Axcaliber Extra Dovetail Jig User manual

Extra
Dovetail Jig
Simple and easy to set up.
The dovetail jig with a large 575mm capacity can tackle projects
on a much larger scale such as carcass construction etc. Robustly
made from heavy gauge steel pressings.Workpieces are held
quickly and securely while the smooth anodised finish on the
8mm thick machined finger template ensures that both parts of
the joint are cut accurately and cleanly. The jig can be used with
any router with a base diameter not exceeding 160mm that will
take 1/4” shank cutters (although lightweight models are most
suitable). Fitted with the cutter supplied, the jig can be used to
cut both lap and rebated lap dovetails for basic unit drawer
construction or, fitted with an optional bearing guided straight
cutter, it will also produce 1/2” strong, precise comb or finger
joints for tool boxes and utility furniture.
Unit 10 Weycroft Avenue, Axminster, Devon EX13 5PH
www.axcaliber.co.uk

Page No.
What’s in the Box................................................................................................................................................................................ 02
Illustration and Parts Description of Dovetail Jig....................................................................................................................03
Introduction...........................................................................................................................................................................................03
Specification..........................................................................................................................................................................................04
Assembling............................................................................................................................................................................................04
Mounting the Jig and Mounting the Jig.....................................................................................................................................04
Preparation of Timber....................................................................................................................................................................... 04
Setting the End Stops..................................................................................................................................................................05-06
Setting Template and Backstop...............................................................................................................................................06-07
Assembling Timber into the Jig.....................................................................................................................................................08
Setting the Dovetail Cutter..............................................................................................................................................................09
Cutting the Joint..................................................................................................................................................................................10
Box Jointing.................................................................................................................................................................................... 10-11
Through Dovetail Comb for Axcaliber Extra Dovetail Jig.................................................................................................... 11
Replacement Comb for Axcaliber Extra Dovetail Jig.... ........................................................................................................ 11
Index of Contents
02
What’s in the Box
Part No Item Qty
1 Template 1
2 Template Securing Screw 4
3 Template Adjusting Knob 2
4 Clamp Adjusting Knob 4
5 Backstop Adjusting Screw 2
6 Top Clamp Bar 1
7 Front Clamp Bar 1
8 Long Horizontal Stop 2
9 Short Vertical Stop 2
10 Clamp Bar Spring 4
11 Main Body 1
12 Backstop 1
13 TCT Router Cutter (666039) 1

Introduction
03
You now own a jig that will make jointing drawers and
boxes with your router a fast and easy task.
Although most routers can be used successfully with
this jig the medium sized machines with fine height
adjusters are the most suitable. Follow these quick set
up instructions and you can soon be producing
accurate and good looking stopped or lapped dovetail
joints without the need for time consuming and
laborious hand work.This type of dovetail gives a
clean smooth interior to the box or drawer with a neat
craftsman - like joint showing on the outside.
A little time spent now getting to know your jig and
establishing the correct settings will pay dividends in
the future. Large clamping knobs and a non-slip
surface provide a secure hold during machining.
Illustration and Parts Description of Dovetail Jig
Fig 1
13
12
3
3
5
2
1
7
4
44
6
8
4
10
11
5
9

Specifications
Code No 953312
Model DTJ24
Rating Trade
Dovetail Size 15mm
Material Thickness 15 to 32mm
Material Width 575mm
Material Thickness Front and back pieces 1/2" (12mm) to 11/4" (32mm)
Side pieces 3/8" (9mm) to 3/4" (18mm)
Joint Size The template and cutter supplied will produce dovetail pins and sockets approximately 3/8"
(9 .5mm) deep and spaced 1" apart. The purchase of a bearing guided straight cutter(order no. 666106),
will enable 1/2" wide box joints to be made in timber up to a maximum thickness of 3/4"(19mm)
04
1. Assembling and Mounting the Jig
Mount the jig to a firm and stable workbench at a
comfortable height, remembering that the router sits
on top of the jig. The jig must be mounted close to the
front edge so as to leave clear passage for the timber
to the front, vertical clamp. Also, leave ample clearance
to the rear of the jig to accommodate the longest
length of timber you are likely to want to work a
dovetail joint on.There are two holes provided in the
base for securing the jig to the bench.The front clamp
holds the side piece and the top clamp holds the front
or back piece of the drawer. The complete joint is cut
in a single pass through the side piece (making the
pins) and into the back or front piece (making the tail
sockets).
2. Preparation of Timber
As with all joinery work the drawer or box
components must be sized and cut square accurately.
It is preferable that the width of the timber is in exact
steps of 1/2" (i.e. 5", 5 1/2", 6", 6 1/2", etc.) as this will
give a series of fully-formed dovetails without part-
formed pins or sockets at the ends.The dovetail joints
are cut with the insides of the components facing
outwards and the edges that will form the top drawer
hard up against the side stops of the jig, therefore the
right hand side of the drawer and corresponding front
joints are cut on the left hand side of the jig and vice
versa. It is a good idea to identify the drawer pieces as
in Fig 2 so that they are positioned correctly in the jig.
Fig 2

05
3. Setting the End Stops
Start by temporarily removing the front clamp bar
from the jig. Now draw a pencil line across the
template, halfway across the first finger and square to
the edges of the template.(see Fig 3).
Set the top left hand stop in line with the line marked
on the template and square to the body of the jig.
Offset the left hand vertical stop 1/2" to the right of
the top one and square with the top face of the jig
(Fig 4).
Mirror these two settings on the right hand side of the
jig, ensuring that 90˚ alignment to the front edge of
the jig is maintained.
Fig 3
Left Hand Stop

06
Fig 4
Unlock the two locking knobs (4) see Fig 5 and
position the template so that the tips of the fingers sit
inside the vertically mounted timber by a minimum of
1/16"(1.5mm) for thin timber and 1/8" (3mm) for thick
timber (see Fig 5).
Set the back stop so that the longest travel the cutter
can make is twice the thickness of the vertically
mounted drawer side pieces, plus the distance from
the centre of the cutter to the edge of the router base
plate that will contact the back stop, less half the
diameter of the cutter (see Fig 5).
Example:- Using an router with a base width of
110mm, a drawer side 15mm thick and the
standard cutter supplied with its tip diameter of
14.8mm, the distance from the tips of the template
fingers to the vertical face of the backstop should
be set at (110/2) +(2 x15) – (14.8/2) = 77.6mm.
It is not essential that this setting is exact at this stage
as final adjustments can be made later on.
Ensure that the template and back stop stay in parallel
with the front edge of the jig during this setting
procedure.
4. Setting Template and Backstop
1/2 "
90˚
90˚
3. Setting the End Stops

0 7
4. Setting Template and Backstop
Fig 5
1/16 " -1/8 "
4

08
Adjust the top and front clamp bars via the clamp
adjusting knobs at either end of each bar so that the
wood is held firmly in place. When narrower pieces of
timber are being worked it is best to use a packing
piece of the same thickness at the opposite end of the
clamp bar to ensure an even grip and to avoid
distorting the bars. Align the timber so that the piece
forming one of the sides of the drawer, mounted in
the front vertical clamp, extends above the front edge
of the jig by the thickness of the piece to be mounted
in the top horizontal clamp (front or back of drawer).
The piece in the top clamp is then butted up to this so
that both are flush under the finger guide (see Fig 6).
5. Assembling Timber into the Jig
Fig 6

09
6. Setting the Dovetail Cutter
Fit the bearing guided cutter securely into the router
collet and then set the cutter depth, preferably using a
fine height adjuster, until the bottom face of the cutter
protrudes below the router base by 18mm (see Fig 7).
Allowing for the 8mm thickness of the template this
will give a nominal dovetail depth of between 9 and
10mm. The fitting of a packaging piece between the
timber and the template should not be necessary
provided that the cutter is set deep enough and the
router is held firmly on the template during cutting
(see following comment).
The cutting depth is critical to the final fit of the joint,
with as little as 0.5mm change in depth making all the
difference. A number of trial cuts will probably be
necessary, with adjustments to the cutter depth being
made to achieve the best fit.
Fig 7
18mm

10
7. Cutting the Joint
Because there may be a need to alter one or more of
the settings in order to get the joint to fit correctly it is
wiser to carry out the initial cuts on two trial pieces of
timber of the same width and thickness as the final
components.
Position the router on the template with the cutter
clear of the timber and switch on.
Now with just a light cut run the router from right to
left across the work, just touching the end of each
finger. Continue the cut allowing the router to do the
work and avoiding any heavy-handed forced contact
with the template. Follow the template in and out of
the finger guides working from left to right. When
completed switch the router off before lifting it from
the jig.
It is important that a firm and even pressure is kept on
the router whilst the joint is being cut; this will both
ensure an accurate joint and prevent any possibility of
the cutter guide bearing disengaging from the slots in
the template.
Remove the pieces from the jig, make a trial fit and
then, if necessary, make the following adjustments:
• If the fit is too loose, increase the cutter depth by
0.5mm.
• If the fit is too tight, decrease the cutter depth by
0.5mm.
• If the pins stand proud of the joint, move the back
stop further back.
• If the pins sit too deep in the joint, move the back
stop further forward.
Having made the necessary adjustments you can
either make a second trial cut or proceed directly to
the final joint. Once the correct settings have been
made then production runs of joints can be
undertaken, although the settings will need to be
checked periodically to maintain accuracy.
Additional cutter avaliable:
Axcaliber Dovetail Cutter (Order no: 951241)
With a greater cutting depth this cutter is offered as
an optional extra to the standard cutter supplied with
the Axminster dovetail jig and is suitable for material
thickness of approx 19-30mm. The cutting depth will
be different from the standard cutter settings when
using this cutter and the depth should initially be set
to 24mm from the base of the router (16mm tail
length plus 8mm comb thickness).Small adjustments
can be made to cutter height dependant on the joint
fit achieved.
8. Box Jointing
Box joints can be formed in timber with a maximum
thickness of 3/4" using a 1/2" template profile cutter,
Stock No 610479.The procedure is different from that
used for dovetailing in that both boards are mounted
vertically in the front clamp and cut independently of
each other with the fingers in one board offset by
1/2" from those on the other.
First of all, the template assembly needs to be brought
forward as far as possible and locked in position with
the locking knobs (4) see Fig 5; this will allow the
cutter to move far enough in the fingers to cut the full
3/4" thickness of timber. Next, the template assembly
should be raised high enough to allow the cutter to
cut to its full depth without fouling the top surface of
the jig body. This can be achieved by placing a timber
spacer (or spacers) underneath both the rear clamp
and the template and locking in position with the rear
clamp. The spacer should be at least 1/8" (3mm)
thicker than the timber being jointed which should be
enough to ensure that the cutter will cut the full depth
without contacting the body of the jig.
The depth of the cutter below the router base plate
should be set to give the required joint depth plus the
thickness of the template (e.g. 19 + 8 = 27mm in the
case of 3/4" timber). It is important to note that when
thinner timber is used the guide bearing will sit higher
up in the template and in this case it may be
necessary to position the timber below the bottom of
the template (with the aid of a thin plywood shim) so
that the bearing still runs within the depth of the
template.

11
The first board should be positioned in the jig with its
left hand edge in line with the left hand edge of one
of the template fingers and its top edge in contact
with the underside of the template as shown in Fig 9.
Place the router on the template with the cutter clear
of the timber, start up the router and then trace
around the template fingers. When cutting is
completed switch off the router and let it come to a
stop before removing from the jig.The second board is
cut in the same way except that its left hand edge is
lined up with the right hand edge of one of the
template fingers; this will automatically produce the
necessary 1/2" offset between the two halves of the
joint. If multiple joints are to be made then it may be
more convenient to use the vertical end stop to
position the timber correctly relative to the template
quickly and accurately each time.
WARNING Before starting to cut the timber make
sure that (a) the bottom of the cutter is well clear of
the top face of the body of the jig and (b) the cutter
guide bearing is running correctly in the template.
8. Box Jointing
Through Dovetail Comb for Axcaliber Extra Dovetail Jig
Replacement Comb for Axcaliber Extra Dovetail Jig
Fig 8
Fig 9
Align one board with left
hand edge of finger, the
other with right hand edge.
A through dovetail comb expands the range of joints that your Axcaliber dovetail jig can produce. Supplied with 1
x 12.7mm x 8° dovetail cutter (1/4” shank), 1 x 6.35mm twin flute cutter (1/4” shank) and two guide bushes.The
standard 1/2” comb supplied with your jig is used to produce the tails of your joint using the dovetail cutter and a
12mm guide bush; tail sockets are then machined using the through dovetail comb, the twin flute cutter and a
10mm guide bush. Smaller 8° dovetail cutters may be purchased for producing a smaller pin size if required.
953314 Dovetail Comb
A replacement template comb for use with the Axcaliber 600mm dovetail jig is available if required.
953313 Replacement Comb