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.
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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
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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
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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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