Incra Ultra lite User manual

OWNER’S MANUAL

Please read this Ownerʼs Manual before

use and keep it at hand for reference.

In the few years since its first appearance in

woodworking shops around the globe, Incra

Jig has quickly established itself as the finest

and most versatile woodworking system

available. At the top of its list of features has always

been its unparalleled positioning accuracy. As a fence

system, Incra Jigʼs amazing precision allows precise fence

placement to within a few thousandths of an inch, regardless of

your skill level. As a joint making machine, these same positioning

capabilities permit an endless variety of box joints and half blind, through

and sliding dovetails to be created. And with decorative joints like the exquisite

Incra Double Dovetail (described in the optional

Incra Master Reference Guide

and Template Library

), Incra Jig makes the impossible quite possible.

Introducing the newest member of the Incra family:

The Incra Jig Ultra Lite

. With built-in micro

adjusting, velvet smooth tracking, and the Incra heritage of precision, your new Incra Jig Ultra Lite

combines some of the best features of its big brother, the Incra Jig Ultra, in a refined, more compact

unit perfect for the router table or drill press. The Ultra Lite carries on the tradition of performance and

accuracy youʼve come to expect from the Incra line of precision tools.

From the

makers of

Incra Jig!

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Applications/General Purpose Fence . . . . . . . . . . . . 5

Zeroing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Applications/Joint Maker . . . . . . . . . . . . . . . . . . . . . 6

Setting the router bit depth of cut . . . . . . . . . . . . . . 6

Centering the bit and installing the template . . . . . . 7

Box joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Half blind dovetails . . . . . . . . . . . . . . . . . . . . . . . . .11

Variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Parts and Optional Accessories . . . . . . . . . . . . . . . .16

CONTENTS

■Important safety instructions for using the Incra Jig Ultra Lite:

before using the Incra Jig Ultra Lite, read and follow all of the

instructions and safety information in this manual.

■When using Incra Jig Ultra Lite in conjunction with any other

tool, first read and follow all instructions and safety

information in that toolʼs ownerʼs manual.

■When Incra Jig Ultra Lite is mounted to a wooden base or

table surface, make sure that all six mounting screws are

securely tightened and the Incra Jig Ultra Lite is firmly held in

place.

■When using the Incra Jig Ultra Lite with a wooden base,

always make sure that the base is securely clamped,

screwed, or otherwise fastened to the work surface before

making a cut.

■Always turn off the power and make sure that the bit or blade

is fully stationary before moving the Incra Jig Ultra Lite to any

new setting.

■Always keep both hands behind the fence when moving the

Incra Jig Ultra Lite to any new setting.

■Before making a cut, always make sure that the carriage

clamp is fully engaged and the jig is securely locked in place.

■When using the Incra Jig Ultra Lite with other tools, make sure

that all safety guards and other safety equipment supplied by

the manufacturer of that tool are securely in place and

functional. Never let the Incra Jig Ultra Lite interfere with

another toolʼs safety equipment.

■Use appropriate safety devices. Keep hands clear of the bit

or blade. Always use a push stick, rubber soled push block,

or other safety devices to keep your hands safely away from

the cutting tool.

■Wear safety glasses, hearing protection, and a dust mask,

and follow all normal shop safety practices.

■Do not alter or modify the Incra Jig Ultra Lite in an attempt to

use it with non-Incra accessories.

SAFETY

Precision

Woodworking System

Attach the Incra Jig Ultra

Lite to a 3/4” plywood base

Begin with a piece of 3⁄4" plywood (or

hardwood) that is 8" wide. The length of the

plywood should match the width of your

router table. Clamp the plywood to the edge

of your router table using (2) C-clamps.

Mark the center of the plywoodʼs length and

position the operatorʼs side of the Ultra Liteʼs

base 2 1⁄4" from the center mark. See Fig. 1.

Attach the base to the plywood through the

six holes using (6) #10 x 7⁄8" phillips pan

head wood screws and #10 flat washers.

Attach hairline cursor

to base

Place one of the #6 flat washers on each of

the #6-32 x 3⁄8" screws. Insert the screws

through the holes in the plastic cursor and

loosely attach the #6-32 hex nuts. slide the

two nuts into the T-slot at the front of the

Ultra Liteʼs base as shown in Fig. 1a. Align

the cursor flush with edge of the base and

tighten the mounting screws.

Attach the Incra Fence

With the plywood base still clamped to

the edge of your router table, carefully slide

the carriage into the base and pull the

carriage clamp up into the locked position.

Insert the #10-32 x 11⁄8" phillips pan head

screws through the thick (gold) washers,

then through the holes on the back of the

fence mounting bracket. Place a thin (silver)

washer on the end of each screw, then

loosely attach the rectangular nut. See

Fig. 2. The raised rim on the nut should

face toward the mounting bracket. Now

slide the thin washer and rectangular nut

into the T-slot on the back of the Incra

Fence. Make sure the thin washer is

captured in the T-slot provided as shown in

Fig 3. Position the fence so that the

mounting bracket is approximately centered

on the fence length and tighten the two

mounting screws.

FIG. 1

Attach Ultra Lite to 3⁄4" plywood base

FIG. 2

Attach the Incra Fence

To achieve a silky smooth

carriage motion when moving the

fence, it is important that your table

surface is flat and smooth. If you find

that your carriage tends to bind slightly

during some portion of its travel, try

loosening the fence mounting screws

then retightening at different locations

along the tableʼs length.

SETUP

FIG. 1a

Attach hairline cursor

FIG. 3

#10 x 7/8"

phillips pan head

wood screws

#10 washer

Center of

plywood

Align cursor flush

with edge of base

#6-32 x 3/8" screw

#6 flat washer

#6-32 hex nuts

Incra Fence

Fence

mounting

bracket

Raised rim on rectangular nut

faces the mounting bracket

#10-32 x 1 1/8" phillips

pan head wood screw

Thick (gold) 5/8" o.d.

flat washer

Thin (silver) 5/8" o.d.

flat washer

Thick gold

washer

Thin silver washer

captured here

Adjusting the fence angle

After mounting the Incra Fence to your

Ultra Lite, check the angle of the fence to

the router table using a machinistʼs or

carpenterʼs square. Sometimes, as a result

of the plywood not being perfectly flat, the

angle may be slightly more or less than 90°.

To correct the angle, place a masking tape

shim between the mounting bracket and the

fence as shown in Fig. 5.

Assemble stop positioner

Place a #8 flat washer on each of the

(2) #8-32 x 1⁄2" thumb screws and insert

through two of the holes in the black plastic

stop positioner. Loosely install the (2) #8-32

hex nuts, then slide the nuts into the T-slot

on the front of the Incra Fence. Fig. 4.

When not in use, simply slide the stop

positioner off the fence.

If you wish to upgrade your Incra

Fence to add the ultra-precise stop

positioning abilities of the New Incra

Stop, see the fence upgrade

package offered on page 16.

FIG. 4

Assemble stop positioner

FIG. 5

#8 flat washer

#8-32 hex nut

#8-32 x 1/2"

thumb screw

Stop

positioner

T-slot

Table

top

Place shim here if angle

is greater than 90°

Place shim here if

angle is less than 90°

Fence upgrade option:

MAINTENANCE

In general, just keeping your Incra Jig clean is all

you need to do to keep the tool in tip top shape.

Occasionally, remove the carriage from the base and

brush or blow out any sawdust or debris that may have

accumulated on the base and the UHMW guide

bearing strips. Use a toothbrush to clean the teeth

on the Incra racks on both the carriage clamp and

on the carriage.

90°

Attach the Incra Jig Ultra

Lite to a 3/4” plywood base

Begin with a piece of 3⁄4" plywood (or

hardwood) that is 8" wide. The length of the

plywood should match the width of your

router table. Clamp the plywood to the edge

of your router table using (2) C-clamps.

Mark the center of the plywoodʼs length and

position the operatorʼs side of the Ultra Liteʼs

base 2 1⁄4" from the center mark. See Fig. 1.

Attach the base to the plywood through the

six holes using (6) #10 x 7⁄8" phillips pan

head wood screws and #10 flat washers.

Attach hairline cursor

to base

Place one of the #6 flat washers on each of

the #6-32 x 3⁄8" screws. Insert the screws

through the holes in the plastic cursor and

loosely attach the #6-32 hex nuts. slide the

two nuts into the T-slot at the front of the

Ultra Liteʼs base as shown in Fig. 1a. Align

the cursor flush with edge of the base and

tighten the mounting screws.

Attach the Incra Fence

With the plywood base still clamped to

the edge of your router table, carefully slide

the carriage into the base and pull the

carriage clamp up into the locked position.

Insert the #10-32 x 11⁄8" phillips pan head

screws through the thick (gold) washers,

then through the holes on the back of the

fence mounting bracket. Place a thin (silver)

washer on the end of each screw, then

loosely attach the rectangular nut. See

Fig. 2. The raised rim on the nut should

face toward the mounting bracket. Now

slide the thin washer and rectangular nut

into the T-slot on the back of the Incra

Fence. Make sure the thin washer is

captured in the T-slot provided as shown in

Fig 3. Position the fence so that the

mounting bracket is approximately centered

on the fence length and tighten the two

mounting screws.

FIG. 1

Attach Ultra Lite to 3⁄4" plywood base

FIG. 2

Attach the Incra Fence

To achieve a silky smooth

carriage motion when moving the

fence, it is important that your table

surface is flat and smooth. If you find

that your carriage tends to bind slightly

during some portion of its travel, try

loosening the fence mounting screws

then retightening at different locations

along the tableʼs length.

SETUP

FIG. 1a

Attach hairline cursor

FIG. 3

#10 x 7/8"

phillips pan head

wood screws

#10 washer

Center of

plywood

Align cursor flush

with edge of base

#6-32 x 3/8" screw

#6 flat washer

#6-32 hex nuts

Incra Fence

Fence

mounting

bracket

Raised rim on rectangular nut

faces the mounting bracket

#10-32 x 1 1/8" phillips

pan head wood screw

Thick (gold) 5/8" o.d.

flat washer

Thin (silver) 5/8" o.d.

flat washer

Thick gold

washer

Thin silver washer

captured here

Adjusting the fence angle

After mounting the Incra Fence to your

Ultra Lite, check the angle of the fence to

the router table using a machinistʼs or

carpenterʼs square. Sometimes, as a result

of the plywood not being perfectly flat, the

angle may be slightly more or less than 90°.

To correct the angle, place a masking tape

shim between the mounting bracket and the

fence as shown in Fig. 5.

Assemble stop positioner

Place a #8 flat washer on each of the

(2) #8-32 x 1⁄2" thumb screws and insert

through two of the holes in the black plastic

stop positioner. Loosely install the (2) #8-32

hex nuts, then slide the nuts into the T-slot

on the front of the Incra Fence. Fig. 4.

When not in use, simply slide the stop

positioner off the fence.

If you wish to upgrade your Incra

Fence to add the ultra-precise stop

positioning abilities of the New Incra

Stop, see the fence upgrade

package offered on page 16.

FIG. 4

Assemble stop positioner

FIG. 5

#8 flat washer

#8-32 hex nut

#8-32 x 1/2"

thumb screw

Stop

positioner

T-slot

Table

top

Place shim here if angle

is greater than 90°

Place shim here if

angle is less than 90°

Fence upgrade option:

MAINTENANCE

In general, just keeping your Incra Jig clean is all

you need to do to keep the tool in tip top shape.

Occasionally, remove the carriage from the base and

brush or blow out any sawdust or debris that may have

accumulated on the base and the UHMW guide

bearing strips. Use a toothbrush to clean the teeth

on the Incra racks on both the carriage clamp and

on the carriage.

90°

Micro adjusting

The micro adjust feature of your new Incra Jig Ultra Lite allows for

precise positioning of the fence to any location between the 1⁄32" tooth

spacing of the Incra sawtoothed racks. Youʼll find this feature extremely

handy the next time you need to widen a mortise by a few thousandths

of an inch for a great fitting mortise and tenon joint. Use the micro

adjuster for a flawless fit when cutting grooves to accept inlay strips,

or to loosen up a tight fitting box joint cut with an undersized bit. Youʼll

find it especially useful for setup operations like “zeroing” (page 5) or

“centering” (page 7). Hereʼs a step-by-step look at operating your

Ultra Lite micro adjuster. See Fig. 7 as you follow the steps

Unlock the carriage clamp

Push the carriage clamp down to unlock the carriage.

Engage the micro adjust mechanism

Continue pushing the carriage clamp handle down until it

touches your plywood sub-base, then hold it there.

Micro adjust the fence position

Turn the micro adjust knob clockwise to move the fence toward

the cutter (forward), counterclockwise to move the fence away from

the cutter (backward). The carriage clamp handle must be held down

as the knob is turned.

Lock the carriage clamp

Pull the carriage clamp up to lock the carriage back in place.

Gauging the distance moved when micro adjusting is easy. A full

turn of the knob equals 1⁄32" of adjustment; a half turn equals 1⁄64".

For smaller adjustments, use the grooves on the knob as a reference.

For each groove that passes the corresponding cursor decal on the

carriage (see Fig. 8), you have moved the fence .002" (two

thousandths of an inch). At the end of the knob, youʼll find a scale

that can be aligned to read zero at any of the grooves on the knob.

This allows you to re-zero the scale after any micro adjustment.

Simply loosen the thumbscrew to rotate the scale.

The micro adjust feature of the Incra Jig Ultra Lite has as adjustment

range of +5⁄32" from mid-range. The range scale decal on the

carriage shows how much range remains in either direction. To read

the scale, just sight along the end of the black bar that holds the blue

Incra racks. When the end of the black bar is aligned with the zero

on the range scale, you are at mid-range. See Fig. 8.

OPERATION

FIG. 6

Moving fence to a new position

Although the clamping pressure has been factory adjusted,

you may wish to fine-tune the pressure to suit your individual

preference. If so, use the thin plastic shims provided and follow the

instructions shown on page 14.

FIG. 7

Micro adjusting

Moving to a new scale setting

With the plywood base clamped to the stationary tool of your choice,

moving the fence to any new scale setting is simple. First, push the

carriage clamp down and release the clamp handle to unlock the

carriage. Grasp the fence mounting bracket as shown in Fig. 6 and

slide the fence to the new position, aligning the mark on the scale or

template directly under the hairline cursor. To secure the carriage at

the new scale location, simply pull the carriage clamp handle up into

the locked position. When moving the carriage, take care not to

accidentally slide the scale in its slot. Caution: For your safety, keep

both hands behind the fence when moving to any new scale position.

FIG. 8

Micro adjust scale

First:

Push

carriage

clamp down

to unlock

carriage

Third: Pull

carriage clamp

up to lock

carriage

First: Push carriage

clamp down to “unlock”

Second: Press

clamp all the

way down and

hold.

Third: Turn

micro adjusting

knob to fine-

tune fence

position

Fourth: Pull carriage

clamp up to lock

carriage back in place

As knob is rotated, each groove

that passes the cursor decal

on the carriage represents

.002" (two thousandths of an

inch) movement of the fence

Use the scale on the end of

the knob to accurately gauge

the distance moved. After

micro adjusting, scale on knob

can be rotated to read zero

Cursor decal

Black bar

Range scale

Micro adjust knob

Second: Grasp fence

mounting bracket and slide

fence to new position

To avoid running out of micro adjustment

range in the middle of a project, you need

to remember two things. First always micro

adjust back to mid-range before beginning a new

project. Second, whenever you need to micro

adjust a distance greater than

1⁄32"

, use the Incra

positioning racks to get as close as possible

before reaching for the micro adjust knob.

FIG. 9

Ultra Lite at the router table

The essence of any Incra Jig is its ability to accurately

position your board for a cutting operation. In a nutshell,

it is a precision fence system. Even when used as a joint

maker, the fact is, you are simply applying a technique to

a very accurate fence system in order to produce the

various possible joints. Using your Incra Jig Ultra Lite as

a general purpose fence is just as easy as using any

other fence in your shop. In fact, it shares in common four

things that all fences have: the straight edge or fence that

your board will be pushed along as you make a cut, a

scale, a hairline cursor, and a clamp. You will use your

Incra Fence as you would any fence, that is, first youʼll

unclamp, then look through the hairline cursor as you

move the fence. When you see your measurement come

under the hairline, youʼll clamp the fence in place. Of

course, this is where the comparison ends because, unlike

other fences, when you clamp your Incra Jig Ultra Lite in

place, it is exactly where you want it to be. Just get the

mark on the scale close to the hairline cursor and the

automatic positioning controls of the patented Incra racks

move the fence to the exact location as you clamp the jig

in place. Itʼs just that easy. Youʼre sure to find many

places in your shop where the precision of the Ultra Lite

will benefit you and your work.

To use Incra Jig Ultra Lite at your router table, position the

plywood base on your router table top as shown in Fig. 9.

The fence should always be on the right hand side of the

router bit as seen from the operatorʼs side of the table.

If you do not yet own a router table top, the dimensions

shown in Fig. 10 will produce a comfortable table size

which allows enough room to use the full range of your

Incra Jig Ultra Lite. Now all you need to do is install a

router bit and “zero” the fence to the bit.

“Zeroing” the Fence to your

Router Bit

In order to ensure accurate results from any fence for

general purpose cutting, the fence must first be “zeroed”

to the cutter. To zero your Incra Fence to the cutter,

release the carriage clamp and slide the fence up to the

edge of the cutter. Sight down the length of the fence to

check for a gap between the fence and the cutter. Fine-

tune any remaining distance by holding the clamp handle

down as you micro adjust the fence position. When the

gap of light disappears, the cutter will be “zero” distance

from the fence. Check to make sure that the router bit is

safely centered on the opening in the fence. Return the

carriage clamp to the locked position, then slide the 1⁄32"

scale to read 0" under the hairline cursor. See Fig. 11.

APPLICATIONS/GENERAL PURPOSE FENCE

For a truly precise “zeroed” setup, follow the

instructions above, then move your fence to a scale

reading of

1⁄4"

and make a test cut on a piece of scrap

stock. (Make sure the scrap stock has a square edge

and that this edge is against the fence during the cut.)

Use a pair of machinist calipers to measure the distance

between the groove and the edge of the board. If it

does not measure exactly .250" (

1⁄4"

), just use the

micro adjuster to accurately fine-tune the remaining

distance.

12"

20"

32"

24"

FIG. 10

Router table top suggested dimensions

FIG. 11

Zeroing the fence to your bit

Feed direction

First: Unlock carriage

clamp and slide fence

up to bit

Second: Hold clamp handle down and

turn micro adjusting knob until gap

between fence and bit disappears

Third: Pull carriage clamp

up into locked position

Fourth: Slide scale to read 0"

under the hairline cursor