Sears Craftsman 171.25450 User manual

ModelNo,
171.25450
CRAFT$1VlAK
INDUSTRIAL
DOVETAIL
FIXTURE
• Assembly
• Operation
iMPORTANT;Thefollowingrouterbitsarerequired
for usewiththis fixture:#25414-1/4-in. Straight RouterBitand
#25415-9/16-in. DovetailRouterBitwhichare used
for THROUGHor OPENJOINTS.
: #25505or #26318-1/2-in. DovetailRouterBitwhich
are usedfor a!l HALFBLINDJOINTS.
Readandfollow
all instructions
carefully.
KEEPTHIS
MANUALFOR
'FUTURE
REFERENCE, Sold bySears,Roebuckand Co,,Hoffman Estates,IL 60179
# 83463

, i i
FAILURETO HEEDALLSAFETYANDOPERATINGINSTRUCTIONS
ANDWARNINGSREGARDINGUSEOF THISPRODUCTCANRESULT
IN SERIOUSBODILYINJURY
1) KNOWYOURPOWERTOOL
Readtheowner'smanualcarefully.Learnitsapplicationsand
Iimitatlonsaswellasthespecificpotentialhazardsparticularto
thistool.
2) GROUNDALLTOOLS(UNLESSDOUBLEINSULATED)
Iftoolis equippedwithanapproved3-conductorcordanda3-
pronggroundingtypeplug,itshouldbepluggedintoathreehole
electricalreceptaute.It adapterisusedtoaccommodateatwo-
prongreceptacle,theadapterwiremustbeattachedto known
ground,(usuallythescrewsecuringreceptaclecoverplate).
Neverremovethirdprong.Neverconnectgreengroundwireto a
terminal.
3) KEEPGUARDSINPLACE
--in workingorder,andinproperadjustmentandalignment.
4) REMOVEADJUSTINGKEYSANDWRENCHES
Forma habitofcheckingtoseethatkeysandadjustingwrenches
areremovedfromtoolbeforeturningit on.
5) KEEPWORKAREACLEAN
Clutteredareasandbenchesinviteaccidents.Floormustnotbe
slipperydoeto waxor sawdust.
6} AVOIDDANGEROUSENVIRONMENT
Donotusepowertoolsindamporwetlocationsorexposethornto
rain.KeepworkareawelIlighted.Provideadequatesurrounding
workspace.
7) KEEPCHILDRENAWAY
All visitorsshooktbekeptata safedistancefromworkarea.
B) MAKEWORKSHOPCHILD-PROOF
--with padlocks,masterswitches,or byremovingstarterkeys.
9) DONOTFORCETOOL
It willdothejob betterandsaferattherateforwhichitwas
designed.
10)USEAPPROPRIATETOOL
Donotforcetoolor attachmentto doajob forwhichitwasnot
designed.
11)WEARAPPROPRIATEAPPAREL
Donotwearlooseclothing,gloves,necktiesorjewelry(rings,
wristwatches)togetcaughtin movingparts.Nonslipfootwearis
recommended.Wearprotectivehaircoveringtocontainlonghair.
Rolllongsleevesel;Dyetheelbow.
12)USESAFETYGOGGLES(HeadProtection)
WearSafetyGoggles(mustcomptywith ANSIZ87.1) atalltimes.
Also,usefaceordustmaskif cuttingoperationisdusty,andear
protectors(plugsor muffs)duringextendedperiodsofoperation.
13)SECUREWORK
Useclampsora visetoholdworkwhenpractical,it'ssaferthan
usingyourhandandfreesbothhandsto operatetool.
14)DONOTOVERREACH
Keepproperfootingandbalanceatalltimes.
15)MAINTAINTOOLSWITHCARE
Keeptools sharpandc]eanfor bestandsafestperformance.Follow
instructionsfor lubricatingandchangingaccessories.
16)DISCONNECTTOOLSBEFORESERVICING
-when changingaccessoriessuchasblades,bits,cutters,etc.
17)AVOIDACCIDENTALSTARTING
Makesureswitchisin OFFpositionbeforepluggingin.
18)USERECOMMENDEDACCESSORIES
Consulttheowner'smanualfor recommendedaccessories.Follow
theinstructionsthataccompanytheaccessories.Theuseof
improperaccessoriesmaycausehazards.
19)NEVERSTANDONTOOL
Seriousinjurycouldoccur;fthetool Istippedorthecuttingtool is
accidentallycontacted.0o notstorematerialsaboveor nearthetool
thatwouldmakeit necessarytostandon thetoolto reachthem.
20)CHECKDAMAGEDPARTS
BeforefurtheruseofthetooI,aguardor otherpartthatis damaged
shouldbecarefullycheckedtoensurethatitwill operateproperly
andperformitsintendedfunction.Checkforalignmentof racy(rig
parts,bindingofmovingparts,breakageof parts,mounting,andany
otherconditionsthat mayaffectits operation.Aguardorotherpart
thatisdamagedshouldbeproperlyrepairedorreplaced.
21)DIRECTIONOFFEED
Feedworkintoabladeor cutteronlyagainstthedirectionofrotation
ofthebladeor cutter.
22)NEVERLEAVETOOLRUNNINGUNA'n'ENDED
Turnpoweroff.Donotleavetooluntilit comestoa completestop.
23)KEEPHANDSAWAYFROMCUT(1NGAREA
24)STOREIDLETOOLS
Whennotin use,toolsshouldbestoredindry,highor Iocked-up
place---outofreachofchildren.
25)O0HOTABUSECORD
Keepcordawayfrom heat,oil,andsharpedges.
28)OUTDOOREXTENSIONCORDS
Whentoo!isusedoutdoors,useonlyextensioncordssuitablefor
useoutdoors,andsomarked.
27)NEVERUSEINANEXPLOSIVEATMOSPHERE
Normalsparkingofthemotorcouldignitefumes,flarnmab;eliquids,
or combustibleitems.
28)DRUGS,ALCOHOL,MEDICATION
Donotoperatetoolwhileundertheinfluenceofdrags,alcohol,or
anymedication.
READANDUNDERSTANDTHISCOMPLETEINSTRUCTIONBOOK
BEFOREUSINGTHISPRODUCT
2

ADDITIONALSAFETYINSTRUCTIONSFORYOUR
INDUSTRIALDOVETAILFIXTURE
1) Alwaysweareyeprotectionthatcomplieswith currentANSI
StandardZ78A.
2) Noiselevelsvarywidely.Toavoidpossiblehearingdamage,wear
earpIugsor muffswhenusingtheDovetailFixturefor hoursata
time.
3) Wearadust maskalongwiththesafetygoggles.
4) Donotusethis DovetailFixturewith routerbitsor guide
bushingsotherthanthosespecifiedforthecutsbeingmade.
5) FollowtheinstructionsinyourRouterOwnersManual.
6) Vibrationscausedbytherouterduringusecancausefasteners
to becomeloose.Beforeuseandperiodicallyduringusecheckall
fastenerstomakesurethattheyareagtightandsecure.
7) Donotusethis productuntilallassemblyinstallationstepshave
beencompleted,andyouhavereadandunderstandnitsafetyand
operationalinstructionsinthis manual,andtheRouterOwners
ManuaL
8) Makesurethattherouterbitisproperlypositionedin therouter
sothatit doesnotcontacttheguidebushingorthetemplatewhen
cutting.
9) TheDovetailFixturemustbesecurelymountedtoaworkbench
or otherstablesurfacewheninuse.Thefrontofthebaseshould
overhangthefrontoftheworkbenchbynomerethan1/4"to provide
clearancewhenclampingworkpiecestotheDovetailFixture.
10) DonotusetheDovetailFixtureasaworksurface.Doingsomay
causedamageto theDovetailFixture,whichcancauseitto beunsafe
to use.Aworkbenchshouldbeusedforthispurpose.
11)Thisproductisdesignedtocutflatworkpieces.Donotcutor
attempttocutworkpiecesthatarenotflatorthatareirregularly
shaped.
12)Thisproductisto beusedforcuttingwoodworkpiecesonly.Do
notusethisproducttocutmetaloranyothernon-woadmaterial.
13)Thisproducthasbeendesignedtocutworkpieceshaving
thicknessesof3/8"to 1".Donotuseforworkpiecesofanyother
thicknesses.
14)DonotclampanyworkpiecestotheDovetailFixtureor makeany
adjustmentsto theDovetailFixtureunlesstherouterhasbeenturned
off,therouterbitisnotturning,andtheRouterhasbeen
disconnectedfromtheelectricaloutlet.
15)Whensetting"lhe-dopth-ot-cut"oftherouterbit,makesurethat
theworkplaceis clampedtotheDovetailFixturein sucha.manner
thattherouterbitdoesnotcutintothe Dovetailbasecausing
damagetoitorpassibleseriousinjurytoyou.
16) ALWAYSUNPLUGTHEROUTERFROMTHE
ELECTRICALOUTLETBEFOREINSTALLINGORREMOVINGROUTER
BITSFROMTHEROUTERANDWHENADJUSTINGTHECUTTING
DEPTHOFTHEROUTERBIT;ORWHENINSTALLINGORCHANGING
GUIDEBUSHINGS,
17)NEVERLiFTTHEROUTERUPWARDSWHENTHEROUTERiS
"ON",THEROUTERBITISROTATING,ANDTHEGUIDEBUSHINGiS
NEARORTOUCHINGTHETEMPLATE,BECAUSETHISWILLCAUSE
THEROUTERBITTOCUTINTOTHETEMPLATEANDDAMAGEIT.
INTRODUCTION
o Your Sears/Craftsmanindustrial DovetailFixtureis an accessory usedwith your Routerto allow you to makedrawers, chests, andthe like
where dovetail joints are used to join the front, back,and sidesof the workpiece.
TheDovetail Fixturewig allow you to make1"spacedflush andflush offset and 318"rabbetedhaif-bfind dovetail joints, in addition you can
make1" spaced (or open) dovetail joints.
• Workplace widths up to 16"can beaccommodated.
Workplacethicknesses between318"and 1" can beaccommodated,
The Dovetail Basehas six pockets molded into its front which aregauges to aid you in setting the "depth-of-cut" for commonly used
depths: 3/8", 1/2", 5/8", 3/4'1,7/8", and 1".
The Dovetail Fixturecomeswith two templates andtwo guide bushings for making bait-blind and through or openjoints.
Sears/Craftsman router bits,#25414 and#25415, WHICH MUSTBEPURCHASEDSEPARATELY,are required to makethe THROUGHor
OPENjoints.
Sears/Craftsman router bit, #25505 or #26318, WHICH MUSTBEPURCHASEDSEPARATELY,is required for making the haIf-bIind joints.
• Eachtemplate has alabel, describingthe joint that can becut, along with set up information, the bit and guide bushing required,and the
stop block setting for a particular joint.
The Dovetail Fixturecan be usedwith al! Sears/Craftsman Routers.
With a separately purchasedSears/Craftsman#25326, Universal Router Adapter,the DovetagFixturecan be usedwith many non-
Craftsman Routers, such as, Black & Decker,Makita,and SkiL
UNPACKINGANDCHECKINGCONTENTS
in orderto simplify handIingandto minimizeany damagethat may occur during shipping, your Industrial Dovetail Fixtureis packaged
unassembled,
Separateall parts from the packing materialsandcheck each onewith the igustrations and list of partsat the endof this manuaIto make
sure that ag partsare presentbeforediscarding any packagingmaterial.
•Ifany parts aremissing or cannot beaccounted for, do not attemptto assemble,install, or usethe industrial DovetailFixture
until the missing parts havebeenobtainedand the product has beenassembled correctly.
Contactyour localSearsRetail Outletfor a repIacement product or for the missing parts.
3

ASSEMBLYINSTRUCTIONS
Thefollowingtoolsarerequiredforassembly:
1) AmediumsizedPhillipsscrewdriver,
2) Asmallor mediumsizedadjustablewrench.
ASSEMBLYOFTHERIGHTSIDETEMPLATESUPPORTTOTHEDOVETAILBASE
1). Placethedovetailbasetopsidedownonaflat surface.
2) insertoneof the5/16-18x2"longroundheadsquareneckboltsintothes!otintherightsideofthebase.(NOTE:Therightsideof the
baseis identifiedbythewordsRIGHTSIDEmoldedintoit.)
3) Placea11/32"I.D_x7/8"O.D.washerontotheboltasshownin Figure1,
4) Threada5/16-18hexnutontothebolt,asshown,untilit bottomsoutagainstthewasher,
5) Backoffthenutfromthewasherbetween1/4and1/2turns.NighthenutsothatthecornersofthenutareverticallYlineduPasshown.
Notethealignmentofthehexpocketinthetemplatesupport.Theboltshouldbefreeto movesidetoside;ifit doesnot, loosenthenut1/3
turnor untilthecornersofthenutpointupanddown.
8) Assembletherighttemplatesupportto therightsideofthedovetailbasesothatthehexoutlinesupandf ts intothehexpocketinthe
righttemplatesupport,(NOTE:TherighttemplatesupporthasthewordsRIGHTSIDEmoldedintoitfor identification.)
7) Assemblea #10-32x5/8°tongpanheadmachinescrew,a 13/64"!.D.x 9/16"O.D.washer,anda#10"32hexnutt° thebaseassh°wnt°
holdthetemplatesupportin place.Securelytightenthenutandscrew_
8) Thetemplatesupportshouldmovefreelyfrontto backalongthesideofthebase,If it doesnot,it meansthatthe5/16-18hexnutistoo
tight ontheboltandshouldbeloosened.Todo this,removethefastenersassembledinstepT,andremovethetemplatesupport;repeatsteps
4 through7.
•ASSEMBLE THE LEFT SIDE TEMPLATE SUPPORT TO THE DOVETAIL BASETHE SAME AS THE RIGHT SIDE
TEMPLATE SUPPORT WAS ASSEMBLED
Fig. 1
"/8"longPANHEADMACHINESCREW
11/32"LO.XT/8"O.D.WASHER
MUSTLINEUP
5/16-18X2"tongROUNDHEAD
SQUARENECKBOLT
?HEXNUT
_.D.WASHER
DOVETAILBASE
_BACKOFDOVETAILBASE

ASSEMBLYOFTHETOPCLAMPINGBARTOTHEDOVETAILBASE
1) Assembleoneoftheboltsupportsto bothofthe5/16-18X3-1/2"longroundheadsquareneckboltsasshowninFigure2.
2) Alignthesquareontheboltwiththesquareholein theboltsupport.Theboltsupportisto =bottom-out"againsttheboltasshownin
Figure3.
FIG.2 5/16-18X3-1/2"FIG.3
longROUND
HEADSQUARE _-x
,o,, FIG. 3a
3) Assembleoneofthespringsto eachofthenylonspringretainersbypushingthespringovertheraisedcylindricalportionof the
springretainerasshownin Figure3aandFigure3b,
4) Positionthedovetailbaseonafiat smoothsurfacesothebackofthebaserestsonthesurface.
NOTE:ALTHOUGHBOTHENDSOFTHEDOVETAILBASEARESHOWNASSEMBLEDINTHEFOLLOWINGFIGURES,THEACTUALASSEM-
BLYISDONEONEENDATATIME.
5) Fromthebottomofthebase,inserta boltwithboltsupportthroughtheslotin thetopofthebasesothe raisedportionofthebolt
supportgoesintotheslot,asshownin Figure4,
Fig, 4SLOTIN SLOTIN
DOVETAIL DOVETAILEASE DOVETAIL BOLTANDBOLT
EASE / BASE
BOLTAND
BOLTSUPPORT
FRONTOFDOVETAILBASE
6) Placea5/16"I.D.X 7/8"O.D.thick nylonwasheroverthe boltsothatthecountersinkfacesawayfromthedovetailbaseasshownin
Figure6. It will benecessaryfor youto holdtheboltin placewhenperformingthis andthefollowingsteps.
HELPFULHINTS:Positiontheboltandtheboltsupportunderthenotchin theribasshownin Figure5,to helpholdtheboltin place,
Fig. 5_NOTCHINRIB
SLOTINDOVETAILBASE
BOLTANDBOLTSUPPORT

7) Placeaspringandspringretainer,assembledinstep3, overtheboltsothespringfitsintothecountersinkin thethickwasherasshown
InFigure6.
8) Pressdownonthespringretaineruntiljusttheendoftheboltsticksoutpasttheendofthespringretainer.
9) Slidetheclampingbarovertheboltsothatthespringretainerabutstheinsideoftheclampingbarasshownin figure6.NOTE:THE
SPRINGRETAINERMUSTPUSHAGAINSTTHECLAMPNGBAR.
10)Placean11/32"I.D.X 7/8"O.D.thin nylonwasherandan 11/3Z I.D.X7/8"O.D.washeroverthebolt.It will benecessaryfor youto
pressdownonthedampingbarwhiledoingthis.
11)Takeoneoftheclampingknobsandthreaditontotheboltasshown.DONOTTHREADtheknobcompletelyontothebolt--just enough
sotheknobholdstheclampingbarin place.
SPRINGAND
NYLONSPRING
RETAINERFIT
INSIDETHEOPEN
SIDEOFTHE
CLAMPINGBAR
(SEECLAMPING
BARDETAIL) \
CLAMPING Assembleclampingbar,knobs,endcapson bothends asshown
tf/32"LD.X 7/B"O.D.WASHER
11/32"LD.X T/8"O.D.
THINNYLONWASHER
SPRING
31/2"BOLT
BOLl
SUPPORT
FIG. 6 KNOB
CLAMPINGBAR
CLAMPINGBARENDCAP
OPENSIDEOFTHECLAMPING
BARPOINTSTOWARDTHETOP
SURFACEOFTHEDOVETAILBASE
11/32"LD.X 7/8"O,D.
t THICKNYLONWASHER
/ TOPSURFACEOFTHE
DOVETAILBASE
-- RIGHTTEMPLATE
SUPPORT
CLAMPINGBARDETAIL
NYLONSPRINGRETAINER
11/32"LD.X7/8"O.D. (RETAINERABUTSTHE
WASHER LAMPING SAR)
/
CLAMPINGBAR(SHOWNWITH /
ENDCUTAWAYANDSECT!ONED /
SONYLONSPRINGRETAINER /
PLACEMENTCANBESEEN) /
COMPRESSION
SPRING
12)Repeatabovesteps4through11for theotherendoftheclampingbar.
13)Assembletheendcapstotheendsoftheclampingbarbypressingthemin;theyaredesignedto be"force-fit"intothebarin oneway
only.It maybenecessaryto "tap"themin bygentlyhittingthemwitha rubbermatletora pieceofwood--sincetheyfit verytightlyintothe
clampingbar,USECARE WHEN DOINGTHISSOAS NOT TO DAMAGE THEEND CAPS,
USECARETHATTHE CAPSAREPROPERLYALIGNEDASSHOWN WHEN ASSEMBLINGTHEM TO THEBAR.
fig.7CLAMPINGBARPARALLELTO
TOPOFBASE JSPACINGTOBE
APPROXIMATELY
1-1/2"
0 0 0
14)Tightentheclampingknobsontotheboltssothatthespacebetweenthebottomoftheclampingbarandthetop ofthebaseisabout
1 1/2".Theciampingbarshouldbeparallettothetopofthebase.
15)AftercompletingtheabovestepsyourDovetailFixtureshouldlookliketheillustrationin Figure7.
6

ASSEMBLYOFTHEFRONTCLAMPINGBARTOTHEDOVETAILBASE
1) Assemblethefront clampingbarto thedovetailbasefollowingthesameprocedureusedto assemblethetop clampingbartothedove-
tail baseasshownin Figure8.The5/16-18X4-1/2"longroundheadsquareneckboltsareused,
Fig. 8
BOLT
0
4 I/2" BOLT / ""
11/32"1.D.X7/8"O.D,
THICKNYLONWASHER
COMPRESSIONSPRING
CLAMPINGBAR
ENDCAP
1!/32"LD.X7/B"O.D,
RETAINER THINNYLONWASHER
CLAMPINGBAR
(SHOWNWITH
ENDCUTAWAY
ANDSECTIONED
SONYLONSPRING
RETAINERPLACE-
MENTCANBE
SEEN)
COMPRESSION
SPRING
NYLONSPRING
RETAINER
(RETAINER
ABUTSTHE
CLAMPINGBAR)
11/32"I.D.X 7/8"O.D.WASHER
ASSEMBLYOFTHECAMHANDLESANDPIVOTSHAFTTOTHEDOVETAILBASE
Afterthecamhandlesandpivotshafthavebeenassembledto thebase,it willbepossibleto accuratelypositionthetemplatesforclose
fittingjoints,
Notethattherearesomegraduationsonbothtemplatesupports.
•Rotatingthecamhandlesothat thepointerlinesup withoneofthegraduationspermitsaccuratefront-to-backpositioningofthe
template.
• Camhandlesaredesignedto provideinfinitetemplateadjustment.
Onegraduationequals1/64"ofmovementofthetemplate.
• Rotatingthecamhandlesothat thepointerlevermovestowardthefrontofthebase.causesthetemplateto alsomovetowardsthefront
ofthebase.
• Converselyrotatingthecamhandlesothatthepointerlevermovestowardthebackofthe base,causesthetemplateto alsomove
towardsthebackofthebasealso.
1) Assembleoneofthecamhandlestothepivotshaftusinga #10-32x5/8"longpanheadmachinescrewanda 13/64"I.D.x9/16"LD.
washer,asshownin Figure9,
2) Usecaresothatthe pivotshaftfitsintothehex-shapedholein thecamhandle.Thepivotshaftmayfit tightlyintothecamhandle;
this isnormal.
3) Makesurethatthepivotshaftbottoms*outinsidethecamhandle.
Fig. 9/ CAMHANDLE
13/64"t.D.X9/16°0.O,WASHER--_,,,,_ _ PIVOTSHAFT
7

4) Securelytightenthescrew,
NOTE:THENEXTTWOSTEPSAREPRE-ASSEMBLYSTEPS.
5) Sgdetheretainerovertheendofthepivotshaftfor about2".Theretainermayfit tightly;thisisnormal
6) Threadthe#1_`16x1/2"_ngpanheadtappingscrewint_theh_eintheretainerunti_itbott_ms-_tagain_tthepiv_tsha_.(Thescrew
willfit tightlyin thehole.)SeeFigure10.
Fig. 10 _#!0-16X 1/2"LONGPANHEADTAPPINGSCREW
7) Loosenthescrewaboutoneturn.Removetheretainerfromtheshaftandsetit asidetemporarily.
8) Assemblethepivotshaftwith camhandleto thebasebyinsertingtheendofthepivotshaftthroughtheholestntherighttemplate
supportandthebase.
9) MAKESURETHEORIENTATIONOFTHECAMHANDLEISASSHOWNINFIGURE11.
10)PlacetheretaineratthelocationshowninFigure12endpushthepivotshaftthrough.THEORIENTATIONOFTHERETAINERRELAT]VE
TOTHECAMHANDLEWITHSCREWMUSTBEASSHOWN.
NOTE:THERETAINERMAYFITTIGHTLYONTHEPIVOTSHAFT;THISISNORMAL.
Fig. 11
DOVETAILBASE

11)Continuepushingthepivotshaftthroughtheholesandtheretaineruntiltheendofthepivotshaftextendsoutofthelefttemplatesupport
asshowin Figure12.
12)Makesuretheendofthecamhandlefits intothe holein thebaseasshown,
Fig. 12
PIVOT,
HOLEINBASE, PtVOTSHAFT
SUPPORT
CAM
HANDLE _"
13)Withthecamhandlepushedin againstthebase,positiontheretaineragainstthesidewallofthebase,asshownin Figure13.Theretainer
shouldbarelytouchthesidewallofthe base.Thepurposeoftheretaineristopreventor minimizetheside-to-sideofthecamhandleand
pivotshaft.
Fig. 13 RVOTSHAFT
-SIDEWALLOFBASE
9

14)Assembletheothercamhandleto theotherendofthepivotshaftusinga 13/64"I,D.x 9/16"O.D,washeranda#10-32X 5/8"long
penheadmachinescrew,asshownin Figure14.
15)Makesurethatthecamhandlelinesupwiththecamhandleattheotherendofthepivotshaftandthat theendofthecamhandlefitsinto
theholein thebase.
16)Tightenthescrewsecurely, LEFTTEMPLATESUPPORT
Fig. 14 /_ #10-32X5/8"LONG
PANHEADMACHINE
SCREW
_" DAMHANDLE
17)Rotateoneofthecamhandtes-ltshoutdrotatefreelyand movethetemplatesupports,
18)Ifthis doesnothappen,loosenthescrewon theretainerandmovetheretainerawayfrom thesidewallslightly,
19)Securelyretightenthescrew.
20)If thereistoomuchside-to-sidemovement(play)ofthecamhandles;loosenthescrewin theretainerandmovetheretainerc/osertothe
sidewaltofthebase.
21)Securelyretightenthescrew,
ASSEMBLYOFTHEFRONTSTOPBLOCKSTOTHEDOVETAILBASE
1) Aseemblethefrontstopblockstothefront ofthedovetailbase,ateachend,using#10-32x 5/8"longflatheadmachinescrews,13/64_
I.D.x 9/16"O.D.washers,and#!0-32 hexnuts,asshownin Figure15.
2) Makesurethattheopenrib portionfits intotheslotin thefrontofthebase.Thestopblockwglfit intotheslotin onepositiononly,
3) Tightenthescrewsecurelyontothenut.
4) Assembletheotherfrontstopblocktooppositeendo1thedovetagbaseinthesamemanner.
Fig. 15 FORREASONSOFCLARITY,THEFRONT
CLAMPINGBAR,KNOBS,BOLTSAND
SPRINGSARENOTSHOWN WASHER
DOVETAILBASE\
SLOT_#10_32XB/8OLONG FLATHEADMACHINE
SCREW
SUPPORT
#10-32HEX
13/64_LD.X9/16°O.D/
WASHER J
FRONTSTOPBLOCI_
_FRONTOFDOVETAtLBASE
5/8"LONGFLATHEAD
MACHINESCREW
10

ASSEMBLYOFTHETOPSTOPBLOCKSTOTHEDOVETAILBASE
•Thetopstopblocksareassembledtothetopofthedovetailbasein oneoftwowaysdependinguponwhichstyleofdovetailjointis
to becut:
a) HALF-BLINDFLUSHJOINTS--The"A" onthestopblockfacestowardthe"middleofthebase".
b) HALF-BUNDRABBETJOINTS_The"B"onthestopblockfacestowardthe"middleofthebase".
c) THROUGHJOINTS--The"A" onthestopblockfacestowardthe"middleofthebase".
• Sincetheflushjointisthemorecommonlyusedjoint,thefollowinginstructionsapplytotheassemblyofthestopblocksforthis
stylejoint.
1) Positionthedovetailfixturerightsideuponaflat surface.
2) Assembleoneofthetopstopblockstothetopsurfaceofthebaseusinga#10-32x 7/8"longflatheadmachinescrew,asshownin
Figure16.ThescrewthreadsintotheholeinthebottomofthesIot.
3) Makesurethatthe"A"facesthe"middleofthebase".
4) Makesuretheopenribportionofthestopblockfits intotheslot in thetopsurfaceofthebase.
Fig. 16 RfBONSTOPBLOCK_
#10_32X 7/8_LONG \
MACHINESCREW
#t0-32X7/8"L'ONGFLAT
HEADMACHINESCREW
TOPSTOPBLOCK
SLOTINTOP/
OFBASE
SLOTINTOP
OFBASE
MIDDLEOFTHEBASE
5) Assembletheremainingtopstopblocktotheoppositeendofthebaseinthesamemanner.
6) Againmakesurethatthe"A"facesthe"middleofthebase"
7) Tightenbothscrewssecurely.
8) Torepositionthestopblocksforrabbetjoints,simplyloosenthescrewsjustenoughsothattheribsonthestopblockscomeoutofthe
slot,Thestopblockisthenrotated180° tothealternateposition,sothe"B"facesthemiddleofthebase,andsecurelyretightenthescrews.
ASSEMBLYOFTHECLAMPINGKNOBSTOTHEDOVETAILBASE
1) Assemb_e1_/32"_D.x 7/8"____was_ers_ntot_e_/1_-18b_itsatb_thends_ft_ed__etai__aseassh__nin Figure17_
2) AssembletheclampingknobsontotheboItsasshown.
3) Threadtheclampingknobsontotheboltssothatthespacingbetweenthewasherandthetemplatesupportsisapproximately1/2".
4) Setthedovetailbaseasideforthetimebeingandcontinueon withthenextsection.
ASSEMBLYOFTHETEMPLATES
/ 5/16-18X2"longROUND
Fig. 17 / HEADSQUARENECK
BOLT
5/t6-t8X2°tongROUND
HEADSQUARENECKBOLT\
\11/32"I.D.XT/8"
// O.D,WASHER
KNOB
CLAMPING/
KNOB
11
!/2"SPACING8ETWEFNWASHERAND
TEMPLATESUPPORT(BOTHENOS)

•Placethetemplatestiffenerintotherectangularslotin theunderneathsideofthetemplate,asshowninFigure18.
NOTE:THETEMPLATEFORCUTTINGHALF-BLINDJOINTSISBEINGUSEDASANILLUSTRATIONINTHEFOLLOWIHGFIGURES.
1) Threada #8-36x3/16"longpanheadmachinescrewthrougheachofthefiveholesinthetemplateandintothethreadedholesin the
templatesupport,asshowninFigure24andsecurelytightenallofthescrews.
Fig. 18 _TEMPLATESTIFFENER
\ _ _ _ J jRECTANGULARSLOT
TEMPLATE
_ _ MACHINESCREwSLOTTEDBINDINGHEAD_ _MA#&3gX3!!6"t°ngPANHEADcHINESCREW
NOTE:ONSOMEEARLYVERSIONSOFTHISPRODUCT,ASLOTTEDBINDINGHEADMACHINESCREWHASBEENSUBSTITUTEDFORTHE
PANHEADSCREWSPECIFIEDFORASSEMBLINGTHETEMPLATESUPPORTSTOTHETEMPLATES.(SEETHESCREWILLUSTRATIONIN
FIGURE18),
2) Assemblethetemplatebracketstothetemplateusingfour#10-32x3/8°longpanheadmachinescrews_asshownin Figure19.
3) MAKESURETHATTHETEMPLATEBRACKETSAREASSEMBLEDTOTHEUNDERNEATHSIDEOFTHETEMPLATE,ASSHOWNIN
FIGURE19,ANDTHATTHEAL]GNMENTOFTHEBRACKETSISALSOASSHOWNINTHEFIGURE.
4) ITISNOTNECESSARYFORTHESCREWSTOBETIGHTENEDATTHISSTAGE;THETEMPLATEBRACKETSSHOULDBEFREETOMOVE
WITHRESPECTTOTHETEMPLATEORELSEITWILLNOTBEPOSSIBLETOALIGNTHETEMPLATEASDESCRIBEDINTHENEXTSECTION.
5) Theassembledtemplateshouldlookliketheillustrationin Figure20.
Fig. 19 #10-32X3/8"tongPANHEADMACHINESCREW
TEMPLATE
'\
_- TEMPLATEBRACKET....
6) AssemblethetemplatestiffenerandthetemplatebracketstotheTEMPLATEFORCUTTINGTHROUGHJOINTSusingthesamemethod
describedintheprecedingsteps1through5,Referto Figure20.
Fig. 20
lg

ALIGNMENTOFTHETEMPLATES
Inorderfor theDovetailFixturetofunctionproperly,it isnecessaryfor thetemplatestobealignedwithrespecttodovetailbase.The
reasonforthis, isthatdovetailcutsareatbothendsoftheDovetailFixture.Whenproperlyaligned,theresultbeingall matingcorners
willalwaysbelinedup.
NOTE:THETEMPLATEFORCUTTINGHALF-BLINDJOINTSISBEINGUSEDASANILLUSTRATIONINTHEFOLLOWINGFIGURES,
1) Withthedovetailbasesti!lhavingthe1/2"spacingbetweenthewasherandthetemplatesupports(Referto Figure17),assemblethe
templateassemblytothedovetailsothat:
a) theslotin thetemplatebracketfitsoverthebolt,
b) thelegofthetemplatebracketis betweenthewasherandthetemplatesupport,and
c) thelegsfit intotheslotsinthetemplatesupports,asshownin Figure21.
d) NOTE:THISPROCEDUREMUSTBEFOLLOWEDWHENEVERTHETEMPLATEISINSTALLEDONTHEDOVETAILFIXTURE.ITISMOST
IMPORTANTTHATLEGOFTHETEMPLATEBRACKETALWAYSBEBETWEENTHEWASHERANDTHETEMPLATESUPPORTORELSETHE
TEMPLATEWILLNOTBEPROPERLYPOSITIONEDFORCUTTINGACCURATEDOVETAILS.Forinitialsetup,Allowthelegsofthetemplate
bracketto "bottomout" intheslotsinthetempiatesupportsasshownin Figure21.
Fig. 21
WASHER
BOLT_
TEMPLATEBRACKET
SLOTIN THETEMPLATEBRACKET
_RtGHTTEMPLATESUPPORT
jSLOTINTHETEMPLATESUPPORT
0
"_TEMPLATEBRACKET"BOTTOMS-OUT"AGAINSTTHIS
SURFACE(BOTHENDSOFDOVETAILBASE)
TOREMOVETHETEMPLATEFROMTHEDOVETAILFIXTURE,LOOSENTHECLAMPINGKNOBSSOTHATSPACINGBETWEENTHE
TEMPLATEBRACKETANDTHEWASHERISABOUT1/2";GENTLYLiFTTHETEMPLATEUPWARDFROMTHEDOVETAILBASESOTHATTHE
TEMPLATEBRACKETCLEARSTHESLOTSINTHETEMPLATESUPPORTANDSTOREINACONVENIENTLOCATION,
2) LightIytightentheclampingknobsatbothendsofthebasesothatthetemplatebracketsareheldin placeagainstthetemplatesupports
asshowninFigure21.
3) Movethetemplatefrom sideto sideonthetemplatebracketssothatitiscenteredwith respecttothetemplatebrackets,Thismeansthat
thetemplateandbracketsshouldlookIikeoneofthefollowingfigures:Figure22,Figure23,or Figure24,Movetemplatefront-to-backsothat
front edgeoftemplateisparallelwith thefrontofthedovetailbase.IneachconditionthetemplateandthetemplatebracketsMUSTbe
symmetricalwith eachother.Thefiguresdonotshowthecompletedovetailfixture,butonlytheunderneathsideofthetemplatewithtemplate
bracketscorrectlypositioned,in orderthatthecorrectpositionsofthepartscanbeseenclearly.
]3

Fig. 22
I
TEMPLATE
_"DISTANCEBETWEENTHESESURFACES
MUSTBEEQUALATBOTHENDS
TEMPLATEBRACKET
CONDITIONONE."TEMPLATEBRACKETSPROTRUDEBEYONDTEMPLATES
Fig. 23
o
jTEMPLATE
J
F
THESESURFACESMUST
BEEQUALATBOTHENDS
_0 0 TEMPLATEBRACKET
CONDITIONTWO;TEMPLATEPROTRUDESBEYONDTEMPLATESBRACKETS
.24
o00
MUSTBEEQUALATBOTHENDS
TEMPLATEBRACKET
CONDITIONTHREE.TEMPLATEEVENWITHTEMPLATEBRACKETS
14

4) Afterthetemplatebracketshavebeencorrectlypositionedonthetemplatesecurelytightenthefourscrewsholdingthetemptatebrackets
to thetemplate.
5) Removethetemplateassemblyfromthebaseandsetit asidefornow.
6) Aligntheothertemplateassemblyin thesamemanner,
ITSHOULDBENOTEDTHATYOUMAYFIND,THATAFTERMAKINGSOMESAMPLECUTS,SLIGHTADJUSTMENTSMAYBEREQUIRED.
HOWTOMAKETHESEADJUSTMENTSISEXPLAINEDINTWOOFTHEFOLLOWINGSECTIONS:"MAKINGADJUSTMENTSFORHALFBLIND
JOINTS"or "MAKINGADJUSTMENTSFOROPEN(THROUGH)JOINTS".
7) Removethetemplateassemblyfromthebaseandsetit asidefornow.(Figure25 below,isanexampleofINCORRECTLYpositioned
templatebrackets,)
CKET
BEYONDTHETEMPLATE
BRACKET
0o!o 0
THETEMPLATEBRACKETEXTENDS
tEMPLATE
CONDITIONFOUR:THISCONDITIONISNOTCORRECT---
TEMPLATEBRACKETEXTENDSBEYONDTHETEMPLATEAND
THETEMPLATEEXTENDSBEYONDTHETEMPLATEBRACKET
• StMPLYMAKESUREBRACKETSAREPOSITIONEDTHESAMEATEACHEND
ASSEMBLYOFA GUIDEBUSHINGTOTHEROUTER
ALWAYSMAKESURETHATTHEROUTERIS"TURNEDOFF"ANDTHATTHEELECTRICALCORDHASBEENUNPLUGGED
FROMTHEELECTRICALOUTLETBEFOREASSEMBLINGAGUIDEBUSHINGTOTHEROUTERORMAKINGANYADJUSTMENTSOR
CHANGINGROUTERBITSINTHEROUTER.
REMOVEANYROUTERBITFROMTHEROUTERBEFOREPROCEEDINGWITHTHEASSEMBLYOFA GUIDEBUSHINGTOTHEROUTER.
Assembly for Sears routers with three hole baseplates:
1) Placethe'routerupsidedawnonaflat surfaceandremoveanyguidebushingthatmaycurrentlybein therouter,
2) Placetheguidebushingrequiredforthetypeof dovetagjointto becutundertherouterbaseplateasshownin Figure26.
Fig. 26 10-32X 3/8°LONGFLATHEAD
MACHINESCREW (1/2"DIAMETERSHOWN)
NOTETHEORIENTATIONOF"
THEGUIDEBUSHING

3) MAKESURETHATTHEORIENTATIONOFTHEGUIDEBUSHINGISASSHOWN,
4) Positiontheguidebushingsothatthethreethreadedholesintheguidebushinglineupwiththecountersunkholesinthebaseplate.
5) Threada#10-32x3/8"longflatheadmachinescrewinteeachontheholes.
6) SecureIytightenthescrews.
Assemblyfor Soars 1/2" Shank Industrial Routers Modal Nos. 27504, 27505 and 27506 or equivalent:
1) Placetherouterupsideonaflatsurfaceandremoveanyguidebushingthat maycurrentlybeintherouter.
2) Placetheguidebushingintherecessedportionoftherouterbaseasshownin Figure27.
3) AlignthecutoutsintheguidebushingwiththethreadedhoIesinthebase.
4) Threadthetwo roundheadscrews,thatcamewiththerouter,intothetwo threadedholesinthebase.
5) Tightenthescrewssecurdy.
B) FORADDITIONALINFORMATIONCONCERNINGTHISMATTER,CONSULTYOURROUTEROWNERSMANUAL.
MAKESURETHATTHEROUTER
BITISALIGNEDWITHORCENTEREDIN THEHOLE
INTHEGUIDEBUSHING.TODOTHIS,LOOSEN
SCREWSHOLDINGBASEPLATEORADAPTER
PLATETOROUTER,CENTERGUIDEBUSHINGHOLE
WITHRESPECTTOROUTERBITANDRETIGHTEN
SCREWSSECURELY
Fig, 27 _ - ROUTERBIT
I i I
',,@,
I I
TEMPLATEGUIDE--
ROUTERBA_
Assembly for other brands of routers:
INORDERTOUSETHEDOVETAILFIXTUREWiTHOTHERBRANDSOFROUTERS,ITWILLBENECESSARYFORYOUTOPURCHASEA
CRAFTSMANUNIVERSALROUTERADAPTERPLATE,MODELNO.25326,FROMSEARS,ANDREPLACETHEBASEPLATEONYOURROUTER
WITHTHEADAPTERPLATE.
1) Placetherouterupsideon aflatsurfaceandremoveanyguidebushingthatmaycurrentlybeintherouter,
2) Placetheguidebushingrequiredforthetypeof dovetailjointto becutundertherouterbaseplateasshowninFigure2&
3) MAKESURETHATTHEORIENTATIONOFTHEGUIDEBUSHINGISASSHOWN,
Fig. 28
NOTETHEORIENTATIONOF
THEGUIDEBUSHING
MACHINESCREW
(t/2"DIAMETERSIlOWN)
MAKESURETHATTHEROUTER
BITtSALIGNEDWITHORCENTEREDINTHEHOLE
IN THEGUIDEBUSHING.TODOTHIS,LOOSEN
SCREWSHOLDINGBASEPLATEORADAPTER
PLATETOROUTER,CENTERGUIDEBUSHING
HOLEWITHRESPECTTOROUTERBITAND
RETIGHTENSCREWSSECURELY
16

4) Positiontheguidebushingsothatthethreethreadedholesintheguidebushinglineupwiththecountersunkholesintheadapterplate.
5) Threada #10-32x3/8"longflatheadmachinescrewintoeachontheholes,
6) Securelytightenthescrews.
Fig. 29 NOTETHEORIENTATIONOF
THEGUIDEBUSHING
_PLATE
INSTALLATIONINSTRUCTIONS
THEDOVETAILFIXTUREMUSTALWAYSBEFIRMLYANDSECURELYMOUNTEDTOA SOLIDANDFIRMWORK
SURFACE,SUCHASAWORKBENCH,BEFOREUSE.FAILURETODOSOCOULDCAUSETHEDOVETAILFIXTURETOTIPOVERORSLIDE
ALONGTHEWORKSURFACE,RESULTINGINPROPERTYDAMAGEANDSERIOUSPERSONALINJURY.
MOUNTINGTHEDOVETAILFIXTURETOA WORKSURFACEORWORKBENCHUSINGCLAMPS
USINGTHISMOUNTINGMETHODALLOWSYOUTOMOUNTTHEDOVETAILFIXTURESOTHATITCANBEEASILYINSTALLED,FORUSE,
ANDREMOVED,FORSTORAGE,WITHOUTPERMANENTLYTAKINGUPSPACEONYOURWORKBENCH
1) Makeasolidwoodmountingboard,32"longx 6-1/4"widex3t4"thick.
2) Rem°vethetemplateassemblyfr°m thebaseifthereis°notherecurrently'
3) Drillthree1/8"diameterholes,3t4"deepintothemountingboardasshownin illustration.
4) PositiontheDovetailFixtureonthetopofthemountingboardsothe holesinthebaselineupwiththedrilledholesinthemountingboard.
5) SecuretheDovetailFixtureto themountingboardusingthree13164"!.D.x 9/16"O.D.washersandthree#10-16x1"longpanheadself
tappingscrewsasshowninFigure30.
FIG. 30
/
THEFRONTOFTHE
TO _1/8"DIAMETERDRILLHOLE
iI
/
TOTHEFRONTOFTHE_
DOVETAILBASE
17

9) Applyinga smallamountofsoaptothescrewthreadswill makeit easiertothreadthescrewsintotheholes.
10)Lineupthefront ofthemountingboardwiththefrontof a workbenchor othersturdysurface,
11)Usingtwo clamps,suchasC-clamps,firmlyclamptheDovetailFixtureto theworkbenchbyclampingonthemountingboardasshownIn
Figure31andFigure31A.
12)Makesurethatthemountingboardlinesupwiththefrontoftheworkbench.
Fig. 31
CLAMPHERE\\k•FRONTSURFACEOF
THEMOUNTtNG
BOARD
;URFACEOF
THEWORKBENCH
FRONTSURFACEOFTHEBASE
Fig. 31,4
FRONTSURFACEOF -]
THEBASE
FRONTSURFACEOFTHE/
MOUNTINGBOARD
FRONTSURFACEOF/
THEWORKBENCH
USINGTHEDOVETAILFIXTURE
STYLES OF DOVETAILJOINTS
FourdifferentstylesofdovetadjointscanbemadewiththeDovetailFixtureusingyourrouter.
• Thesejointsaredescribedinthefollowingsections.
Half Blind Flush Joint:
• TheHalfBlindFlushJointis usedwhentheheightofboththedrawerfront andthedrawerbackisthesameheightasthedrawersides;
andthelengthofboththedrawerfrontandthedrawerbackisthesameasthewidthofthedrawer.
SeeFigure32.
18

NOTE:THENORMALDEPTHOFCUTFORAHALFBLINDFLUSHJOINTIS3/8". _DRAWERFRONT(PtNPtECE)
Fig. 32
DRAWERSIDE(TAILPIECE)
J
DRAWERBACK(PiNPIECE)_
SIDE(TAILPIECE)
HALFBILHDFLUSHJOINT
HalfBlindFlushOffsetJoint:
TheHaftBlindFlushOffsetJointis usedwhen:
Theheightof boththedrawerfrontandthedrawerbackisthesameheightasthedrawersides;thetengthofthedrawerfrontis 1/8"
longer(1/16"onaside)thanthewidth ofthedrawer;andthelengthofthedrawerbackisthesameasthewidth ofthedrawer.
SeeFigure33.
Toobtaintheoffset,cuta 1t16"deepby3/8"widerabbetontheoppositeendsontheinsideofthedrawerfront.
NOTE:THENORMALDEPTHOFCUTFORAHALFBLINDFLUSHOFFSETJOINTIS3/8",
Fig. 33 _DRAWERFRONT(PINPIECE)
DRAWERSIDE(TAILPIECE)
DRAWERStDE(TAILPIECE)
TAILS
J
DRAWERBACK(PINPIECE)J_
HALFBILNDFLUSHOFFSETJOINT
19

HalfBlindRabbetedJoint:
TheHalfBlindRabbetedJointis usedwhen:
thedrawerfrontoverlapstheopeningforthedraweron allfoursidesoftheofthedraweropening(top bottom andtwosides)thatis;
thelengthofthedrawerfrontis3/4 longer(3/8"on aside)thanthewidthofthedrawer;theheightofthedrawerfrontisalso3/4"higher
(3/8°onside)thantheheightofthedrawer;thetengthofthedrawerbackisthesameasthewidthof thedrawer;andtheheightofthe
drawerbackisthesameastheheightofthedrawer
SeeFigure34
Toobtainthisjointcuta3/8"deepby3/8"widerabbetaroundtheinsideperipheryofthedrawerfront
NOTE:THENORMALDEPTHOFCUTFORAHALFBLINDRABBETJOINTIS3/8", /DRAWERFRONT(PiNPIECE)
Fig.34 "WIDERABBETAROUNDTHE
PERIPHERYOFTHEDRAWERFRONT
DRAWERSIDE(TAILPIECE)\\
DRAWERSIDE(TAILPIECE)
TAILS
DRAWERBACK(PINPIECE)
HALFBLINDRABBETEDJOINT
Openor ThroughJoint:
• TheOpenorThroughJointissimilartotheHalfB{indJoint exceptthatjointseamsarevisibieonthefront,back,andsidesofthe
workpiece;on theHalfBlindJoints,theseamsarevisibleonlyonthesidesoftheworkpiece,
•Althoughthisstyleofjointcanbealsousedfor drawersits mostpopularuseisfor makingboxes,andsmallandfargochests
•Theheightof boththefrontandthebackofthedraweror chestisthesameastheheightasthesidesof thedraweror chest;
andthelengthofboththefrontandthebackofthedraweror chestIsthesameasthewidthofthedrawerorchest
SeeFigure35
NOTE:THEDEPTHOFCUTISDETERMINEDBYTHETHICKNESSESOFTHEFRONT,BACKANDSIDEPIECES,
• Thefrontandbackpieces(sometimescalledpin pieces")arecut independentlyfrom thesidepieces(sometimescalledtail pieces)
• The'tail pieces arecutfirst usingoneedgeofthetemplateanda dovetailrouterbit Thedepthof cutis equaltothethicknessofthe
pin pieces
The'pin pieces'arecutnextusingtheotheredgeofthetemplateanda straightrouterbit Thedepthof cutis equa{tothethicknessofthe
taiI pieces Adjustmentsaremadeatthispointtoobtainjoint fit
Fig.35 _TAILS ii FRONT(PtNPtECE)
TAILS --____ I \ RIDE(TAILPIECE)
OPEN(THROUGH)JOINT _-_-_ BACK(PtNPIECE)
2O