Leigh rtj400 User manual

Router Table Dovetail Jig
LEIGH RTJ400
UserGuide
Dedicated Customer Support
1-800-663-8932

22
RTJ400 User Guide
Introduction
Dedicated Customer Support
1-800-663-8932
Your New Leigh RTJ400 Router Table Dovetail Jig for
Through Dovetails, Half-Blind Dovetails and Box Joints
The RTJ400 was designed for the ever increasing use of router
tables in shops everywhere. The RTJ400 can produce sizes and
types of joints not possible with typical template jigs, including
through dovetails, half-blind dovetails and box joints (finger
joints), and thanks to the patented Leigh eBush, perfect fitting
joints are guaranteed every time.
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, Chapter 15.
Reminder: If at first you don’t succeed, read the instructions!
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"[12mm x 50mm].
Do not be concerned that the inch/millimeter equivalents are
not mathematically “correct”. Just use the dimensions that
apply to your guides and bits.
The RTJ400 is covered by the following patent: U.S. Patent No. 8,534,329
Patents for all Leigh elliptical guide bushings: U.S. 8,256,475 UK GB2443974
Contents
Introduction 2
Jig Features 3
Bit Specifications 4
Accessory Kit for the RTJ400 5
Router Table Requirements 6
Chapter 1 Assembling the RTJ400 7
Chapter 2 Glossary of Symbols 11
Chapter 3 Using your Jig Safely 13
Chapter 4 Basic Jig Functions 15
Chapter 5 Wood Preparation 19
Chapter 6 The Leigh eBush 21
Chapter 7 Through Dovetails 23
Chapter 8 Half Pitch Through Dovetails 29
Chapter 9 Half-Blind Dovetails 35
Rabbeted Half-Blind Dovetails 40
Chapter 10 3/8" Box (Finger) Joints 43
3/8" Half-Blind Box Joints 48
Chapter 11 3/4" Box (Finger) Joints 53
Chapter 12 3/16" Box (Finger) Joints 59
Chapter 13 3/32" Box (Finger) Joints 65
Chapter 14 Jig Parts 71
Chapter 15 Customer Support 73
Chapter 16 Quick Reference 74
Board Width Selection 74

3
RTJ400 User Guide
Introduction
A
Jig Template,CNC machined, with holes and slots to position the frame,
and precision guides for routing tails, pins & sockets
BJig Frame, CNC machined, with pins that fit into template holes & slots
CFrame Latches,2,to secure jig frame to jig template
DHex Key,1/8" Ball End
ECam-Action Speed-Clamps, 4, for mounting workpieces to jig
F Blockers, 10, inserted in template guide openings to prevent routing
GStop Rod, inserted in template holes to limit cutting depth
HSidestops, 2, for mounting workpieces; adjustable for all joint types
IBit Depth Gauge, for setting cutting depth on half-blind dovetails
JInstruction Strips, 5, for quick reference; inserted in jig top
KDovetail Bit 120-500, 1/2" x 1/2" x 14º
LDovetail Bit 80-500, 1/2" x 13/16" x 8°
MStraight Bit 143-500, 3/8" x 1-1/4"
NStraight Bit 160, 1/2" x 1-1/4"
OGuide Bushing, e10 Elliptical eBush, for perfect joint fit
PPin Wrench, to adjust e10 eBush
QUser Guide, Fully Illustrated
RVideo, Instructional
B
A
O
J
J
I
E
H
B
A
C
D
Q
R
P
N
M
L
K
G
F
N
RTJ400 Jig Features and Parts
See complete list of jig parts in Chapter 14.
You will need:
• A router table that accepts standard
size (1-3/8"OD) guide bushings
Note: See page 6 for instructions on
fitting the Leigh eBush to your router
table.

44
RTJ400 User Guide
Introduction
Leigh Bits
75-8
A B
Bit
Diameter
7/16"
Carbide Tipped
Carbide Tipped
High Speed Steel
High Speed Steel
Carbide Tipped
Solid Carbide
Carbide Tipped
Solid Carbide
High Speed Steel
Carbide Tipped
High Speed Steel
Solid Carbide
2-3/8" 8º 160
180
180C
160
180
180C
160
180
180C
160
180
180C
e101-3/4"
1-3/4"
1-3/4"
1-3/4"
1-3/4"
1-3/4"
5/8" 8mm
140-8
170C*
5/16" 2-3/4" – –
–
e7
1-3/4"1-1/4" 8mm
5/16" 2-3/4" – –e7 1-3/4"
1-1/4" 8mm
[5/16"]
180C*
1/2" 3-1/2" ––
1-3/4"
1-3/4"
1-1/4" 1/2"
Max.
Cutting
Depth
C
Shank
Diameter
D
Shank
Length
E
Overall
Length
F
Angle
Use with
e-Bush
Use with
Collet/Collet
Reducer
*
Bits 80-500, 160, 120-500 & 143-500 come with the RTJ400
*
Spiral upcut bits rout cleaner and faster, leaving a smoother finish
80-500*1/2" 2-3/4" 8º 160
180
180C
e101-3/4"
13/16" 1/2"
–
–e10
180*
1/2" 3-1/2"1-1/4" 1/2"
166*
High Speed Steel
163
3/16" ––
––
–e7–
–
e10
e10
e10
70-8 3/8"
Carbide Tipped
2-1/4" 8º e10
e10
e10
1-3/4"
1/2" 8mm
60-8 5/16"
Carbide Tipped
2-1/8" 8º
1-3/4"
3/8" 8mm
50-8 1/4"
Carbide Tipped
2" 8º
1-3/4"
1/4" 8mm
8mm collet
or
172-8 collet
reducer
8mm collet
or
172-8 collet
reducer
8mm collet
or
172-8 collet
reducer
8mm collet
or
172-8 collet
reducer
8mm collet
or
172-8 collet
reducer
8mm collet
or
172-8 collet
reducer
8mm collet
or
172-8 collet
reducer
–
e10
–
–
2-7/8"5/8" 1/4"
170*
5/16" 3"1" 8mm
[5/16"]
143-500*
3/8"
3/8"
3/8"
3-1/4"1-1/4" 1/2"
166C*
3/16" 2-1/2"5/8" 1/4"
173-500*
Solid Carbide
173-500C*
3-3/4"1-1/4" 1/2"
160*
1/2"
collet
1/2"
collet
1/2"
collet
1/2"
collet
1/2"
collet
1/2"
collet
1/2"
collet
1/2"
collet
1/2"
collet
1/2"
collet
1/4"
collet
1/4"
collet
1/4"
collet
2"
3/32" –– e10 2"3/8" 1/4"
–
e10
1/2" 3" – 1-3/4"
1-1/4" 1/2"
172-8
1/2" to 8mm collet reducer
1 1/4" long. For 8mm shank bits
e10
Carbide Tipped
Carbide Tipped
1/2" 2-3/8" 18º – 1-3/4"
1-3/4"
3/8" 1/2"
–14º e10
120-500*
Carbide Tipped
128-500
1/2" 2-1/2"
1/2" 1/2"
112-500
–
140-8
170
170C
–
–
–
–
Use with
Straight Bit
Half Pitch ThroughFull Pitch Through
Use with
Straight Bit
–
–
–
–
–
140-8
170
170C
140-8
170
170C
140-8
170
170C
–
–
–
–
–
–e10
1/2" 2-9/16" 12º 1-3/4"
19/32" 1/2"
e10
e7
& e10
–
–
Use with
e-Bush
–
–
–
–
–
e7
& e10
e7
& e10
e7
& e10
–
1-3/4" –
e10
–
3"1-1/4" 1/2" ––
–
–
–
–
–
–
Through Dovetails
Half-Blind Dovetails
Box Joints
CF
A
B
D
E
C
D B
E
A
RTJ400 BIT SPECIFICATIONS
This chart shows all bits available for the RTJ400.
Bits for the RTJ400

5
RTJ400 User Guide
Introduction
This optional kit offers great savings over individual prices, and opens up a world of possibilities. Available from leighjigs.com
Accessory Kit for the RTJ400 (ACRTJ)
163
166 140-8
50-8 60-8 70-8 75-8 128-500
112-500
172-8
e7
The ACRTJ includes:
Through Dovetail Bits
Carbide tipped, 8º, 8mm shank, for through
and half pitch through dovetail tails
50-8 1/4" bit
60-8 5/16" bit
70-8 3/8" bit
75-8 7/16" bit
Straight Bit for Half Pitch Dovetails
Carbide tipped, 8mm shank, for half pitch
through dovetail pins
140-8 5/16" bit
Half-Blind Dovetail Bits
Carbide tipped, for half-blind dovetails
112-500 12º 1/2" bit
128-500 18º 1/2" bit
Straight Bits for Box Joints
High speed steel, for box joints
163 3/32" bit
166 3/16" bit (spiral upcut)
Collet Reducer
For 8mm shank bits
172-8 1/2" to 8mm, 1-1/4" long
Guide Bushing
For half pitch through dovetail pins
e7 Leigh elliptical eBush

66
RTJ400 User Guide
Introduction
1
3
/ 8 "
0.100
"
1
3
/ 16 "
Router tables are typically used with a bearing or fence, however, the Leigh RTJ400 is guided around a guide bushing mounted in the
router table. Leigh eBushes (guide bushings) are designed around the decades-old Porter Cable/Black & Decker industry standard.
Therefore, you will need an insert ring to fit the eBush to your router table or router plate. See specifications below. ■
Router Table Requirements
Router Table
eBush
Insert Ring
Insert Plate
1 3/16"
1 3/8"
0.100"
To fit the eBush to your router table
insert plate, you need a 1-3/8" diameter
counter bore insert ring. Check with
your router table or router plate
(router lift) manufacturer, as to what
adaptation, if any, is required.
Leigh eBush and Nut

7
7
The following instructions will guide you through the assembly
process for the Leigh RTJ400 Router Table Dovetail Jig.
RTJ400 OPERATION
CHAPTER 1
Assembling the RTJ400

8
8
RTJ400 User Guide Chapter 1
Assembling the RTJ400
B
B
A
C
C
A
A
A
A
C
A
A
B
C
1-3 Insert the two square nuts into the rear of the frame Aand
slide them to each end of the frame.
1-2 Template Latches: Slide a latch Ainto each end of the
template making sure the washer Bis in the T-slot. Use the hex
key Cthrough the slot on the bottom of the template to firmly
tighten the latches, pulling the hex nuts down into each latch
recess. Adjust the latches so they are stiff to slide on the template.
1-6 When installing the second clamp, insert the T-bolt first
and the heel last A.
1-4 Sidestops: Attach the two sidestops Ato the square nuts
in the frame using the hex socket button head screws B, and
lightly tighten one sidestop at each end of the frame.
1-1 Template Clamps: Insert the clamp T-bolt head Ainto
the T-slot at each end of the template Bfollowed by the clamp
heel C. Make sure the heels are pointing out at both ends of the
template.
1-5 Frame Clamps: Insert the heel Aof a pre-assembled
clamp assembly into the end of the frame T-slot Bfollowed by
the clamp T-bolt C, and slide the clamp to the other end of the
frame. Note: The clamp arm spring washers are under tension.
They may need to be pulled away from the T-bolt to aid in ease
of assembly.
A
B
B

9
9
RTJ400 User Guide Chapter 1
Assembling the RTJ400
A
B
1-8 The frame is located on the template by a pin on the frame
handles. Place the frame on the template by inserting the right
frame pin in the ALL TD TAILS hole Aand the left frame pin in
the
TD TAILS & BJ slot B.  To prevent damage to the frame
pin always remove the right frame pin first when lifting the
frame handle.
1-9 Pivot both latches to secure the frame to the template.
Double check the latches to ensure they are fully seated.
 Only when the frame is latched securely is it safe to lift and
or carry the jig by the handles.
1-7 Stop Rod: Insert the stop rod in the ¾" slot A. The
stop rod remains here for all routing operations except half-blind
dovetails and box joints. Note: The stop rod may have been
shipped in this location.
1-12 You will have leftover parts. Keep them to use as required
for various jig operations. ■
A
1-10 If not already in channel, slide the Quick Reference strips
into the channel in the top of the jig A.
Leftover parts:
• bit depth gauge
• ten blockers
• e10 guide bushing & nut
• pin wrench
• DVD
• this user guide
A
1-11 Store the hex key in the left hand handle.

10
10
RTJ400 User Guide Chapter 1
Assembling the RTJ400

11
11
“Outside” of board
“Inside” of board
“Either side“ of board
“Outside” of board (on other side of board)
“Inside” of board (on other side of board)
“Either side“ of board (on other side of board)
“This edge” against sidestop
“This edge” against sidestop
“This edge” against sidestop (on other side of board)
“This edge” against sidestop (on other side of board)
Which Way Around Should the Board Go?
The following symbols/icons are used throughout this user guide.
They indicate which side of a board faces out when clamped
in the jig, and which edge goes against the sidestop. They also
indicate which faces are in or out when assembled. Dashed line
symbols indicate the other side of the board (hidden from view).
Note: Before you place the boards in the jig, you must mark
them with the appropriate symbols.
2-2 Note: Because through dovetail pin and tail boards are
rotated and clamped with the same face against the frame, both
side edges are alternately used against the sidestop.
2-3 Box joint boards are clamped against the frame both face
in and face out for alternate end cuts. With box joints, the same
side edge always goes against the sidestop. ■
2-1 Icons such as the one used on the board above indicate
which side of the board faces away from the operator when
clamped in jig, and which faces are in or out when assembled.
RTJ400 OPERATION
CHAPTER 2
Glossary of Symbols

Glossary of Symbols
12
RTJ400 User Guide
Chapter 2

13
13
Safety is not optional.
Read and follow the recommendations in this chapter.
3-2 Always wear:
• approved safety glasses;
• a face mask to protect yourself from harmful dust;
• hearing protection.
3-1 Read the owner’s user guide that came with your router
and router table. It is essential to understand all manufacturer’s
instructions completely.
3-4 Always disconnect the power source and be sure
the router has stopped turning before fitting 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.
3-3  Never drink alcohol or take medications that can
cause drowsiness while operating a router.
RTJ400 OPERATION
CHAPTER 3
Using Your Jig Safely

1414
RTJ400 User Guide
Using Your Jig Safely
Chapter 3
3-5 Do not tilt the jig. Keep the template flat on the router table
at all times.
3-6 Chips and sawdust are thrown out at high speed. Always
stand and use the RTJ400 from behind the router bit, opposite
to chip and sawdust ejection. ■

15
15
A
B
4-3 In this orientation, pin holes Aand corresponding slots
Bare for half-blind dovetails, through tails and box joints.
C
D
A
Router Table Surface
Template Markings and Orientation
Frame Pin Positioning
Quick Reference Strips
Routing Position
Sidestops
Clamping
Backer Board
Router Table Surface
4-1 Make sure there are no ridges
A
anywhere on the router
table surface. The template must slide smoothly over the table top.
If the router table is not flat it will have the effect of changing the
bit height as the template moves across the table.
4-4 In this orientation, pin holes
Cand corresponding slots D
are for through dovetail pins and half pitch through dovetail pins.
Template Markings and Orientation
4-2 The engraved side of the template always faces up. The
markings clearly identify which pin hole or slot to position
the frame pin into, based on the joint type and size. Template
orientation is shown in the next two steps.
IMPORTANT NOTE: Many of the images in this user guide show the “action” side of the jig, however the operator stands behind
the RTJ400, away from the chips and sawdust thrown off by the router bit.
RTJ400 OPERATION
CHAPTER 4
Basic Jig Functions
A

16
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RTJ400 User Guide
Basic Jig Functions
Chapter 4
Frame Pin Positioning
4-5 The frame is positioned on the template by inserting the
frame pins into the pin holes Aand slots B. The frame pins are
intended to be snug in the template holes.  To prevent damage
to the frame pin always remove the right frame pin first.
4-6  Be sure to latch the frame securely each time the frame
is repositioned. Only when the frame is latched securely is it safe
to lift and or carry the jig by the handles.
Routing Position
4-8 Always use the right-hand side of the jig as shown above,
except where specified. Note: When instructed to rout from right
to left, this is from the “operator’s” position, standing behind
the RTJ400.
Quick Reference Strips
4-7 Quick Reference strips Afor each joint type are stored in
the slot on the top of the jig frame.
Sidestops
4-9 The adjustable sidestops are user set in a predetermined
position for box joints, or positioned against the edge of the
workpiece.
Clamping
4-10 Cam-action speed-clamps are exceptionally strong. The
clamp arms in conjunction with the machined texturing on the
template and frame ensure secure clamping.
B
A
A

17
17
RTJ400 User Guide
Basic Jig Functions Chapter 4
A
A
A
Backer Board
4-12 A short backer board Ais clamped horizontally behind the
tail board, to help prevent tearout, and to direct dust and chips
away when routing. ■
4-11  Always ensure that the frame clamp levers do not
project below the frame when engaged A.
A

18
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RTJ400 User Guide
Basic Jig Functions
Chapter 4

19
19
1
2
3
Garbage In — Garbage Out
This adage of the computer age stands equally true for dovetail joinery.
5-1 Accurate and perfectly aligned joints require stock that is
straight, flat, even thickness and equal widths, with square ends
and edges. Note: Plywood is generally unsuitable for routing
because of tearout problems.
5-2 You will want to test the jig, so prepare boards of suitable
size for the required joint type and size. Use them for practice
with the jig’s various joint modes so you can see how the different
modes work. Note: Two boards of different thicknesses can be
joined as easily as one thickness.
RTJ400 OPERATION
CHAPTER 5
Wood Preparation
5-3 
Dovetail joints are intended for joining end-grain
to end-grain
1. Dovetails in side-grain 2do not work because the
wood will tear out badly when routing and the pins and tails would
easily break off 3, either during or soon after the assembly when
the boards start expanding or contracting at different rates. ■

20
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RTJ400 User Guide
The Leigh eBush
Chapter 5