Woodhaven 7640 User Manual

1

7640

Keller

Dovetail Kit

Please Read Carefully!

BEFORE BEGINNING

Read the instructions at least once, familiarizing yourself
with the parts and instructions before beginning.
Your stock should be flat, square and between 1/4 and 3/4"
thick. The boards do not all have to be the same thickness. Cut
the finished length of the boards between 1/32" and 1/16" longer
then the finished length. This gets removed after assembly. Use
scraps for the initial test cuts.

ASSEMBLY

Remove the existing template from your 7600-7603
Woodhaven Dovetail Jig and replace it with the Keller Dovetail
Template (7640T1).
first as this is the non-adjustable part of the joint.
Install the dovetail bit (7533) in your router and
set the depth of cut to 1/64" more than the thickness of
your stock (maximum 3/4" thick stock capacity), taking
into account the 1/2" thickness of the template.
Swap the locations of the existing stops and
position them even with the first opening at each
end of the template for now. See fig. 1.

CUT DOVETAILS

Loosen the two ratchet handles on the two template
nuts and raise or lower the template until a scrap board just
fits between the underside of the template and the top edge
of the Ultra Track, then retighten the handles. Position the
edge of the scrap flush with the face of the Ultra Track and
clamp it in place using the dovetail jigs clamps. The scrap
board should be at least 1/16" thicker and about 1" wider
than the work. The scrap board prevents tear out when the
bit exits the back of the work and provides an extra margin
of safety to help insure the bit won’t hit the Ultra Track.
Install the work in the front of the jig with the OUTSIDE
FACE of the work against the Ultra Track. Place the end of
the work against the underside of the template and the edge of
the work against the edge of the stop. Adjust the stop position
to align the work where desired in relation to the fingers on
the template (center or offset pattern as desired). Tighten
the front clamps to hold the work in place. See fig. 2.
Make a test cut in some scrap. Cut from left to right,
following the fingers of the template. If you get chipping on
the exposed face of your work you may need to clamp a scrap
of 1/4" plywood or hardboard to the face of the work. When
satisfied, make all the dovetail cuts in all of your parts.

The dovetail half of the joints need to be cut

Parts List:

Part Description Quantity

7640T1 Keller Dovetail Template . . . . . . . . . . . . . . . . 1

7640T2 Keller Pin Template . . . . . . . . . . . . . . . . . . . . 1

7533 Dovetail Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7543 Straight Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1

2

CUTTING PINS

Install the Keller Pin Template (7640T2) in place of the
Keller Dovetail Template. Install the straight bit (7543) in your
router. Set the depth of cut to 1/64" to 1/32" more than the
thickness of your stock, taking into account the 1/2" thickness
of the Pin Template.

Install a new piece of scrap in place of the scarp
used for the dovetails, following the same process.
Install the work in the front of the jig with the INSIDE
FACE of the part against the Ultra Track. Place the end of
the work against the underside of the template and the edge
of the work against the edge of the stop. The stops must
not be moved from the location they were at when you cut
the dovetails or the parts will not line up when assembled!!
Tighten the front clamps to hold the work in place. See fig. 3.
Make a test cut in some scrap. Cut from left to right,
following the fingers of the template. If you get chipping on
the face of your work you may need to clamp a scrap
of 1/4" plywood or hardboard to the face of the work.
Test the fit of the pins in the dovetailed part. The
parts should go together with light tapping at most. If the
pins are too loose, move the Pin Template forward. If the
pins are too tight, move the Pin Template back. A 1/16"
(.0625) adjustment (forward or back) of the Pin Template
makes a 1/64" (.015) difference in pin width. The template
brackets/pin template are adjusted in or out by loosening
the two 3/4" bolts holding the template brackets to the tem­plate nuts. Make equal adjustments to both template brack­ets. When satisfied, make all the pin cuts on all of your
parts. See fig. 4.
Any excess overhang of pins and dovetails can be
removed by sanding or routing after assembly.

3

4

Move template

brackets/pin template

forward to make

the pins larger and

tighten the joint..

Move template brackets/

pin template back to

make the pins smaller

and loosen the joint.

Template

Template

Bracket

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