Craftsman 17125455 User manual

iNDUSTRiALDOVETAILJIG
IMPORTANT:. The fo!lowing router bits are required for use
with this jig-
• VA #22437, or MAGNA #M 910t6, 1/4" Straight Router Bit, and
VA #22501, or MAGNA #M91114, 9t16" Dovetail Router Bit
which are used for THROUGH or OPEN JOINTS.
•VA #22500, or MAGNA #M91113, 1t2" Dovetail Router Bit,
which is used for all HALF BLIND JOINTS.
17125455
WARNING:
Beforeoperatingproduct,readthis
manualandfollow all its Safetyand
OperatingInstructions.

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
Assembly of
Assembly of
Assembly of
Assembly of
Assembly of
the Top Clamping Bar to the Dovetail Base .................................... 7
the Front Clamping Bar to the Dovetail Base ............................... 9
the Cam Handles and Pivot Shaft to the Dovetail Base ................ 10
the Front Stop Blocks to the Dovetail Base ................................ 13
the Top Stop Blocks to the Dovetail Base ........................................ 14
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 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

SAFETY GUIDELINES - DEFINITIONS
This manual contains informa-
tion that is important for you to
know and understand. This
information relates to protect-
ing YOUR SAFETY and
PREVENTING EQUIPMENT
PROBLEMS. To help you rec-
ognize this information, we use
the symbols to the righL
Please read the manual and
pay attention to these sections.
IADANGER I
URGENT SAFETYINFORMATION-A
HAZARDTHATWILLCAUSESERF
OtISINJURYORLOSSOFLIFE
I,AWARNINGI
IMPORTANTSAFETYINFORMA-
TION_A HAZARD THAT MIGHT
CAUSESERIOUSINJURYORLOSS
OFLIFE
I CAUTION]
INFORMATIONFORPREVENTING
DAMAGETOEQUIPMENT
[ NoTE]
INFORMATIONTHATYOUSHOULD
PAYSPECIALAITENTIONTO
['_WARNINGI Failure to heed all safety and operating instructions and warnings regarding use of this
product can result in serious bodily injury
1. Know your power tool
Read the owner's manual carefuify Learn its
application and limitations as welt 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
Ftoor 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 wifl 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 Nomstip 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 A_so, 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

16. Disconnect tools before servicing
Before servicing, when changing accessories
such as blades, bits, cutters, etc
17. Avoid accidental starting
Make sure swilch 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 ff the cut_
ring _ootis accidentally contacted DO NOT store materi-
als above or near the tool making it
necessary to stand on the toot to reach them
20. Check damaged parts
Before further use of the Iool, 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 comptele 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
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 thatthey are all are tight and secure
7 Do net use this product until all assembly installa-
tion steps have been completed, and you have read
and understand all safeb/and operational instruc-
tions 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 ofthe
workbench by no more than 1/4" to provide clear-
ance 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 fiat 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 work-
pieces only Do not use this product to cut metal
or any other non-wood material.
13 This product has been designed to cut work-
pieces having thicknesses of 3/8" to 1" Do not use
Ior 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 dam-
age to it or possible serious injury to you.

16 L'_WARNING_ ALWAYS UNPLUG THE
ROUTER FROM THE ELECTRICAL OUTLET
BEFORE INSTALLING OR REMOVING ROUTER
BITS FROM THE ROUTER AND WHEN ADJUST-
ING 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 BtT 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
• 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 tem-
plates and two guide bushings for making halt-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 t"
spaced open, or through, dovetail joints
• Workpieces up to 16" wide can be accommodated
oWorkpieces with thicknesses between 3f8" 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", I/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 ioints
• 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
Refer to Parts List on Page 47
• tn 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
.i,A ,,anypartsarem,ss,ngorcannot
be accounted for, do not attempt to assemble, instaIl,
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

ALTHOUGHYOURINDUSTRIALDOVETAILJIG
COMESASSEMBLED,THEFOLLOWINGASSEM-
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 tS TO TAKE PLACE
TOOLS REQUIRED
- A medium sized Phillips screwdSver
° A smafl or medium adjustable wrench
ASSEMBLY OF THE RIGHT SIDE TEMPLATE
SUPPORT TO THE DOVETAIL BASE
1 Ptace the dovetail base topside down on a fiat surface
2 insert one of the 5/16-18 x 2" long round head square
FIGURE 1
neck botts 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" t D, x 7/8" OD 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
10_32X 5/8" LONG PANHEAD
MACHINE SCREW
HEXES MUST LINE UP
5t16-18 X 2" LONG ROUND HEAD
SQUARE NECK BOLT
t3/64" I D X 9/t6" O D WASHER
"" # 10_32 HEX NUT
"" BACK OF DoVETAiL BASE

!UrpSAlignthenutsothatthecomersofthenu_areverti-
calfyline_JUpasshownNotethealignmentofthehex
pocketinlhetemplatesupportTheboltshouldbefreeto
movesidetoside;ifitdoesnot,loosenthenut1/3turnor
untilthecornersofthenutpointupanddown
6 Assembletherighttemplatesupporttotherightsideof
the dovetail base so that the hex nut lines up and lits 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 #t0-32 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
lhe base as shown to hold the template support in place
Securely tighten thenut 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 loos-
ened 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-l/2" long round head square neck bolts as
shown in Figure 2
2 Align the square on the bolt with lhe 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 spdngs 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 fiat smooth surface so
the back of the base rests on the surface
[ NOTE ] ALTHOUGH BOTH ENDS OF THE
DOVETAIL BASE ARE SHOWN ASSEMBLED IN THE
FOLLOWING FIGURES, THE ACTUAL ASSEMBLY IS
DONE ONE END AT A TIMEo
5 From the bottom of the base, insert a bolt with bolt sup-
port 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
FIGURE 2
FIGURE 3A FIGURE 3B
(_ NYLON
SPRING
RETAINER
COMPRESSION /'J_f
SPRING
SPRING TO
BOTTOM
OUT
AGAINST
SURFACE
FIGURE 4
BOLT 11/
SLOT IN
DOVETAIL BASE DOVETAIL BASE
/ / SLOT IN
DOVETAIL
BASE kq
X\
BOLT AND BOLT
SUPPORT
/
/
FRONT OF DOVETAIL BASE

6 Placean11/32"IDX7/8"ODwasherandthena
5/16"IDX7/8"ODthicknylonwasherovertheboltIt
willbenecessarytoholdtheboilinplacewhenperforming
thisandthefollowingsteps
HELPFULHINTS:Positiontheboltandtheboltsupport
underthenotchintheribasshowninFigure5,tohelp
holdtheboltinplace
7 Placeaspringoverthebolt,asshowninFigure6
8 Placea5/16"IDX7/8"QDthicknylonwasherand
thenan!1/32"IDX7/8"ODwasherovertheboiland
pressdownonthespringuntiljusttheendofthebolt
sticksoutpasttheendofthewasher
g Slidetheclampingbaroverthebollsothatthewashers
aresandwichedbetweenthespringandtheinsideofthe
clampingbarasshowninFigure6 NOTE:THESPRING
MUSTPUSHAGAINSTTHETHICKNYLONWASHERS
ANDNOTAGAINSTTHESTEELWASHERS
t0 Placean11/32"tDX7/8"ODthinnylonwasherand
an11/32"ID X7/8"ODwasheroverthebellItwilibe
necessaryforyoutopressdownontheclampingbarwhile
doingthis
11Takeoneoftheclampingknobsandthreaditontothe
boilasshownDONOTTHREADtheknobcompletely
ontothebolt--justenoughsotheknobhoidstheclamping
barinplace
t2 Repeatabovesteps4through10fortheotherendof
theclampingbar
13Assembletheendcapstotheendsoftheclampingbar
bypressingthemin;theyaredesignedtobe"force-fit"into
FIGURE5
j NOTCH
IN RIB
._---- SLOT IN
DOVETAIL
BASE
BOLT AND
BOLT
SUPPORT
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 tlgh|ty into the clamping bar
USE CARE WHEN DOING THIS SO AS NOT TO DAM-
AGE 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
FIGURE 6 Assemble clamping bar, knobs, end caps on both ends as shown
CLAMPING KNOB , 11/32" I.D.
',\ X 7/8" O D WASHER
\" !t/32" I.D X 7/8" O D. CLAMPING BAR DETAIL
SPRING AND
NYLON SPRING
RETAINER FIT
]NSlDE THE
OPEN SIDE OF
THE CLAMPING
BAR
(SEE CLAMPING
BAR DETAIL)
COMPRESSION
SPRING
3 t12"
j/*
BOLT
SUPPORT // l
//Z-
TOP SURFACE OF
THE DOVETAIL
CLAMPING BAR
•CLAMPING BAR
f_END CAP
L_.! ) OPEN SIDE OF
_-_\/ THE CLAMPING BAR
POINTS TOWARD
"_ THE TOP SURFACE
OF THE DOVETAIL
i BASE
€/1t132" I.D.
_, /X 7/8" O D
/THICK
-_ NYLON
__._WASHER
RIGHT
TEMPLATE
SUPPORT
NYLON SPRING
RETAINER
(RETAINER ABUTS THE
11/32" I,D X 7/8" CLAMPING BAR
O D WASHER __
WASHER .--[ _,
CLAMP,NG AB S.OWNW,THI
END CUT AWAY AND SECTIONED
SO NYLON SPRING RETAINER
PLACEMENT CAN BE SEEN)
COMPRESSION
SPRING

FIGURE7
CLAMPINGBARPARALLELTO
TOPOFBASE
00 0
SPACING TO BE
//APPROXIMATELY
t-112"
ASSEMBLY OF THE FRONT CLAMPING BAR TO
THE DOVETAIL BASE
t Assemble the front clamping bar !o the front of the dove-
tail base following the same procedure used Io assemble
the top clamping bar to the dovetail base as shown in
Figure 8 The 5/16-18 X 4-1/2" long round head square
neck bolts are used
FIGURE 8
DOVETAIL
BOLT SUPPORT j7
CLAMPING BAR f
NYLON SPRING /'t"
RETAINER
CLAMPING BAR
(SHOWN WITH END
CUT AWAY AND
SECTIONED SO
NYLON SPRING
RETAINER PLACEr
MENT CAN BE ,.
SEEN) "\, \.
COMPRESSION
SPRING "__
1/2" BOLT
!1/32' I.D. X 7/8' O.D.
THICK NYLON WASHER
COMPRESSION SPRING
• CLAMPING BAR
END CAP
11132"I,D X 7/8" 0 D.
THIN NYLON WASHER
tt/32" I D X 7/8" O D
\\ \
NYLON
SPRING
RETAINER
(RETAINER
ABUTS THE
CLAMPING
BAR)
CLAMPING KNOB

ASSEMBLYOFTHECAMHANDLESANDPIVOT
SHAFTTOTHEDOVETAILBASE
•After the cam handles and pivot shaft have been assem _
bled to the base, it wil! 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 posi-
tioning of the template
• Cam handles are designed to provide infinite template
adjustment
• One graduation equals 1/64" of movement of the tem-
plate
• Rotating the cam handle so that the lever moves toward
the front of the base, causes the template to also move
towards the lront 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 Iowards the back of the base also
1 Assemble one of the cam handles to the pivot shaft
using a #10-32 x 5/8" tong panhead machine screw and a
13/64" I D x 9/16" ID 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 handie
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
FIGURE 9
13/64"1D X 9/16_'O D WASHER _\ \
#10_32.X5/8" LONG /
PANHEAD MACHINE SCREW
/CAM HANDLE
/_PIVOT SHAFT
J j
<--LT-,:
FIGURE 10
#10-16 X 1/2" LONG PANHEAD TAPPING SCREW
_ RETAINER
/
x\__ PIVOT SHAFT
10

7 LoosenthescrewaboutoneturnRemovetheretainer
fromtheshaftandsetitasidetemporarily
8Assernblethepivotshaftwithcamhandletothebaseby
insertingtheendofthepivotshaftthroughtheholesinthe
righttemplatesupportandthebase
9 MAKESURETHEORIENTATIONOF THE CAM HAN-
DLE 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
FIGURE 11
CAM HANDLE
PIVOT SHAFT ._
HOLE IN BASE
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 teft 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
// RETAINER
RIGHT TEMPLATE
DOVETAIL BASE /
RGURE 12
CAM
HANDLE
HOLE IN BASE
PIVOT SHAFT i,vo
• ._ ........ HOLE tN
BASE
iA ............../LJJ
11

13Withthecamhandlepushedinagainstthebase,
positiontheretaineragains!thesidewallofthebase,as
showninFigure13Theretainershouldbarelytouchthe
sidewallofthebaseThepurposeoftheretaineristo
preventorminimizetheside-to-sideofthecamhandleand
pivotshaft
14Assembletheothercamhandletotheotherendofthe
pivotshaftusinga13/64"1Dx9/16"ODwasherand
a#10-32X5/8"longpanheadmachinescrew,asshownin
Figure14
15Makesurethatthecamhandlelinesupwiththecam
handleattheotherendofthepivotshaftandthattheend
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 retain-
er 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
FIGURE 13
_LOF BASE
FIGURE 14 LEFT TEMPLATE SUPPORT
j PIVOT SHAFT
/
J// / #t0_32 X 5/8" LONG
\\ X 9/16" O D WASHER
\" CAM HANDLE
12

ASSEMBLY OF THE FRONT STOP BLOCKS TO
THE DOVETAIL BASE
1 Assemble the front stop blocks to the front of the dove-
tail 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
#!0-32 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
FIGURE 15
FOR REASONS OF CLARITY, THE FRONT
CLAMPING BAR, KNOBS, BOLTS AND
SPRINGS ARE NOT SHOWN
DOVETAIL BASE
RIGHT _
TEMPLATE ../.,.._ \'_ 7
SUPPORT _____/_\ _ "_
\\
OD WASHER V /i,'_&.
FRONT STOP BLOCK /
,,o 32HExNUT
/L%;f PLATE
_T_// FRONT STOP BLOCK
" #10-32 X 5/8" LONG
FLATHEAD MACHINE
SCREW
FRONT OF DOVETAIL BASE
#t0-,32 X 5/8" LONG FLATHEAD
MACHINE SCREW
t3

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 dovetait 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
screw, as shown in Figure t6 The screw threads into the
hole in the bottom of the slot
3Make sure that the "A" faces the "middte 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, simpty
loosen the screws just enough so that the dbs on the stop
blocks come out of the slot The stop block is then rotated
180 ° to the attemate position, so the "B" faces the middle
of the base, and securefy retighten the screws
FIGURE 16
#10-32 X 7/8" LONG FLAT HEAD \
MACHINE SCREW \
TOP STOP BLOCK
RIB ON STOP BLOCK ,
\\ #10-32 X 7/8" LONG FLAT
MACHINE SCREW
RIB ON STOP BLOCK
/'
SLOT IN TOP //
OF BASE
SLOT IN TOP
OF BASE
BASE
ASSEMBLY OF THE CLAMPING KNOBS TO THE
DOVETAIL BASE
1 Assemble 11/32" ID x 7/8" O D washers onto the 5/!6-
18 bolts at both ends of the dovetail base as shown in
Figure 17.
2 Assemble the clamping knobs onto the bolts as shown
FIGURE 17
5/16-18 X 2" LONG ROUND
HEAD SQUARE NECK BOLT
1t132" I D X 7/8"
OD
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 con-
tinue on with the next section
5/16-18 X 2" LONG ROUND
HEAD SQUARE NECK BOLT
/CLAMPING
// KNOB
CLAMPING /
KNOB
14
\1/2" SPACING BETWEEN
WASHER AND TEMPLATE
SUPPORT (BOTH ENDS)

ASSEMBLY OF THE TEMPLATES
•Ptace the template stiffener into the rectangular slot in the
underneath side of the template, as shown in Figure 16
NOTE: THE TEMPLATE FOR cUTTING HALF-BLIND
JOINTS 1S 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 TH1S PROD-
UCT, A SLOTTED BINDING HEAD MACHINE SCREW
HAS BEEN SUBSTITUTED FOR THE PANHEAD SCREW
SPECIFIED FOR ASSEMBLING THE TEMPLATE SUP-
PORTS TO THE TEMPLATES (SEE THE SCREW ILLUS-
TRATION 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 t9
3MAKE SURE THAT THE TEMPLATE BRACKETS ARE
ASSEMBLED TO THE UNDERNEATH SIDE OF THE
TEMPLATE, AS SHOWN IN FIGURE lg, 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 BRACK-
ETS 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 took like the illustration
in Figure 20
6 Assemble the template stiffener and the template brack-
ets to the TEMPLATE FOR CUTTING THROUGH JOINTS
using the same method described in the preceding steps 1
through 5 Refer to Figure 20
FIGURE 18
\ \ \
!_' _ TEMPLATE STIFFENER
RECTANGULAR SLOT
TEMPLATE
\ \ \
SLOTTED BINDING HEAD
MACHINE SCREW
_--- #8-36 X 3/t6" LONG
\ PANHEAD MACHINE
SCREW
\\ '\
\
/TEMPLATE BRACKET "_--,o
TEMPLATE
FIGURE 20
15

ALIGNMENTOFTHETEMPLATES
•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 comers wi}l always be lined up
• NOTE: THE TEMPLATE FOR CUTTING HALF-BLIND
JOINTS IS BEING USED AS AN ILLUSTRATION IN THE
FOLLOWING FIGURES°
t= With the dovetail base stiB having the 1/2" spacing
between the washer and the template supports (Refer to
Figure 17), assemble the template assembly to the dove-
tail base so that:
a) the slot in the template bracket fits over the bo_t
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 SUP-
PORT OR ELSE THE TEMPLATE WILL NOT BE
PROPERLY POSITIONED FOR CUTTING ACCURATE
DOVETAILS,
For initia! 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 SPAC-
ING BETWEEN THE TEMPLATE BRACKET AND THE
WASHER IS ABOUT 1/2"; GENTLY LIFTTHE 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 he]d in place
against the template supports as shown in Figure 21
3Move the template from side to side on the templale
brackets so Ihat it is centered with respect to the template
brackets This means that the template and brackets
should took 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 tem-
plate brackets MUST be symmetrical with each other The
figures do not show the complete Dovetail Jig, but only the
underneath side of the tempJate with template brackets
correctly positioned, in order that the correct positions of
FIGURE 21
jj RtGHTTEMPLATE SUPPORT
BOLT
/SLOT tN THE TEMPLATE SUPPORT
TEMPLATE BRACKET
SLOT
LTEMPLATE BRACKET "BOTTOMS-OUT" AGAINST
THIS SURFACE (BOTH ENDS OF DOVETAIL BASE)
16

FIGURE22
(
OO
DISTANCE BETWEN THESE
SURFACES MUST BE EQUAL
AT BOTH ENDS
TEMPLATE BRACKET
CONDITION ONE: TEMPLATE BRACKETS PROTRUDE BEYOND TEMPLATES
FIGURE 23
'O
TEMPLATE BRACKET
CONDITION TWO: TEMPLATE PROTRUDES BEYOND TEMPLATES BRACKETS
FIGURE 24 rLrolio
________---_ TEMPLATE
AT BOTH ENDS
0
-TEMPLATE BRACKET
CONDITION THREE: TEMPLATE EVEN WITH TEMPLATE BRACKETS
17

4 Afterthetemplatebracketshavebeencorrectlyposi-
tionedonthetemplatesecurelytightenthefourscrews
holdingthe template brackets to the template
5 Remove the template assembly from the base and set it
aside for now
6 Align the other template assembly in the same manner
IT SHOULD BE NOTED THAT YOU MAY FIND, THAT
AFTER MAKING SOME SAMPLE CUTS, SLIGHT
FIGURE 25
TEMPLATE BRACKET ,\
THE TEMPLATE EXTENDS
BEYOND THE TEMPLATE
BRACKET
ADJUSTMENTS MAY BE REQUIRED HOW TO MAKE
THESE ADJUSTMENTS IS EXPLAINED IN TWO OF THE
FOLLOWING SECTIONS: "TROUBLESHOOTING FOR
HALF BLIND JOINTS" or "TROUBLESHOOTING FOR
OPEN (THROUGH) JOINTS"
7 Remove the template assembly from the base and
set it aside for now (Figure 25 below, is an example of
INCORRECTLY positioned template brackets )
TEMPLATE ,
\,,\
o o
BRACKET EXTENDS
BEYOND THE
TEMPLATE
CONDITION FOUR: THIS CONDITION IS NOT CORRECT -
TEMPLATE BRACKET EXTENDS BEYOND THE TEMPLATE AND
THE TEMPLATE EXTENDS BEYOND THE TEMPLATE BRACKET
•SIMPLY MAKE SURE BRACKETS ABE POSmONED THE SAME AT EACH END
ASSEMBLY OF THE ADAPTER PLATE TO THE
ROUTER
[A¢kWARNING]
ALWAYS MAKE SURE THATTHE ROUTER IS q*URNED
OFF" AND THATTHE ELECTRICAL CORD HAS BEEN
UNPLUGGED FROM THE ELECTRICAL OUTLET
BEFORE ASSEMBLING THE ADAPTER PLATE AND A
GUIDE BUSHING TO THE ROUTER; OR WHEN MAKING
ANY ADJUSTMENTS, OR CHANGING ROUTER BITS IN
THE ROUTER
1 Remove any router bit currently installed in the router
FIGURE 26
SCREW ':a_'_,
i i
J I
tI
I I
1 I
tI
SCREW "b"_\
I I
I I
I I
t I
I I
I I
I I
I I
I I
I I
i i
2 Remove the router base plate now on the router, by
removing the screws holding the base plate to time router
3 Depending on the make of router, either three or four of
the loIIowing screw types and sizes will have been used:
a) #8 ( 164 dia) Pan Head Screw
b) #t0 (I90 din) Pan Head Screw
c) #8 ( 164 din) Flat Countersunk Head Screw
d) #10 ( t90 dia) Flat Countersunk Head Screw
4 Compare the screws removed with those shown in
Figure 26
SCREW 'c"
I 1
I 1
I 1
i 1
i t
SCREW "d"
I t
i *
18

5 If the screws look like Screw "a" or Screw "b", use either
three or four of the 13/64" ID x 15/32" OD washers when
installing the adapter plate to the router as shown in
Figure 27
6 Your Dovetail Jig comes with four countersunk bushings
with an 11/64" hole and four countersunk bushings with a
13/64" hole Refer to Figure 28
FIGURE 27
7 If the screws look like Screw "c", use either three or four
of the bushings with an 11/64" din hofe when installing
the adapter plate to the router as shown in Figure 29
8 If the screws look like Screw "d", use either three or four
of the bushings with a 13/64" dia hole when installing the
adapter plate to the router as shown above in Figure 29
FIGURE 28
SCREW
PAN HEAD
SCREW
, PAN HEAD SCREW
i/WASHER
//PAN HEAD SCREW
(_jWASHER
4
4
0 11/32
--O t1/64
O 25/64
F O 13/64
FIGURE 29
HEAD
SCREW
BUSHING--.-.
WITH Oll/64
HOLE
SCREW
BUSHING
Oll/64 HOLE
d_ #8 FLAT HEAD SCREW
'_ BUSHING WITH Otl/64 HOLE
"-_,\ _j #8 FLAT HEAD SCREW
\, '0_ /BUSHING WITH
\ _/Oll/64 HOLE
PLATE
19

Thefiguresbelowshowtheviewsoftheadapterplateasit
wouldappearwheninstalledonarouterwiththerouter
turnedoverwiththerouterbasefacingupward
Threeofthemostpopularmountingholeconfiguralions
areshown
Figure30showsthemountingarrangementusingthree
screws
Figure31showsthemountingarrangementusingfour
screwswhenthescrewsareat45degreestothesideof
the front of the router
Figure 32 shows the mounting arrangement using four
screws when the screws are in line with the front of the
router
In most cases, the adapter plate will fit your router
However, in those cases where the router is extremely
smatl or extremely large, rated at 1-3/4 HP or larger, the
adapter plate cannot be used
g Set the router upside down on a workbench or other flat
stable surface
10 Position the adapter plate on the router so that the
threaded holes in the router base line-up with slots (or
holes) in the adapter plate
The recessed arrow in the adapter plate should point
FIGURE 30
©
©
toward the front of the router)
11 Line-up the center of the hole in the adapter plate with
the collet hole in the router This will ensure accurate cuts
I2 Using the screws removed in Step 2 above, in combi_
nation with either the washers or countersunk bushings,
assemble the adapter plate Io the router if the bushing are
used the heads of the screws must be flush with, or slight-
ly below the top of the bushing
THE TOPS OF THE SCREWS MUST NOT PROTRUDE
ABOVE THE TOP SURFACE OF THE ADAPTER PLATE
If for some reason the countersunk head screws being
used are too short, too long, or protrude above the top of
the adapter plate, obtain pan head screws that are 1/4" or
3/8" long with the proper thread from a hardware store or
DYI outlet Use these with the washers, instead of the
bushings, to assemble the adapter plate to the router
t3 TIGHTEN ALL SCREWS SECURELY
14 Check to see that center of the router co]Iet hole still
lines-up with the large center ho_e in the adapter plate
15 If it does not loosen the screws and reposition the
adapter plate so the hole Iines-up with the router collet hole
16 TIGHTEN ALL SCREWS SECURELY
FIGURE 32
©
©
/
FIGURE 31
©°@ ©
2O