Leigh D4R Pro User manual

For the
Leigh D4R Pro Dovetail Jig
DEDICATED CUSTOMER SUPPORT
1-800-663-8932

CONTENTS AND STANDARDS
ii
D4R Pro User Guide
Contents and Standards........................................................ii
Chapter 1 Jig Assembly, Mounting, and Using The Clamps .................1
Chapter 2 Adjusting the Finger Assembly.............................................7
Chapter 3 How Routers with Guidebushes Work.................................9
Chapter 4 Basic Jig Functions and Scale Modes ..................................11
Chapter 5 Using Your Jig Safely ...........................................................13
Chapter 6 Wood Preparation ...............................................................15
Chapter 7 Router Preparation ..............................................................17
Chapter 8 Through Dovetails ...............................................................19
Chapter 9 Large and Small Through Dovetails....................................29
Chapter 10 Variably Spaced Half-Blind Dovetails .................................31
Chapter 11 Single Pass Half-Blind Dovetails .........................................39
Chapter 12 Rabbeted Half-Blind Dovetails............................................45
Chapter 13 End-on-End Dovetails..........................................................47
Chapter 14 Asymmetric Dovetails .........................................................49
Chapter 15 Box Joints .............................................................................53
Chapter 16 Sliding Dovetails..................................................................59
Chapter 17 Hints & Tips ..........................................................................65
Appendix I Attaching the Leigh e-Bush to the Router..........................69
Appendix II Bit Selection .........................................................................71
Appendix III Jig Parts ................................................................................79
Appendix IV Customer Support ...............................................................83

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CONTENTS AND STANDARDS D4R Pro User Guide
Your New Leigh D4R Pro Dovetail Jig
Congratulations! You now own the world’s most useful and versatile dovetailing tool. The Leigh D4R Pro Dovetail
Jig will help you rout an infinite variety of joints, and all of its major functions are described in detail in this guide.
A very helpful DVD is also included, but the guide is essential reading.
Important! Inches and Millimetres
The D4R Pro jig can be ordered in inch or metric versions.
They're identical except for the calibration scales. This Leigh
English-language user guide shows measurements in both inches
and millimetres, with “inches” first, followed by “millimetres”
in square brackets.
Example:
3⁄4”x 51⁄2”x8” [20x140x200mm]
Do not be concerned if the inch/millimetre equivalents are not
exact. Just use the dimensions which apply to your jig.
To simplify the instructions, most jig illustrations show a jig
considerably shorter than the standard 24"[610mm].
Where finger assembly scales overlay an illustration, the “inches”
scale will be at the top, and “millimetres” scale at the bot-
tom. Only the right hand “active” half of the scales are illustrated.
For clarity, setting positions are indicated with a red line in the
guide only. On the jig, the lines are black.
1
2
We recommend that you first assemble and mount the jig,
carefully following the instructions in the first section of the
guide. Then read the rest of the guide, following along with the
basic functions and principles of operation, before you try to
do any actual joinery routing. By all means, rout a few practice
joints in scrap boards before you use the jig to rout a precious
hardwood work piece!
If you have any questions that are not answered in this guide,
please contact Leigh customer support:
Tel: [phone] email: [email protected]
But remember: “If at first you don’t succeed, read the instruc-
tions!”
*See Appendix IV – Customer Support

CONTENTS AND STANDARDS
iv
D4R Pro User Guide
Glossary of Symbols
To help you understand the instructions and illustrations in this
manual, we have used a number of international symbols, plus
a few special ones of our own.They are all explained below. You
needn’t worry about memorizing these symbols now, because
they are repeated quite frequently in this user guide, and you
will soon get used to them.
The Leigh jig’s guidefinger assembly can be in any one of four
joint modes, depending on what type of joint and which part
of the joint you are routing. Each finger assembly scale has it’s
own mode icon , identifying the joint part being routed.
You will also find the joint mode icon in the top left corner of
most illustrations, indicating which finger assembly mode
to use.
Sometimes a joint mode icon will be used to identify a
board.
These are the four joint mode icons:
TD Tails
(tails for through dovetail joints)
TD Pins
(pins for through dovetail joints)
HB Tails
(tails for half-blind dovetail joints)
HB Pins
(pins for half-blind dovetail joints)
2
3

v
CONTENTS AND STANDARDS D4R Pro User Guide
Which Way Round Should the Board Go?
As virtually all dovetail joinery is used to make boxes,
drawers and chests etc., we devised these simple (and
hopefully intuitive) icons to indicate which side of a
board faces inwards or outwards on the finished “box”,
and which side of the board faces outward (toward
you, the operator), when it is clamped in the jig.
The following symbols indicate:
This edge against sidestop
This edge against sidestop
Sawcut allowance
฀Caution: use special care for this
operation
Numbered References in text
฀This icon indicates the
“outside” of a board. All
through dovetail pin boards
are mounted in the jig with
this “outside” face away
from the jig (toward you, the
operator).
฀This icon indicates the
“inside” of a board. All half-
blind pin and half-blind tail
boards, and through dovetail
tail boards, are mounted in the
jig with the “inside” face away
from the jig toward you, the
operator.
฀This icon indicates boards
that are mounted both ways
e.g. sliding dovetails and end-
on-end dovetails.
Dotted line icons indicate
the “other” side of the board
in the illustrations.
Centreline of board or layout
Equals
Does not equal
Approximately

CONTENTS AND STANDARDS
vi
D4R Pro User Guide
Contact your dealer for more details
Add Leigh Accessories to make your jig even more versatile.
Leigh Brand Bit Sets Offer Great
Savings...and the Box Is Free!
Save over individual bit prices. Each top quality
bit set includes a box with foam insert that
accepts all shank sizes, and a handy bit chart in
the lid to list out all the bit specs. Choose from
7-piece, 10-piece, 12-piece or 16-piece Bit Sets.
Combine the VRS with a Bit Set
for Exceptional Savings!
The D4R Pro Accessory Kit is the best deal going.
Enjoy great savings on the 12-piece Bit Set and
even greater savings when you combine it with
the VRSD24 Vacuum & Router Support.
Finally, Dust-Free Routing
and Superb Router Support!
A must-have!
The VRS Vacuum & Router Support is the ul-
timate dust and chip collector. As an added
bonus, the VRS provides full width router sup-
port to your D4R Pro. It’s simple to attach and
the collector adapts to most popular vacuum
hose sizes.

vii
CONTENTS AND STANDARDS D4R Pro User Guide
Contact your dealer for more details
Optional Leigh Templates and Attachments
Super Precise, Super Easy
Finger Joints
Finger joints are very strong, aesthetically
pleasing and easy to produce. Add a Finger
Joint Template to your D4R Pro Jig and rout
perfect finger joints in minutes.
Six Unique Isoloc Joints,
Only from Leigh
The patented Isoloc joint gives any corner
joint a very unique look. These one-of-a-kind
patterns will really set your woodworking
pieces apart from the rest. Great savings
when you buy all three templates.
Classic Multiple Mortise
and Tenon Joints that Last
The Leigh M2 Attachment is the only one of
its kind. The multiple mortise and tenon joint
is ideal for “shelf to upright” construction
and produces extremely strong joints that
stand the test of time.
Need a Helping Hand?
Use Leigh Hold-Down Clamps
Leigh Hold-Down Clamps are tough, versatile and
immensely strong! They employ proven cam-action
technology developed for the award-winning Leigh
jigs, the D4R Pro and FMT. Bench clamps can be used
in any size hole and surface clamps can be mounted
on any flat surface, both on any angle. You can never
have too many clamps!

CONTENTS AND STANDARDS
viii
D4R Pro User Guide

10
1 2 3 4
5 6 7 8
9
Jig Assembly, Mounting,
and Using the Clamps
D4R Pro - CHAPTER 1
Make Sure You Have All the Parts.
Before you start to assemble your Leigh D4R Pro, check to make sure you have received all the required parts.
The small carton you removed from the end of the main
carton contains:
1. 1 Leigh e7 Elliptical Guidebush & Pin Wrench
2 Spacers
2. 2 Dovetail bits, 1 straight bit, 1 Collet Reducer,
3. 2 scale assemblies with 5⁄64" hex key
4. 2 support brackets
5. 2 support bracket knobs
6. Square-head guidefinger screwdriver
7. 4 clamp springs
4 clamp T-bolts
4 flat washers
4 T-bolt nuts
2 square nuts
1 flat head machine screw
1 Leigh wrench/gauge
4 Jig Hold-down Nuts & Machine Screws 1⁄4"-20
8. 4 cam-action speed clamps
4 cam clamp step washers
…and any other small optional items you may have
ordered with your new jig. Check the packing slip for this
information.
The main carton contains:
9. 1 main jig body
1 Leigh jig User Guide
Warranty/Registration Card
DVD instructional video (English only)
The large inner box contains:
10.1 finger assembly on 2 bars
D4R Pro has 26 guidefingers (13 pairs)
2 lengths bridge extrusion
1 cross cut fence
1 nylon Stop Rod
2 clamp bars
If any items are missing from your jig, contact your supplier
or Leigh Industries immediately.
See Appendix IV - Customer Support.
Important Note
Mount your jig securely and assemble it completely before you try to
use it.
Make sure you have read and understood all the material in the Safety
section of this user guide before using the jig.
1

JIG ASSEMBLY, MOUNTING, AND USING THE CLAMPS
2
Chapter 1 D4R Pro User Guide
35/16"[84mm]
6"[150mm]+
295/16"[745mm]
37"[940mm]+
1"[24mm]
1
2
4
3
1-1 Prepare a flat board at least 3⁄4"[20mm] thick, and a mini-
mum of 37"x6"[940x150mm]. Drill four 9⁄32"[7mm] holes on
29
5⁄16"x 3 5⁄16"[755x84,2mm] centres, 1"[24mm} in from the front
edge of the board . Countersink or counterbore the under-
side if the board is thicker, so that the four 1⁄4-20x1" long machine
screws will project above the top surface by 3⁄8"[9,5mm] .
1-2 Turn the jig body upside-down on two blocks (to protect
the side stops). Using the four nuts and four countersunk machine
screws, bolt the base board to the jig using the two nut recesses in
each end housing. Holes drilled 1"[24mm] from the front edge
of the board go to the front of the jig. Now you can clamp your
D4R to any bench.
1
1-3 With the jig right side up, insert one square nut (part #284)
into each of the channels in the main extrusion. These nuts are
for possible future attachment of accessories.
1-4 Insert the four clamp T-bolts into the T-slots (two at each
end of the jig). Position so that the washers seat into the round
milled recesses. Tighten the four clamp bolt nuts with the Leigh
wrench.
1-5 Place four springs and two clamp bars on the T-bolts.
Make sure the clamp bars move freely on the T-bolts.
1-6 Place one black step washer ฀on each T-bolt with the
flat side against the clamp bar. Screw a clamp lever assembly onto
each T-bolt, making sure the cam lobes are between the step
washer sidewalls.
1