEMPLATE BRACKETS ARE
ASSEMBLED TO THE UNDERNEATH SIDE OF THE
TEMPLATE, AS SHOWN IN FIGURE 19, AND THAT THE
ALIGNMENT OF THE BRACKETS IS ALSO AS SHOWN
IN THE FIGURE.
4. IT IS NOT NECESSARY FOR THE SCREWS TO BE
TIGHTENED AT THIS STAGE; THE TEMPLATE BRACKETS SHOULD BE FREE TO MOVE WITH RESPECT TO
THE TEMPLATE OR ELSE IT WILL NOT BE POSSIBLE
TO ALIGN THE TEMPLATE AS DESCRIBED IN THE
NEXT SECTION.
5. The assembled template should look like the illustration
in Figure 20.
6. Assemble the template stiffener and the template brackets to the TEMPLATE FOR CUTTING THROUGH JOINTS
using the same method described in the preceding steps 1
through 5. Refer to Figure 20.
16
ALIGNMENT OF THE TEMPLATES
• In order for the Dovetail Jig to function properly, it is
necessary for the templates to be aligned with respect to
dovetail base. The reason for this, is that dovetail cuts are
at both ends of the Dovetail Jig. When properly aligned,
the result being all mating corners will always be lined up.
• NOTE: THE TEMPLATE FOR CUTTING HALF-BLIND
JOINTS IS BEING USED AS AN ILLUSTRATION IN THE
FOLLOWING FIGURES.
1. With the dovetail base still having the 1/2" spacing
between the washer and the template supports (Refer to
Figure 17), assemble the template assembly to the dovetail base so that:
a) the slot in the template bracket fits over the bolt
b) the leg of the template bracket is between the washer
and the template support, and
c) the legs fit into the slots in the template supports, as
shown in Figure 21.
d) NOTE: THIS PROCEDURE MUST BE FOLLOWED
WHENEVER THE TEMPLATE IS INSTALLED ON THE
DOVETAIL JIG. IT IS MOST IMPORTANT THAT LEG
OF THE TEMPLATE BRACKET ALWAYS BE
BETWEEN THE WASHER AND THE TEMPLATE SUPPORT OR ELSE THE TEMPLATE WILL NOT BE
PROPERLY POSITIONED FOR CUTTING ACCURATE
DOVETAILS.
For initial setup, Allow the legs of the template bracket to
“bottom out” in the slots in the template supports as
shown in Figure 21.
• TO REMOVE THE TEMPLATE FROM THE DOVETAIL
JIG, LOOSEN THE CLAMPING KNOBS SO THAT SPACING BETWEEN THE TEMPLATE BRACKET AND THE
WASHER IS ABOUT 1/2"; GENTLY LIFT THE TEMPLATE
UPWARD FROM THE DOVETAIL BASE SO THAT THE
TEMPLATE BRACKET CLEARS THE SLOTS IN THE
TEMPLATE SUPPORT AND STORE IN A CONVENIENT
LOCATION.
2. Lightly tighten the clamping knobs at both ends of the
base so that the template brackets are held in place
against the template supports as shown in Figure 21.
3. Move the template from side to side on the template
brackets so that it is centered with respect to the template
brackets. This means that the template and brackets
should look like one of the following figures: Figure 22,
Figure 23. or Figure 24. Move template front-to-back so
that front edge of template is parallel with the front of the
dovetail base. In each condition the template and the template brackets MUST be symmetrical with each other. The
figures do not show the complete Dovetail Jig, but only the
underneath side of the template with template brackets
correctly positioned, in order that the correct positions of
RIGHT TEMPLATE SUPPORT
WASHER
BOLT
TEMPLATE BRACKET
SLOT IN THE TEMPLATE BRACKET
SLOT IN THE TEMPLATE SUPPORT
TEMPLATE BRACKET “BOTTOMS-OUT” AGAINST
THIS SURFACE (BOTH ENDS OF DOVETAIL BASE)
FIGURE 21
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