Woodhaven 4556 User Manual
BEFORE BEGINNING
Identify and verify that you have all the parts listed. Read the
instructions at least once, familiarizing yourself with the parts before
beginning. You’ll need a #3 Phillips screwdriver for assembly.
The majority of the parts have the hardware pre-attached and
just need to be attached to the Ultra Track. You may need to loosen
the hardware to install the parts, or reattach the hardware if it came
loose during shipping. Replacement Sub-Fences (4556F) are available
from Woodhaven, or you can make your own out of 3/4" material.
The Portable Box Joint Jig is designed to be used on work
that is clamped in a stationary position. It’s perfect for work that
is too heavy or cumbersome to pass over a stationary cutter on a
table saw or router table. The jig will cut box joints 1/2" to 1-9/16"
wide a minimum of 1/2" deep in stock a maximum of 2" thick.
For cutting, you'll need a 1/2" collet router, a 3/4" diameter
bushing and a 1/2" diameter bit. Spiral upcut bits are excellent
for cutting solid woods. Select a bit with the shortest possible
cut length. You'll also need a 6" bar clamp (for the first and last
cuts on the work) and a workbench/vise to hold the work.
4556
Portable Box
Joint Jig
Please Read Carefully!
Parts List
Please identify and verify that you have all of the hardware
prior to assembly. Parts listed in this box are shown in
photos & drawings in the instructions.:
Part Description Quantity
4412 12” Ultra Track . . . . . . . . . . . . . . . . . . . . . . . . 1
4556B1 Router Support . . . . . . . . . . . . . . . . . . . . . . . . 2
4556B2 Clamps, pre-assembled . . . . . . . . . . . . . . . . . 2
4556C Router Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4556D Inch Setup Jigs, 5 pc. set . . . . . . . . . . . . . . . . 1
4556F Sub-Fence, 2 pc. set . . . . . . . . . . . . . . . . . . . . 1
4556S Aluminum Stops, 2 pc. set . . . . . . . . . . . . . . 1
Stop & Sub-Fence Assembly:
1
These parts get installed in the T-slots on the face of the 12"
Ultra Track (4412). The Sub-Fence (4556F) is a two piece set.
Both pieces are rectangular in shape with one of the pieces having
a rectangular cutout. With the bottom edge of the 12" Ultra Track
(4412) resting on a flat surface, install the rectangular Sub-Fence
(without the cutout) on the Track with the oval nuts in the upper and
lower T-slots of the track. Position the end of the Sub-Fence even
with the right end of the track and loosely tighten the screws. This
Sub-Fence can be rotated 180º so the opposite end can be used.
4412
4556F
The Aluminum Stops (4556S) consists of two aluminum angle
components & hdw.: Stationary Stop - angle with a slot and a hole,
and an Adjustable Stop - angle with a notch and a hole. Install the
Stop assembly (4556S - loosen screws) on the track by inserting the
nuts, long portion of nuts facing away from each other, in the upper
T-slot of the track. Slide the Stops to the right, against the end of the
rectangular Sub-Fence, and loosely tighten both screws.
Install the remaining MDF Sub-Fence (4556F with cut
out) flush with the left end of the track and tighten the screws.
There will be about a 1/8" gap between the two Sub-fences.
Stationary Stop
Rear
Adjustable Stop
Front
Install Router Supports & Router Stops:
2
Slightly loosen the Stops and Sub-Fences installed before so they don't interfere with the installation and tightening of the Router
Supports. The Router Supports a Router Stops get installed on the top T-slot of the 12" Ultra Track. The two Router Supports (4556B1)
and Router Stops (4556C) are identical and are ribbed to fit into the T-slot of the track. Slide one of the Router Supports in from the left end of
the Ultra Track, position it 2-3/4" in from the left end of the track and firmly tighten the two screws. This Left Router Support should NEVER
be adjusted from this position.
Determine what size joint you'll be cutting. For 1/2" to 1" joints, you'll use one
Router Stop (4556C) between the Router Supports. For joints larger than 1", place
both Router Stops between them. Place the Router Stops so their long end over
hangs the sub-fences. Attach one or both Router Stops to the track.
Slide the Right Router Support on the track, position it about 1" from Left
Router Support and loosely tighten it. The Right Router Support is what you will
adjust to set the joint size. If you have one Router Stop left, install it near
the Right Router Support.
4556C
The Stops and Sub-Fences should
be flush against the underside
of the Router Supports, then
retightened.
2-3/4"
Install Clamps:
3
The Clamps get installed on the rear upper T-slot of the 12" Ultra
Track. The two Clamps (4556B2) have a hex bolt and pin that fits
into the T-slot of the track. Loosen the knob and slide the bolt head into
the T-slot first, followed by the pin. When the pin is inside the T-slot a
1/2" or so from the end of the track, tighten the knob on the hex bolt.
Reposition the Clamps if necessary to avoid interference with your router.
Left Router Support
4556B2
4556C
4556B1
Right Router Support
4556B1
4556B2
Clamp Plate:
Rear View
Adjust Clamps for work thickness:
4
by adjusting the 3/4" knob at the back of the Clamp. Make sure
the end of the bolt on the 3/4" knob remains bottomed out in the
recessed hole at the back of the Clamp Pad. Next turn the 3/4"
knob approximately 1/4 turn more, pushing the top of the Clamp
Pad slightly away from the work. When tightened, the Clamp Pad
should sit flat on the work. Tighten the 2" T-Knob at the front of the
Clamp Pad until the Jig is snug on the work. Do not over tighten!
You'll also need to provide a 6" bar clamp (for the first
and last few cuts on the work) to clamp the opposite side
of the work from the Clamp Pad when it's only possible
for one of the Clamp Pads to engage on the work.
Place the work between the Clamp Pad and the Sub-
Fence. Position the Clamp Pad so it's flat against the work
1
Bar
Clamp
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