Leigh B975 User manual

See Page 65 for Customer Support
1-800-663-8932
User Guide
Leigh Router Joinery Jigs
Router Table
Workbench
Leigh Box Joint
&Beehive Jig
Model B975
For WorkBench or Router Table Use

B975 User Guide
2
Chapter 1 Introduction 5
Jig Parts 5
Bit Specifications 7
Symbols for Board Position 8
Clamping 8
Chapter 2 Safety 9
Chapter 3 The Leigh e10 eBush 11
Chapter 4 Mounting & Assembly 15
Chapter 5 Routing Box Joints 25
Chapter 6 Routing Wider Boards 37
Chapter 7 Router Table Operation 47
Chapter 8 Guide Bushing Adapter Selection 63
Chapter 9 Customer Support 65
Contents
5 Year Warranty
Leigh stands behind its products with a 5 year limited warranty. See the
complete warranty in Chapter 9, Customer Support.
Your New Leigh Box Joint & Beehive Jig, Model B975
The Leigh Box Joint & Beehive Jig, Model B975, is a simple, easy-to-use tool for making
1/2" and 3/4" box joints on boards up to 13/16"[20.6mm] thick, and from 1-1/2"[38mm]
to 17-13/16"[453mm] wide. Not by accident, the full 9-11/16"[246mm] width of the jig
is the standard height of a typical beehive super, used in North America.
Customer Support
If you have any questions that are not answered in this user guide, please call Leigh Customer
Support: 1-800-663-8932 in North America or email: [email protected]. For support
contacts in your country of purchase, see Customer Support at the end of this Guide.
Leigh user guides are updated as required. A downloadable pdf of the latest version can be
found on the Support page at leighjigs.com.
Reminder: If at first you don’t succeed, read the instructions!

B975 User Guide
3
*You must be at least 21 years of age to enter. Employees of Leigh Industries Ltd. and their families are ineligible to enter or win.
This offer void where prohibited by law.Customer must complete a short online questionnaire. One winner will be drawn every
two months. Winners will be notified by email and by phone. Leigh product is only available directly from Leigh or its international
distributor in the region of the winner. No cash value. Value is in the currency of the country of winner equal to $300.00 USD based
on currency exchange at the time of the draw. Complete details available at www.leighjigs.com.
Register your Leigh B975
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B975 User Guide
4
This page is left blank intentionally.

5
*Leigh e10 Elliptical Guide Bushing: U.S. Patent no. 9,375,860 UK Patent no. GB2443974
Note: PDF of User Guide included on DVD
If any parts are missing from your jig, please notify your supplier
or Leigh immediately. See Chapter 9, Customer Support.
PART DESCRIPTION PART NO. QUANTITY
AJig Template with Decal 313503 1
Bag 1 BSide Stop Assembly, 1/2" 313530 1
CSide Stop Assembly, 3/4" 313535 1
DStep-over Cam with O-ring, 1/2" 313550 1
EStep-over Cam with O-ring, 3/4" 313555 1
Bag 2 FPan Head Wood Screws, No.8 x 1" 313585 10
GGuide Bushing, e10* eBush e10 1
HStraight Bit, 1/2" 160 1
IPin Wrench 730V 1
Bag 3 JFully Illustrated User Guide 313565 1
KInstructional DVD 313570 1
What’s Included
B975 User Guide
CHAPTER 1
Introduction
A
B
C
D
E
F
G
H
K
I
J

B975 User Guide
Chapter 1 Introduction
6
1/2" Bit
e10 eBush
Clamps
(User Supplied)
Step-over Cam 3/4"
Step-over Cam 1/2"
MDF Beam
(User Made)
Side Stop
Template
Router (User Supplied)
Leigh Box Joint & Beehive Jig
Thumb Lock
Pin Board and
Socket Board Stops

B975 User Guide
Chapter 1 Introduction
7
Bit Specifications
Leigh Bits
A
Bit
Diameter
B
Max.
Cutting
Depth
C
Shank
Diameter
D
Shank
Length
E
Overall
Length
Use with Collet/
Collet reducer
Use with
eBush
160*Carbide tipped 1/2" 1-1/4" 1/2" 1-7/8" 3-1/8" 1/2"
Collet e10
180** High Speed Steel 1/2" 1-3/4" 1/2" 1-3/4" 3-1/2" 1/2"
Collet e10
180C** Solid Carbide 1/2" 1-5/8" 1/2" 1-7/8" 3-1/2" 1/2"
Collet e10
Bit Specifications
There is only one bit size used with the Box Joint & Beehive Jig. Your new jig is shipped
with a 1/2", 2 flute, carbide tipped straight bit. You may also use a 1/2" spiral up cut bit
in high speed steel or solid carbide.
E
* 160 bit comes with the Beehive Box Joint Jig
** Optional spiral up cut bits rout cleaner and faster, leaving a smoother finish
A
C
B
D
E
A
C
Units of Measure
IMPORTANT! INCHES AND MILLIMETERS
Text and illustrations in this English language user guide indicate dimensions in both
inches and millimeters, where applicable, with “inches” first, followed by “millimeters” in
square brackets, i.e. 1/2" x 2"[12.7mm x 51mm].
Don’t be concerned that the inch/millimeter equivalents are not mathematically
“correct”.
BD

B975 User Guide
Chapter 1 Introduction
8
Symbols for Board Position
The following symbols are used throughout this user guide. They indicate which edge of
the board goes against the side stop.
This board edge against the side stop.
This board edge against the side stop (on other side of the board hidden from view).
Box Assembly
Assemble the box, keeping the
marked edges of the boards together
as shown.
Clamping
Note: Before mounting and
routing the boards, you
should mark them with the
appropriate symbols. With
box joints, the same board
edge Aalways goes against the
side stop. Boards are clamped
against the beam both face in and
face out for alternate end cuts. A
A

9
Always wear:
• approved safety glasses;
• a face mask to protect yourself
from harmful dust;
• hearing protection.
Safety is not optional. Read and
follow the recommendations here.
Never drink alcohol or
take medications that can cause
drowsiness while operating a router.
Read the owner’s manual that
came with your router and router
table. It is essential to understand
all manufacturer’s instructions
completely.
B975 User Guide
CHAPTER 2
Safety

10
B975 User Guide
Chapter 2 Safety
Always disconnect the power
source before installing bits, guide
bushings or making adjustments. Before
reconnecting the router to the power
source, make sure the bit and collet
revolve freely with and without the
guide bushing in place.
After routing, wait for the bit to come
to a complete stop before removing the
router from the jig.
Never rout at face level.
Chips and sawdust are thrown out at
high speed. ■

Do not tilt the router. Keep
the router flat on the jig during all
routing.

11
B975 User Guide
CHAPTER 3
The Leigh e10 eBush
3-2 The barrel of the e10 steers
the router and the bit in and around
the openings of the template.
3-1 How the e10 Works
Routing on the B975 requires a
router fitted with the included e10
eBush (guide bushing).
The e10 is installed in the base of
the router and the guide bushing
retaining nut is screwed on, under
the router base.
Patents for Leigh elliptical guide bushings: U.S. 9,375,860 UK GB2443974
Note: Normal tolerances with bits, guide bushings
and router runout will generally produce poor fitting
joints. The included Leigh e10 elliptical guide bushing
(eBush) solves this problem.

12
B975 User Guide
12
Chapter 3 The Leigh eBush
3-5 All routing starts with
the eBush in the No.5 position.
This allows adjustment for a tighter
or looser fit. Turning the eBush
toward the 10 position Aresults in a
tighter fit. Turning the eBush toward
the 0 position Bresults in a looser fit.
Be sure to retighten the e-Bush
nut after each adjustment.
AB
3-4 The Leigh eBush barrel A
is elliptical , unlike plain circular
template guide bushings B. When
the e10 is rotated, the effective
diameter of the barrel changes,
allowing fit adjustments as small as
0.001"[0.025mm]. The e10 eBush
is included with the jig.
B
A
3-3 The Leigh eBush System is
designed around the 1-3/8" industry
standard. Some routers accept the
Leigh eBush directly. Many routers
require the use of a guide bushing
adapter. If your router requires an
adapter, please see the Guide Bushing
Adapter chart and Leigh guide
bushing adapters in Chapter 8.
1 3/16"
0.100"
1 3/8"

13
B975 User Guide
Chapter 3 The Leigh eBush
3-6 Joint Fit Adjustment The
effective diameter of the e10 is 5/8" at
the 10 position. Rotating the eBush
to the 0 position reduces the effective
diameter by 0.020"[0.5mm].
5/8" 0.010"
0.010"
3-7 One increment of the eBush
changes the joint glue line by
0.002"[0.05mm]. Half an increment
changes the fit by an incredible
0.001"[0.025mm]. A perfect fit will
be established with one or two test
cuts.
3-8 Each chapter provides a place
to mark your perfect eBush setting,
for easy repeatability the next time.
May 5, 3/4" joint
Walnut, 160 bit
Feb.28, 1/2" joint
Maple, 160 bit
EXAMPLE ONLY

14
B975 User Guide
14
Chapter 3 The Leigh eBush
3-11 Install the e10-Bush in the
router base and use the pin wrench
to align the 0 to the reference line.
The 0 setting is only used for beam
preparation. All other routing begins
with the eBush set to 5.
Be sure to retighten the eBush
nut after each adjustment. ■
3-10 Make a small scratch line on
the router base or eBush adapter,
at the 12 o’clock position. This will
be a reference line for all eBush
settings A.
3-9 Fitting the eBush to the
Router. Place the router on the jig
with handles positioned the way you
would normally hold the router A.
Then turn the router upside down
and place it on the workbench B,
keeping the same face of the router
toward you.
A
A
B
A

15
B975 User Guide
CHAPTER 4
Mounting
& Assembly
The instructions on the
following pages will guide
you through the assembly
process for the Leigh B975.
You will need:
• A workbench with vice or a
portable workbench
• 2 pieces of 3/4" MDF to make
a beam 1-1/2"x 3-1/2" x 16"
[38mm x 90mm x 406mm]
• Router with 1/2" collet
• Electric drill, preferably bench
or pedestal, but handheld will
work
• 1/8" drill bit
• Two Quick-Grip clamps
• Square, ruler or tape measure
• No.2 Phillips screwdriver
• Wood Glue

16
B975 User Guide
Chapter 4 Mounting & Assembly
4-1 Making the Beam We
recommend laminating the two
pieces of 3/4" MDF. Place the glued
pieces in a vice or use clamps to hold
them together. The template will be
attached to the top of the beam, so
be sure the top edges are flush and
free of glue residue. Set aside to dry
completely. Alternatively, a common
2x4 may be used. See step 4-15 for
special instructions.
4-3 The 1/2" comb has position-
ing ridges Amolded into the
bottom side of the template.
A
4-2 One side of the template is
used for 3/4" box joints and the
other side is used for 1/2" joints.

B975 User Guide
Chapter 4 Mounting & Assembly
17
4-4 With the 3/4" comb facing
you, lay the template flat on the
beam and center it left to right. Slide
the template forward until the ridges
on the underside of the 1/2" comb
contact the back of the beam. The
template is now positioned correctly.
4-5 Use a pencil and mark the
location of all screw holes on the top
of the template. Hold the template in
place and proceed to the next step.
4-6 Make a pencil line on the top
of the beam at each end of the jig on
the 3/4" and 1/2" sides.

18
B975 User Guide
Chapter 4 Mounting & Assembly
4-8 Mark layout lines for the side
stops. First, place the beam flat on
the workbench with the 1/2" side
of the beam facing up. Use a square
and draw a vertical line down from
the positioning mark on the top of
the beam.
4-9 Next, draw a horizontal line,
1" down from the top of the beam.
Rotate the beam and repeat for the
3/4" side.
4-7 Remove the template and
mark 3/4" and 1/2" beside the lines,
to indicate which is the 3/4" and
which is the 1/2" side of the beam.
1"
3/4"
1/2 "
1/2 "
1/2 "

B975 User Guide
Chapter 4 Mounting & Assembly
19
4-11 Install the 3/4" side stop. Lift
the thumb lock
A
, retract the center
portion of the 3/4" side stop fully
and press the thumb lock down to
lock it in place. Position it against
the layout lines as shown.
Use a pencil to mark the screw hole
locations.
Rotate the beam and repeat the
process for the 1/2" side.
4-12 Use a drill press or hand drill
with a 1/8" bit to drill pilot holes at
all screw hole locations.
4-10 The 3/4" and 1/2" side stops
will be attached in the following
steps.
3/4" Side Stop
1/2" Side Stop
3/4"

20
B975 User Guide
Chapter 4 Mounting & Assembly
4-15 Alternatively, you can use
a straight, flat 16"[406mm] piece
of common 2x4. Since a 2x4 has
slightly rounded corners, the top
edge should be squared off.
4-14 Place the beam on the
workbench with the 3/4" side of the
beam facing up. Position the 3/4"
side stop against the horizontal and
vertical lines, with the thumb lock
facing the left end of the beam, and
attach it using the included screws.
Again, use a screwdriver, not a power
drill, to attach the side stop.
Repeat the process with the 1/2" side
stop on the 1/2" side of the beam.
4-13 Clamp the beam in the vice
with its 3/4" side facing you. Position
the template on the beam with the
3/4" side of the template facing you.
Align it with the pre-drilled holes.
Use a screwdriver to attach the
template with six of the included
screws.  Do not use a power
drill, as this may overstress the
template.