Woodstock W1099 User Manual

P.O. Box 2309

Bellingham, WA 98227

DOVETAIL JIG

W1099

OPERATING MANUAL

WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE

OR FORM WITHOUT THE WRITTEN APPROVAL OF WOODSTOCK INTERNATIONAL, INC.

REPRINTED FEBRUARY 1999, PRINTED IN TAIWAN

TABLE OF CONTENTS

I. INTRODUCTION .............................................................................................................................2

II. COMMENTARY ..............................................................................................................................

III. SAFETY RULES FOR ALL TOOLS ..............................................................................................

IV. UNPACKING ...................................................................................................................................

V. ASSEMBLY .....................................................................................................................................

A. HAND LEVERS ......................................................................................................................

B. MOUNTING ............................................................................................................................4

VI. CAPACITIES ....................................................................................................................................

VII. PREPARATION ...............................................................................................................................

VIII. ADJUSTMENT LOCATIONS .........................................................................................................

IX. CLAMP ADJUSTING ......................................................................................................................

X. SIDE STOP SET UP .........................................................................................................................

XI. TEMPLATE ADJUSTMENT ...........................................................................................................

XII. FENCE ADJUSTMENT .................................................................................................................

XIII. OPERATIONS ................................................................................................................................

A. REGULAR USE ....................................................................................................................

B. RABBETED DRAWER FRONTS .......................................................................................

XIV. TROUBLESHOOTING ..................................................................................................................14

A. TEAR OUT ............................................................................................................................

B. EXCESSIVE FIT ...................................................................................................................

C. INCOMPLETE FIT ...............................................................................................................

D. OFFSET EDGES ...................................................................................................................

E. FIT TOO TIGHT OR TOO LOOSE .....................................................................................

F. UNEVEN FIT ........................................................................................................................

XV. WARRANTY ..................................................................................................................................

XVI. CLOSURE .......................................................................................................................................

XVII. PARTS DIAGRAM ........................................................................................................................

XVIII. PARTS LIST ...................................................................................................................................

XIX. TOOL DATA ..................................................................................................................................

XX. INDEX ............................................................................................................................................

WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE

OR FORM WITHOUT THE WRITTEN APPROVAL OF WOODSTOCK INTERNATIONAL, INC.

REVISED FEBRUARY 1999, PRINTED IN TAIWAN

Woodstock Intl., Inc. W1099

- 1 -

I. INTRODUCTION

II. COMMENTARY

Woodstock International, Inc. is proud to offer the W1099 12" Dovetail Jig. Suitable for pro duction work or small scale dovetail joinery, the Model W1099 enables you to simultaneously cut

/8" half-blind dovetails and pins with a router, guide bushing, and dovetail bit. The Dovetail Jig handles stock up to 1 mounts easily to your bench top. Heavy, stamped steel construction provides excellent rigidity and strength, while the horizontal and vertical cam action clamps securely hold your wood in place.

Woodstock is committed to offering top quality products and supporting them through customer service and technical documentation. The manual you are reading represents our latest effort to pro duce the best documentation possible. If you have any criticisms or comments you feel we should consider for our next printing, please write us at the address below.

Manager, Technical Documentation

Woodstock International, Inc.

Bellingham, WA 98227

If you have any parts problems or requests, please contact the dealer where the W1099 Dovetail Jig was purchased or call Woodstock International at 1-800-840-8420 between 8am and 5pm Pacific Standard Time, Monday through Friday.

/4" thick and 12" wide and

P.O. Box 2309

To operate this, or any tool, safely and efficiently,

it is essential to become as familiar with its char acteristics as possible. Take as much time as necessary to become acquainted with the W1099 Dovetail Jig. The time you invest before you use it will be time well spent. Also, read and follow all of the safety procedures noted in this manual. If you do not understand any of the operations or safety guidelines discussed in this manual, please answer all questions before attempting to use this jig.The specifications, drawings, and photographs illustrated in this manual represent the Model W1099 as supplied when the manual was prepared. But owing to Woodstock’s policy of continuous improvement, changes to the Model W1099 may occur at any time with no obligation on the part of Woodstock. Should you receive a manual update, please keep it with the manual for future reference.

The information in this manual has been obtained from sources we believe to be as reliable and as up-to-date as possible. We have included some important safety measures which we believe to be essential to this tool’s operation. While most safe ty measures are generally universal, Woodstock reminds you that each work environment is differ ent and safety rules should be considered as they apply to your situation.

We also believe additional sources of information are important to realize the full potential of this tool. Trade journals, woodworking magazines, and your local library are good places to find such information.

The Model W1099 was designed for making precise dovetails. It must never be modi fied and/or used for any other purpose. Modifications or improper use of this tool will void all warranties and MAY CAUSE SERIOUS PERSONAL INJURY. If you are confused about any aspect of the jig, DO NOT use it until you have resolved any questions you might have.

- 2 - Woodstock Intl., Inc. W1099

III. SAFETY RULES FOR ALL TOOLS

1. KNOW YOUR POWER TOOL. Read the owner’s manual carefully. Learn the tool’s applications and limitations, as well as its particular hazards.

2. KEEP ALL GUARDS IN PLACE and in working order.

3. GROUND ALL TOOLS. If an adapter is used to accommodate a two-prong receptacle, the adapter plug must be attached to a known ground. Never remove the grounding prong.

4. REMOVE ADJUSTING KEYS AND WRENCHES. Make it a habit to check that keys and adjusting wrenches are removed from the machine before turning it on.

5. KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents.

6. AVOID DANGEROUS ENVIRONMENTS. Do not use power tools in damp or wet loca tions or expose them to rain. Keep your work area well lighted.

7. KEEP CHILDREN AND VISITORS AWAY. All children and visitors should be kept a safe distance away from your work area.

8. MAKE WORKSHOP CHILD-PROOF with padlocks, master switches, or by removing starter keys.

9. DO NOT FORCE TOOL. Tools work better and more safely when they are allowed to work at their own speed.

10. WEAR PROPER APPAREL. Do not wear loose clothing, gloves, neckties, or jewelry that might get caught in moving parts. Nonslip footwear should be worn. Wear a hat or other protective head wear if your hair is long.

11. NEVER STAND OR LEAN ON TOOL.

12. USE SAFETY GLASSES AND EAR PRO TECTION. Also use a DUST MASK if the cutting operation is dusty.

13. DO NOT OVERREACH. Keep proper footing and balance at all times.

14. MAINTAIN TOOLS IN TOP CONDITION. Keep tools sharp and clean for best and safest performance. Follow instructions for lubricat ing and changing accessories.

15. DISCONNECT TOOLS FROM POWER before servicing and when changing acces sories, such as blades, bits, and cutters.

16. AVOID ACCIDENTAL STARTING. Make sure the switch is in the “ before plugging in the cord.

17. CHECK DAMAGED PARTS. Do not operate the machine until you are certain it is in

perfect running condition.

18. NEVER LEAVE THE TOOL RUNNING UNATTENDED - TURN POWER OFF. Do not leave the tool until it comes to a full stop.

19. DO NOT OPERATE THE TOOL IF USING DRUGS, ALCOHOL, OR MEDICATION.

20. DO NOT WORK IN HASTE or operate machine if you are mentally or physically fatigued.

21. IF THERE IS SOMETHING YOU DO NOT KNOW OR UNDERSTAND, DO NOT OPERATE MACHINE! Ask for help first. Confusion can be dangerous.

22. BAD HABITS ARE DANGEROUS. Review all safety procedures often.

These safety rules cannot cover every situation in a woodshop. Consider your conditions when setting up and using your jig.

OFF” position

- 3 - Woodstock Intl., Inc. W1099

IV. UNPACKING

V. ASSEMBLY

Remove the items packed in the carton. It may be a good idea to save the carton and packing material in case they might be needed in the future. Upon removal of all items from the package, you should have:

1. Dovetail Jig

2. Hand Levers (2)

3. Manual

Hand Lever

Dovetail Jig

Hand Lever

Figure 1 shows the dovetail jig with handles.

A. HAND LEVERS

The jig is shipped fully assembled except for the two hand levers. Screw the threaded end of each hand lever into the clamping rods located on the top and front of the dovetail jig. Tighten until secure. Figure 1.

B. MOUNTING

1. Place the jig on your bench top so the front lap rests against the front of the bench top.

2. Locate the mounting holes in the rear of the jig. Scribe the hole locations and determine whether to use nuts and bolts, or lag screws. Drill the appropriate size holes.

3. Secure the jig to your bench top. Screws can be tightened by inserting a long screwdriver through the unthreaded holes in the back of the jig.

Hint: If you do not wish to permanently devote bench space to the dovetail jig, mount the jig to a piece of bench top.

/4" plywood that can be clamped to your

- 4 - Woodstock Intl., Inc. W1099

VI. CAPACITIES VII. PREPARATION

The W1099 is designed to produce half-blind

dovetail joints with a router,

and 14°,

/2" dovetail router bit. Half-blind dove-

/16" guide bushing,

tails are very strong and are commonly used in fine drawer construction. The term “half-blind” refers to the fact that the pins and tails can only be seen from the side.

1. The W1099 is capable of processing material

up to 1

2. It is designed to be used with

/4" thick and up to 12" wide.

/4" shank, 1/2",

14° dovetail bits only. The bit should pro

trude approximately

/32" below the base.

3. The maximum router base size that can be used with this jig is 7" in diameter.

4. The guide bushing should protrude

/16" from the base of the router and be 7/16" in

/8" to

outside diameter (O.D.).

It is important to plan your work before starting. If joining multiple pieces for a drawer or series of drawers, it is best to label the pieces as front, back and sides and which face will be inside or outside. It is also best to label the ends so it is clear which end mates with another. Labeling will save setup time and avoid costly mistakes in the long run.

A typical drawer has a

made of

/2" material. The dovetail jig’s design

/4" thick front with sides

requires that you use the same stock thickness for the back as you do for the front. Your drawer

fronts and backs must be at least

/8" thick to fully accommodate the length of the dovetails without compromising strength.

After all the pieces have been cut to size and checked to ensure squareness, set them on a bench in the order that they will be fitted together. Lay each piece down so the inside faces up. Label each piece on the inside as shown in Figure 3.

This jig can only be used with a guide bushing attached to your router base.

The table below shows the pin widths produced by different sized templates. Your jig comes with a 1/2" template. Other templates are available from your local Woodstock dealer.

Template Size Bit Size

/2"

/16"

/2"

Tail

Bushing Size

/16"

Pin Width

Figure 2 gives a description of dovetail pins.

Pin Width

/8"

/2"

/4"

Depth

Figure 3 shows the pieces laid out for labeling.

- 5 - Woodstock Intl., Inc. W1099

VIII. ADJUSTMENT LOCATIONS

The W1099 Dovetail Jig has been designed to accommodate various stock thicknesses and router base sizes. Figure 4 shows the locations for all necessary Dovetail Jig adjustments.

Front and back pieces mount horizontally on top of the jig and side pieces mount vertically in the

When describing adjustments and operations in this manual, reference is made to the pieces being joined as fronts, backs or sides. These pieces indicate drawer fronts, backs, and sides.

front of the jig. The insides of the boards always face out!

1. The hand levers clamp your workpiece in place.

2. The fence knobs hold the fence in place. Loosen these knobs to adjust fence position. Router travel is stopped when the router base contacts the fence.

3. The upper side stops align the workpiece horizontally under the template.

Hand Lever

Template Knob

Fence Knob

4. The front side stops align the vertical workpiece to the horizontal workpiece.

5. The template knobs hold the template in place. Loosen these knobs to adjust template position.

6. The clamping pressure knobs control the height of the clamping bar and adjust cam clamping pressure.

Clamping Pressure Knob

Upper Side Stops

Front Side Stops

Clamping Pressure Knob

Hand Lever

Figure 4 shows the adjustment locations for the dovetail jig.

- 6 - Woodstock Intl., Inc. W1099

+ 14 hidden pages