Porter-Cable OMNIJIG 55160 User manual

A20465
Instruction manual
55160
77240
OMNIJIG®
JOINERY SYSTEM
A24502 - 11-16-07 Rev. A Copyright © 2007 PORTER-CABLE
Product may vary slightly from photo.
Le produit peut être légèrement différer de la photo.
El artículo puede variar levemente con relación a la foto.
Product may vary slightly
from picture.
www.deltaportercable.com
(22428)
(25192)
RTD10000496AA

PORTER-CABLE OMNIJIG®Page iii
Safety
General safety rules iv
Router safety iv
OMNIJIG®JOINERY SYSTEM safety iv
Introduction
Joinery overview 2
Standard OMNIJIG®parts 3
OMNIJIG®accessories 4
Familiarization 6
Wood preparation 7
Project layout 7
Board lengths 8
Tips for making drawers and boxes 9
Basic Operations
Setting up the OMNIJIG® 12
Bench mounting 13
Router bit depth pod 13
Instructional DVD 13
Typical omnijig adjustments 14
Placing and sizing stops 14
Removing and replacing templates 14
Accessory templates 15
Edge guides 15
Mounting the wood 15
Variable fingers 16
Selecting bits and template guides 17
Setting router bit depth and making the cut 17
O-ring installation 17
Dovetail setup guide 18
Through dovetails
Variable-spaced half-blind dovetails
Narrow pins
Single pass half-blind dovetails
Router bit depth pod 19
User defined gauges on 24" and 16”
How to select the proper gauge
Making cuts 20
Safe cutting
Tip for reducing tear-out during cuts
Accessories 20
Dust collection 20
Storage case positioning 21
Appendix 66-67
TABLE OF CONTENTS
Through Dovetails
23
Variable-Spaced
Half-Blind Dovetails
31
Single-Pass
Half-Blind
Dovetails
39
Models 55160 AND 77240
Rabbeted
Half-Blind Dovetails
45
Sliding Tapered
Dovetails
51
Box Joints
59
Applications
4825 Highway 45 North UÊJackson, TN 38305
1.888.848.5175 UÊdeltaportercable.com/jigs
A NOTE ABOUT USING THE OMNIJIG®
Though the OMNIJIG®is designed to make quality joinery from the start, we strongly suggest you practice
cutting and fitting several joints using scrap wood. This will build up your confidence in the jig and in your own
abilities. This fitting process may also require that you make adjustments to the template stops and/or router
bit depth gauges to achieve your desired joint fit for your application. At the end of each chapter there are tips
that detail these adjustments.

Page iv PORTER-CABLE OMNIJIG®
Read and understand all instructions. Failure to follow all instructions listed below, may result
in electric shock, fire and/or serious personal injury.
There are certain applications for which this tool was designed. Do not modiy and/or use for
any applications other than for which it was designed. If you have any questions relative to its application DO
NOT use the tool until you have written PORTER-CABLE and we have advised you. You can write to Technical
Service Manager; PORTER-CABLE; 4825 Highway 45 North; Jackson, TN 38305.
SAVE THESE INSTRUCTIONS
GENERAL SAFETY RULES
1. KEEP WORK AREA CLEAN. Cluttered areas and benches invite injuries.
2. AVOID DANGEROUS ENVIRONMENT. Don’t expose power tools to rain. Don’t use power tools in damp or
wet locations. Keep area well lit. Avoid chemical or corrosive environment. Do not use tool in presence of
flammable liquids or gases.
3. GUARD AGAINST ELECTRIC SHOCK. Prevent body contact with grounded surfaces. For example: pipes,
radiators, ranges, refrigerator enclosures.
4. KEEP CHILDREN AWAY. Do not let visitors contact tool or extension cord. All visitors should be kept away from
work area.
5. STORE IDLE TOOLS. When not in use, tools should be stored in dry, and high or locked-up place – out of reach
of children.
6. DON’T FORCE TOOL. It will do the job better and safer at the rate for which it was intended.
7. USE RIGHT TOOL. Don’t force small tool or attachment to do the job of a heavy duty tool. Don’t use tool for
purpose not intended – for example – do not use a circular saw for cutting tree limbs or logs.
8. DRESS PROPERLY. Do not wear loose clothing or jewelry. Loose clothing, draw strings and jewelry can be
caught in moving parts. Rubber gloves and non-skid footwear are recommended when working outdoors.
Wear protective hair covering to contain long hair.
9. USE ANSI Z87.1 SAFETY GLASSES. Wear safety glasses or goggles while operating power tools. Also face
or dust mask if operation creates dust. All persons in the area where power tools are being operated should
also wear safety glasses and face or dust mask.
10. WEAR ANSI S3.19 EAR PROTECTION to safeguard against possible hearing loss.
11. DON’T ABUSE CORD. Never carry tool by cord or yank it to disconnect from receptacle. Keep cord from heat,
oil, and sharp edges. Have damaged or worn power cord and strain reliever replaced immediately. DO NOT
ATTEMPT TO REPAIR POWER CORD.
12. SECURE WORK. Use clamps or a vise to hold work. It’s safer than using your hand and it frees both hands to
operate tool.
13. DON’T OVERREACH. Keep proper footing and balance at all times.
14. MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for better and safer performance. Follow
instructions for lubricating and changing accessories. Inspect tool cords periodically and if damaged, have
repaired by authorized service facility. Inspect extension cords periodically and replace if damaged. Have all
worn, broken or lost parts replaced immediately. Keep handles dry, clean and free from oil and grease.
15. DISCONNECT TOOLS when not in use, before servicing, and when changing accessories such as blades, bits, cutters,
etc.
16. REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to see that keys and adjusting
wrenches are removed from the tool before turning it on.
17. AVOID UNINTENTIONAL STARTING. Do not carry a plugged-in tool with finger on switch. Be sure switch is
off when plugging in. Keep hands, body and clothing clear of blades, bits, cutters, etc. when plugging in the
tool.
18. STAY ALERT. Watch what you are doing. Use common sense. Do not operate tool when you are tired or while
under the influence of medication, alcohol or drugs.
19. CHECK DAMAGED PARTS. Before further use of the tool, a guard or other part that is damaged should
be carefully checked to determine 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 other part that is damaged should be properly repaired or replaced by
an authorized service center unless otherwise indicated elsewhere in this instruction manual. Have defective
switches replaced by an authorized service center. Do not use tool if switch does not turn it on and off.
ROUTER SAFETY RULES
Wear appropriate hearing protection during use [ANSI S12.6 (S3.19)]. Under some conditions
and duration of use, noise from this product may contribute to hearing loss.
SAFETY RULES
Some dust created by power sanding, sawing, grinding, drilling, and other construction activi-
ties contains chemicals known to cause cancer, birth defects or other reproductive harm. Some examples of
these chemicals are:
UÊ i>`ÊvÀÊi>`L>Ãi`Ê«>Ì°
UÊÊ VÀÞÃÌ>iÊÃV>ÊvÀÊLÀVÃÊ>`ÊViiÌÊ>`ÊÌiÀÊ>ÃÀÞÊ«À`ÕVÌð
UÊ >ÀÃiVÊ>`ÊVÀÕÊvÀÊViV>ÞÌÀi>Ìi`ÊÕLiÀÊ®°
Your risk from these exposures varies, depending on how often you do this type of work. To reduce your expo-
sure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those
dust masks that are specially designed to filter out microscopic particles.
Avoid prolonged contact with dust from power sanding, sawing, grinding, drilling, and other
construction activities. Wear protective clothing and wash exposed areas with soap and water. Allowing dust to
get into your mouth, eyes, or lay on the skin may promote absorption of harmful chemicals.
Use of this tool can generate and/or disburse dust, which may cause serious and permanent
respiratory or other injury. Always use NIOSH/OSHA approved respiratory protection appropriate for the dust
exposure. Direct particles away from face and body.
ALWAYS USE SAFETY GLASSES. Everyday eyeglasses are NOT safety glasses. Also use face
or dust mask if cutting operation is dusty. ALWAYS WEAR CERTIFIED SAFETY EQUIPMENT:
UÊ  -Ê<nÇ°£ÊiÞiÊ«ÀÌiVÌÊ É-Ê<{°Î®
UÊ  -Ê-£Ó°ÈÊ-ΰ£®Êi>À}Ê«ÀÌiVÌ
UÊ "-É"-É-ÊÀiëÀ>ÌÀÞÊ«ÀÌiVÌ
UÊ Hold tool by insulated gripping surfaces when performing an operation where the cutting tool may contact
hidden wiring or its own cord. Contact with a "live" wire will make exposed metal parts of the tool "live"
and shock the operator.
UÊ Use clamps or another practical way to secure and support the workpiece to a stable platform. Holding
the work by hand or against your body leaves it unstable and may lead to loss of control.
UÊ iÌ>ÊVÕÌÌ}ÊÜÌÊÀÕÌiÀ\ÊvÊÕÃ}ÊÀÕÌiÀÊvÀÊiÌ>ÊVÕÌÌ}]ÊVi>ÊÕÌÊÌÊvÌi°ÊiÌ>Ê`ÕÃÌÊ>`ÊV«ÃÊvÌiÊ
accumulate on interior surfaces and could create a risk of serious injury, electrical shock or death.
UÊ Never run the motor unit when it is not inserted in one of the router bases. The motor is not designed to
be handheld.
UÊ Keep handles dry, clean, and free from oil and grease. This will enable better control of the tool.
UÊ Keep hands away from cutting area. Never reach under the workpiece for any reason. Keep the router base
firmly in contact with the workpiece when cutting. Hold the router only by the handles. These precautions
will reduce the risk of personal injury.
UÊ Use sharp cutters. Dull cutters may cause the router to swerve or stall under pressure.
UÊ Never touch the bit immediately after use. It may be extremely hot.
UÊ Be sure that the motor has stopped completely before you lay the router down. If the cutter head is still
spinning when the tool is laid down, it could cause injury or damage.
UÊ Be sure that the router bit is clear of the workpiece before starting the motor. If the bit is in contact with
the workpiece when the motor starts it could make the router jump, causing damage or injury.
UÊ Do not press spindle lock button while the motor is running. Doing so can damage the spindle lock.
OMNIJIG®JOINERY SYSTEM SAFETY RULES
To reduce the risk of injury, when making cuts:
UÊ ,i>`Ê>`ÊÕ`iÀÃÌ>`Ê>ÊÃÌÀÕVÌÃÊÀi>Ìi`ÊÌÊ«iÀ>Ì}ÊÌiÊOMNIJIG®JOINERY SYSTEM and
making your desired joint.
UÊ iÊÃÕÀiÊ>Êv>ÃÌiiÀÃÊLÃ]ÊÃVÀiÜÃ]ÊiÌV°®ÊÊÌiÊOMNIJIG®have been tightened following any
adjustments.
UÊ iÊÃÕÀiÊÌiÊÌi«>ÌiÊÃÌ«ÃÊ>ÀiÊÊ«>Vi°
UÊ 1ÃiÊLÌÊ>`ÃÊÊÌiÊÀÕÌiÀÊÜiÊ>}ÊÌiÊVÕÌ
UÊ iÊÃÕÀiÊÌiÊÜ`ÊLi}ÊVÕÌÊÃÊÃiVÕÀi`ÊLÞÊÌiÊ>««À«À>ÌiÊÜÀ«iViÊV>«°
UÊ vÌiÀÊ>}Ê>ÊVÕÌÊ>`ÊÌÕÀ}ÊÌiÊÀÕÌiÀÊvv]Ê`ÊÌÊÛiÊÌiÊÀÕÌiÀÊÀÊÞÕÀÊ>`ÃÊÕÌÊÌiÊÀÕÌiÀÊLÌÊ
stops spinning.
UÊ ÃViVÌÊÀÕÌiÀÊvÀÊ«ÜiÀÊ>vÌiÀÊ>}Ê>ÊVÕÌ]ÊÜiÊ>}Ê>ÞÊ>`ÕÃÌiÌÃÊÀÊÜiÊÛ}Ê
wood on and off the jig.
UÊ vÊÃ>Ü`ÕÃÌÊ«iÃÊÕ«Ê>ÌÊÞÕÀÊviiÌ]ÊLiÊÃÕÀiÊÌÊVi>ÊÌÊ>Ü>ÞÊvÀÊÌiÊÜÀÊ>Ài>ÊÌÊ>Û`ÊÃ««}ÊÊÌ°
UÊ ÊÌÊÀ>ÃiÊÀÕÌiÀÊvvÊÌiÊ}ÊÜiÊÌÊÃÊÃÌÊÀÕ}°Ê/iÊë}ÊLÌÊVÕ`Ê`>>}iÊÌiÊv}iÀÃÊ>`Ê
cause sparks.
UÊ iÊV>ÀivÕÊÜiÊ>`}ÊÛ>À>LiÊv}iÀÊÌi«>ÌiÃÊLiV>ÕÃiÊvÊÌiÊÃ>À«Êv}iÀð

PORTER-CABLE OMNIJIG®Page 1
INTRODUCTION
This chapter gives you some background knowledge of
dovetail and other joints and how to prepare the wood for a
successful project. We'll also explain the basic parts of the
OMNIJIG®JOINERY SYSTEM and tell you about accessories
that can add functionality to your OMNIJIG®.
Introduction

Page 2 PORTER-CABLE OMNIJIG®
INTRODUCTION
JOINERY OVERVIEW
The dovetail joint is a traditional joint which dates all the
way back to the ancient Egyptians. It is both strong and
visually appealing. This joint has flared protrusions (tails)
(A) Fig. 1 that are cut into one board ("tailboard") and
protrusions with slanted sides (pins) (B) that are cut in
the other board ("pinboard"). In drawer construction,
the drawer front is the pinboard and drawer side is the
tailboard.
When the two pieces are joined, the tails and pins lock
together mechanically. Pulling on the drawer front will
pull the drawer side as well without the need for fasteners
(screws, nails, etc.). Since the pins and tails have a
sufficient amount of surface, the joint is made even
stronger by glue.
Types of dovetails include through dovetails (Fig. 2),
variable-spaced half-blind dovetails (Fig. 3), single-
pass half-blind dovetails (Fig. 4) and rabbeted half-blind
dovetails (Fig. 5).
A similar joint, called a box joint (Fig. 6), has straight
protrusions called fingers on both boards. This joint is
used on jewelry boxes and other small boxes. The box
joint is strong because it has a large surface area for
glue.
The Dovetail Dado, or Sliding Tapered Dovetail (Fig. 7),
consists of a dovetail-shaped dado (C) in one board and
a dovetail-shaped tenon (D) in the other board.
NOTE: This manual includes instructions for these basic
dovetail jig operations. Please visit our Web Site at www.
deltaportercable.com/jigs for the supplementary manual
that gives instruction for more advanced procedures.
8:1 DOVETAIL RATIO
The traditional angle for dovetails in hardwood is to cut
them at ratio of 8 to 1, which equates to an angle of 7.1
degrees. In order to be historically accurate, the OMNI-
JIG®JOINERY SYSTEM was designed to match this ratio.
As Dovetail bits are measured in angles and not ratios,
7 degrees (Fig. 8) was selected for the system. Fig. 8
shows a cross-section of a typical tail.
Fig. 1
Fig. 2
Fig. 3 Fig. 4
Fig. 5
Fig. 6
B
A
Fig. 7
C
D
Fig. 8
7 degrees

PORTER-CABLE OMNIJIG®Page 3
INTRODUCTION
STANDARD OMINJIG®PARTS
The OMNIJIG®comes standard with various
bits, template guides, stops and a template.
UThe 24" OMNIJIG®comes standard with a
variable finger template that is used to cut through
dovetails and half-blind dovetails (variable and
single-pass).
UThe 16" OMNIJIG®comes standard with a
single-pass half-blind/sliding tapered dovetail
template that is used to cut single-pass half-blind
joints and the sliding tapered dovetail dado.
Standard equipment for each is shown here.
77240: 24" OMNIJIG SYSTEM
1. Jig base
2. 24" variable finger template
3. Instructional DVD
4. Left and right stops (labeled A4, B1, C1)
5. Dovetail bit (labeled D4)
6. Straight bit (labeled S2)
7. Square screwdriver
8. Wrench
9. Template guides, G0 (85/128"), G1 (5/8"),
G2 (39/64"), G3 (19/32"), G4 (37/64"), G5
(9/16") and G6 (15/32")
10. Lock nuts (for all template guides)
11. Router bit depth pod
12. Stabilizer bar
13. Two rubber O-rings
14. Dovetail setup guide (not shown)
55160: 16" OMNIJIG SYSTEM
1. Jig base
2. 16" single-pass half-blind/sliding tapered
dovetail template
3. Instructional DVD
4. Left and right stops (labeled C2)
5. Dovetail bit (labeled D4)
6. Square screwdriver
7. Wrench
8. Template guides, labeled G2 (39/64"), G3
(19/32"), G4 (37/64") and G5 (9/16")
9. Lock nut (for all template guides)
10. Stabilizer bar
11. Router bit depth pod
12. Two rubber O-rings
55160
77240
1
2
3
44
567
8
9
4
1
2
3
4
56
8
7
9
10
11
12
10
11
13
12

Page 4 PORTER-CABLE OMNIJIG®
INTRODUCTION
OMNIJIG®ACCESSORIES
An accessory kit available for the OMNIJIG®can
help you cut box joints (16" or 24"). In addition,
different templates are available: a 16" variable
finger template; a 24" single-pass half-blind/
sliding tapered dovetail template; and 24" and 16"
miniature variable finger templates. The miniature
templates are designed to cut smaller workpieces
for more decorative joints.
Here's what is included in each accessory
package. The catalog numbers for each size are
included below.
Box joint accessory kits (Fig. 9)
77245 (For use with the 16” and 24” variable
finger templates, 77241 or 55161)
55165 (For use with the 16” and 24” miniature
finger templates, 77246 or 55166)
77245
1. Straight bit (S3)
2. Two sets of double stops (“Box left” and
“Box right”)
3. 5 template guides (G3.1, G3.2, G3.3, G3.4
and G3.5)
4. Box Joint Setup Guide (not shown)
55165
1. Straight Bit (S0)
2. Two sets of double stops (“Mini Box left”
and “Mini Box right”)
3. 7 Template Guides (G6, G6.1, G6.2, G6.3,
G6.4, G6.5, G9)
4. Box Joint Setup Guide (not shown)
Single-pass half-blind/sliding tapered dovetail
template (Fig. 10)
(24" - 77248; 16" - 55168)
1. Template
2. Left and right stops (labeled C2)
Fig. 9
Fig. 10
12
3
2
1
12
3
77245 55165

PORTER-CABLE OMNIJIG®Page 5
INTRODUCTION
Fig. 11
Fig. 12
Variable finger template (Fig. 11)
(24" - 77241; 16" - 55161)
1. Template
2. Router bit depth gauges
3. Left and right stops (labeled A4, B1 and C1)
(FOR 55161 ONLY:)
4. Template guides, one labeled G1 (5/8"), one labeled G6
(15/32") and one labeled G0 (85/128")
5. Lock nut for template guides
6. Straight bit (labeled S2)
7. One rubber O-ring
8. Dovetail setup guide (not shown)
Miniature variable finger template (Fig. 12)
(24" - 77246; 16" - 55166)
1. Template
2. Dovetail bit (labeled D1)
3. Straight bit (labeled S1)
4. Template guides, one labeled G7 (3/8") and one labeled
G8 (23/64")
5. Lock nut for template guides
6. Left and right stops (labeled A8 and B2)
7. Router bit depth gauge
8. One rubber O-ring
9. Dovetail setup guide (not shown)
SPECIFICATIONS OF ROUTER BITS INCLUDED
IN VARIOUS BASE UNITS AND ACCESSORIES:
Router
Bits
Cutting
Diameter
Flute
Length
Shank
Length
D0 1/4" 13/32" 1/4"
D1 9/32" 17/32" 1/4"
D2 5/16" 21/32" 1/4"
D3 3/8" 25/32" 1/2"
D4 1/2" 25/32" 1/2"
D5 9/16" 1-1/32" 1/2"
D6 3/4" 1-17/32" 1/2"
S0 9/32" 25/32" 1/4"
S1 1/4" 21/32" 1/4"
S2 3/8" 1-17/32" 1/2"
S3 31/64" 1-17/32" 1/2"
1
245
6
1
2 3 5
6
7
4
7
8
3
NOTE: Other router bits and other accessories (dust collection adapter, storage box for tools, etc.) are
available to expand the capabilities of your OMNIJIG®. Contact your nearest PORTER-CABLE dealer for
more information.

Page 6 PORTER-CABLE OMNIJIG®
INTRODUCTION
FAMILIARIZATION
You need to be familiar with the basic parts
of the OMNIJIG®. This picture above shows
standard items that come with the 24"
OMNIJIG®.
The basic parts include:
A. Template
B. Finger set. These are either variable fingers
(as shown) or fixed (not shown).
C. Router bit depth gauge
D. Workpiece clamping bar (horizontal and
vertical)
E. Workpiece clamping bar lock knobs
(horizontal and vertical)
F. Workpiece clamping lever (horizontal and
vertical)
G. Template mounting rod lock knobs
H. Template lock knobs
I. Stabilizer bar
J. Stabilizer bar lock knobs
K. Stops
L. Router bit depth pod
M. Edge guides (black and silver)
A
D
C
D
B
E
F
G
H
I
J
K
L
M
K
E
F

PORTER-CABLE OMNIJIG®Page 7
INTRODUCTION
WOOD PREPARATION
Properly preparing the materials for your project is the key to
good-looking and tight-fitting joints. You must cut your wood
at perfect right angles (Fig. 13). Cuts that are off even one
degree will not align correctly (Fig. 14).
Also, your workpieces must be flat and not cupped. Orient
your wood so that end grain is joined to end grain (Fig. 15)
to make the joint strong. Using the long grain (Fig. 16) in the
workpiece will result in a weak joint.
INSPECT MATERIALS FOR DEFECTS. Knots
and splinters can be thrown with great force. Make sure
defective materials are not used on the OMNIJIG®.
PROJECT LAYOUT
Keeping track of the outer and inner face of each workpiece
and how the different parts mate with each other is very
important.
STEP 1: Lay out the workpieces face down and label the
inside faces with an “I" (Fig. 17). Label the other
side "O" for "outside surface."
STEP 2: Label the corners “A", “B", “C", and “D" (Fig. 18).
STEP 3: Label the tail boards (drawer sides) with a “T"
(Fig. 19).
STEP 4: Label the pin boards (drawer front and back) with
a “P" (Fig. 20)
Fig. 13 Fig. 14
Fig. 15 Fig. 16
Fig. 17
Fig. 19
Fig. 18
Fig. 20
I
I
I
I
B
B
D
D
A
A
C
C
T
T
P
P
long grain

Page 8 PORTER-CABLE OMNIJIG®
INTRODUCTION
BOARD LENGTHS
To determine what length your workpieces should be in a
typical dovetail drawer project, first visualize your final project
and determine the following:
* What kind of joints will you use on the front of the drawer
and on the back of the drawer?
* What are the outside dimensions of the resulting drawer?
* What is the tail height (the distance "Y" in Fig. 21) on the
dovetail joints you will make?
* How thick is your pinboard (the distance "X" in Fig. 21)?
NOTE: For our example, we will assume the drawer is 12 inches
long and 10 inches wide; tail height for all dovetails is 3/8"; and
the pinboards are 3/4" thick
NOTE: The pinboards do not have to be the same thickness.
Also, the tail height from corner to corner can vary if desired.
Now, follow this guide:
PINBOARD
The pinboard should be 10 inches long.
NOTE: The pinboard length is always determined by the final
project outside dimensions - whether the joints used are
through dovetail or half-blind dovetail.
TAILBOARD
THROUGH DOVETAIL ON BACK AND FRONT (Fig. 22)
If doing through dovetails on the back and front, both boards
are always cut to match the outside dimensions of the project.
In this case, the tailboard will be 12 inches.
HALF-BLIND ON FRONT/
THROUGH DOVETAIL ON BACK (Fig. 23)
For a half-blind dovetail, the length of the tailboard is determined
by subtracting the pinboard thickness (3/4") from the outside
dimension of the tailboard side (12") and then adding back the
tail height distance (3/8"). This means the tailboard would be
cut to 11 5/8" length.
HALF-BLIND ON FRONT AND BACK (Fig. 24)
The board length for tailboards in this example is determined
by subtracting the thickness of both pinboards (1-1/2") from
the outside dimension of the tailboard side (12"). This equals
10-1/2". Then, you add back the sum of the desired tail heights
(3/4"). This equals 11-1/4".
Through dovetails
in all four corners
Half-blind on the front
corners; through
dovetail on back
Half-blind
in all four
corners
X
Y
Fig. 21
Pinboard
Tailboard
Pinboard
Tailboard
Fig. 22
Fig. 23
Fig. 24
10 INCHES
12 INCHES
10 INCHES
12 INCHES
10 INCHES
12 INCHES
Pinboard
Tailboard

PORTER-CABLE OMNIJIG®Page 9
INTRODUCTION
Fig. 25 Fig. 26
Fig. 27
Fig. 28
VISIBLE
HIDDEN
VISIBLE
A
B
GROOVE IN HALF-BLIND DOVETAIL
PINBOARD ALIGNED WITH TAIL
TIPS FOR MAKING
DRAWERS AND BOXES
Tails (A) Fig. 25 are cut into the sides of the drawers, while
pins (B) are cut into the fronts and backs of drawers.
You can use either solid wood or plywood for the drawer
bottoms. Insert the bottoms in a groove along the bottom of
the inside fronts and sides. Allow the drawer bottom to be
free-floating (without glue) to allow for seasonal expansion
and contraction.
The grooves can go all the way to the ends of the boards
if the joints are half-blind dovetails. To accomplish this,
position the groove so that it runs through one of the tails on
the side (Fig. 26).
You will have to stop the grooves on through dovetails or box
joints before they reach the end of the board to prevent them
from being seen, as shown in Fig. 27.
Fig. 28 shows what the groove looks like in the board when it
is hidden or visible in the through dovetail or box joints.

Page 10 PORTER-CABLE OMNIJIG
®

PORTER-CABLE OMNIJIG®Page 11
BASIC OPERATIONS
Basic
Operations

Page 12 PORTER-CABLE OMNIJIG®
BASIC OPERATIONS
SETTING UP THE OMNIJIG®
In addition to the manual, there are a number of in-
structional labels located on the OMNIJIG®, plus set-
up guide cards (standard with some models) that are
provided to help guide you through the various ap-
plications that can be achieved. As you read through
the manual be sure to refer to the labels located on
the templates and stabilizer bar (examples are shown
to the right) and setup guides as applicable.
NOTE: Examples of labels and setup guides are
shown for illustration purposes only and should not
be used for guidance.
Read the instruction manual for your
router before attempting any cuts on the OMNIJIG®.
ALWAYS USE SAFETY GLASSES.
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eyeglasses are NOT safety glasses. Also use face
or dust mask if cutting operation is dusty. ALWAYS
WEAR CERTIFIED SAFETY EQUIPMENT:
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Overlap Adjustment
Single-Pass Half-Blind Dovetails
If
Recessed
If
Proud
C
Single-Pass Half-Blind Dovetails
A20377
Put black edge guide on right
Put silver edge guide on left
Mount finger assembly with
facing up and to the left
$Tails
Slide all fingers to left
Insert bar into fingers
Select dovetail bit and template guide
Set bit depth
Cut tails & pins in same pass
Outside surface
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GUDZHUIURQW
Outside surface of tail
ERDUGGUDZHUVLGH
(rear stop
DGMXVWPHQW
GLUHFWLRQ
Cut first
$Tails %3LQV
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Cut second
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Variable-Spaced Half-Blind DovetailsThrough Dovetails
Cut first (drawer front)
Cut second (drawer side)
A
Through Dovetails
B
Variable-Spaced Half-Blind Dovetails

PORTER-CABLE OMNIJIG®Page 13
BASIC OPERATIONS
BENCH MOUNTING
The OMNIJIG®base is designed so it can be either
clamped to the edge of a sturdy workbench (as shown
in Fig. C1) or bolted to the table through the holes (A)
Fig. C1 provided in the base. The OMNIJIG®should be
secured using one of these mounting methods at all
times.
NOTE: When carrying the jig, grab the workpiece
mounting bars (WW) Fig. C1 for best support.
ROUTER BIT DEPTH POD
Install router bit depth pod (B) Fig. C2, on the back
workpiece clamping bar at holes (C) Fig. C2 using the
included screws.
INSTRUCTIONAL DVD
Before using the OMNIJIG®for the first time, you may
want to watch the included DVD to get familiar with the
operations and set-up for the OMNIJIG®.
Fig. C1
Fig. C2
B
A
C
WW
WW

Page 14 PORTER-CABLE OMNIJIG®
BASIC OPERATIONS
TYPICAL OMNIJIG ADJUSTMENTS
PLACING AND SIZING STOPS
Setup for all joints includes the selection of either single or double stops (D and E) Fig.
C5 included with your unit. Two stops are necessary - one for the left and one for the
right of the OMNIJIG®- and enable the template to be pushed up against them and
locked in place to set the template's position on the jig. The various stops are set to
different lengths to accommodate the wide variety of applications that can be performed
with the jig. For each application, the template must rest at a specific location on the jig
before the cuts are made.
While all stops that come as standard with either the OMNIJIG®or template accessories
are pre-set dimensionally, they can be adjusted to meet your own specific requirements.
By adjusting the stop screws (G) Fig C5 forward or backward, the position of the
template on the jig can be altered. When sizing the stops to your own specifications,
you need to make sure that both stops (left and right) are set to the same dimensions.
To do this, set one to your dimensions and then place both left and right stop together
as shown in Fig. C6 and make sure the tips of the unset screw post hits the post on the
properly sized stop, as shown.
IMPORTANT: Each pair of stops must be oriented left and right on the jig, so that the
labels on the stops are readable as you look at the jig from the front. The 'left' stop is
therefore placed to your left for example. The knurled knobs (F) Fig C5, must be added
and tightened to the back of the jig once the template stops are in place. Their purpose
is to firmly hold the template stops in the jig to ensure that the template is positioned
correctly. The stops are able to move if the knobs are not appropriately tightened, which
in turn can allow the template to be misaligned. An ill-fitting joint can result.
NOTE:Ê9ÕÊV>Ê>`ÕÃÌÊÃÌ«ÃÊvÀÊÛ>ÀÕÃÊ>««V>ÌðÊ-iiÊ** 8\Ê-< Ê9"1,Ê"7 Ê
STOPS" for more.
REMOVING AND REPLACING TEMPLATES
Templates for the jig are mounted and secured onto two mounting bars (H) Fig. C7. The
bars (H) must be raised to remove or replace a template. Also, the template's knurled
thumb screws (L) need to be loose.
To remove a template:
1. Remove the stabilizer bar (J) by loosening knurled thumb screws at each end of bar.
The stabilizer bar (J) Fig. C7 can be mounted temporarily on the back of the router bit
depth pod (K) as shown in Fig. C7.
2. Loosen the knurled thumb screws (L) Fig. C7 on both ends of the template.
3. Loosen template mounting rod lock knobs (M) and raise the mounting bars (H).
4. Slide template off to remove.
5. When placing the template back on the jig, be sure the screws (L) are still loose.
Place the template on the bars (H) and lower the template on the workpiece.
6. Replace stabilizer bar (J) back onto bars (H).
7. Hold the template down in the center, then tighten template mounting rod lock knobs
(M)
8. Tighten the template’s knurled thumb screws (L). Then, tighten stabilizer bar.
NOTE: Be sure the template and stabilizer bar are on the rods (H) Fig. C7 and positioned
correctly over the workpiece before they are locked down.
NOTE: Most templates include on-board labels on the upper left side (R) Fig. C7 to guide
you through key steps of setting up and making cuts.
Fig. C5
Fig. C6
E
F
G
D
Fig. C7
M
K
J
H
L
R
M
DD

PORTER-CABLE OMNIJIG®Page 15
BASIC OPERATIONS
ACCESSORY TEMPLATES
Templates included with the Omnijig are pre-set, but before plac-
ing an accessory template onto the bars for the first time, you will
need to make a one-time adjustment:
1. Loosen (do not remove) square-head screws on both sides
of the templates. Examples of square head screws shown at
(S) Fig. C8.
2. Loosen the knurled thumb screws (L) at both ends of the
template.
3. Slide the template onto the bars, lower the bars and push
template firmly against the stops and down onto the
workpiece. Tighten the template mounting rod lock knobs
(M).
4. Tighten the knurled thumb screws and then tighten square-
head screws that were loosened above.
5. The template is now properly adjusted for your jig.
EDGE GUIDES
Edge guides (one shown at (N) fig. C9) are provided to help align
the sides of the wood properly. When a workpiece is mounted
in the vertical or horizontal plane of the jig, it needs to be flush
against the proper guide.
For some joints, the workpieces need to line up, as seen in Fig. C9.
In others, the pieces need to be mounted offset from each other, as
seen in Fig. C9A. Follow your joint’s specific instructions on wood
mounting.
NOTE: When the boards are mounted offset from each other, the
distance of offset is 1/2".
Some joints require the edge guides to be moved from one end of
the jig to the other. To accomplish this, loosen the two square drive
screws on each guide (an example is shown at T, Fig C10), move
the edge guides, and then retighten the square drive screws.
NOTE: To ensure the edge guides stay square with the jig, when re-
tightening, be sure the top screw is tightened before the bottom.
MOUNTING THE WOOD
Before placing wood into the jig to be cut, make sure it is square
on all four sides. (Read the WOOD PREPARATION section for tips
on making sure your workpiece is square.)
Because the instructions for most joints are located on labels on
the left side of the templates, the wood being cut (U) or (W) Fig.
C11 is usually shown lined up on the left side of the jig.
Fig. C9
Fig. C9A
Fig. C10
N
U
V
T
S
Fig. C8
Single-pass half-blind/sliding
tapered dovetail fixed finger
template
Eight screws (four shown)
Fig. C12
W
J
L
M
S
Variable finger template
Eight screws (four shown)
L
L
M
T
Fig. C11

Page 16 PORTER-CABLE OMNIJIG®
BASIC OPERATIONS
For horizontally mounted workpieces (W) always include
a scrap piece (V) Fig. C13 of the same thickness on the
opposite side to ensure flatness of the template and to
provide stability.
NOTE: Before mounting the wood, it may help to
remove the stabilizer bar (J) Fig. C12. Also, raise and
lock the mounting bars (H) Fig. C13 above the jig while
positioning your workpiece. Remember to loosen the
template's knurled thumb screws (L) Fig. C12 before
loosening the template mounting rod lock knobs (M) Fig.
C13 as you raise the template.
Workpieces can be mounted in either the horizontal (W)
Fig. C13 or vertical (X) position to be cut, depending on
the joint you are making. Both vertically and horizontally
mounted wood is clamped the same way:
1. Loosen the workpiece locking bar knobs (Y) Fig.
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horizontal piece, or up for the vertical piece.
2. Slide in wood so it is snug and square against the
proper left-side edge guide.
3. Tighten the workpiece locking bar knobs (Y) until bar
almost touches the workpiece.
4. Clamp workpiece locking bar down and secure the
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the jig for horizontal workpiece, or pushing down for
vertical workpiece.
Before cutting most joints, make sure the template is flat
down on the horizontal wood and the vertical piece is
pushed up against the bottom of the template.
NOTE: Also, before mounting the workpieces, be sure
the jig base is free from wood chips or dust build-up. The
boards to be cut must be flat against the jig base and
edge guides to ensure joint accuracy and consistency.
VARIABLE FINGERS
The variable-spaced template is shipped with the fingers
in position to cut single-pass half blind dovetails (as
shown in Fig. C14.
To take advantage of the variable spacing functionality,
first loosen set screw located at (AA) Fig. C14 with
supplied square screwdriver (BB) and slide the bar out.
(Be sure to re-attach screw for use later).
Then, slightly loosen the finger's screws - one is shown
at (CC) - and slide fingers where desired.
NOTE: If a finger will not move, push down slightly on the
screw after it is loose to release the finger.
Fig. C13
Fig. C14
W
X
Y
Y
Y
Y
Z
Z
BB
AA
CC
H
H
V
M