Woodhaven 7902 User manual

7902
Dado Jig
Owners Manual
Please Read Carefully!
Part# Description Qty.
5864 1-5/8” Ratchet Knob 2
Part# Description Qty.
HB030 1” Bolt 6
Part# Description Qty.
MB020 1/4-20 x 1/2” Screw 36
Part# Description Qty.
MF035 10-24 x 1/2” Screw 2
Part# Description Qty.
5760B Oval Nut 42
7902 Dado Jig
Hardware List:
Identify and verify that you have all of the
hardware shown below prior to assembly.
Please read the instructions at least once,
familiarizing yourself with the parts
before beginning. You’ll need to supply a
#2 Phillips screwdriver for assembly.
7902 Parts List:
Parts listed below are shown in photos in the instructions:
Part Description Quantity
4412 12” Ultra Track . . . . . . . . . . . . . . . . . . . . 1
4424 24” Ultra Track . . . . . . . . . . . . . . . . . . . . 1
4436 36” Ultra Track . . . . . . . . . . . . . . . . . . . . 1
7900T 36” Ultra Track with 2 holes . . . . . . . . 1
7900A 1/4” MDF Fence . . . . . . . . . . . . . . . . . . . 2
7900B 3/4” Edge Fence . . . . . . . . . . . . . . . . . . . 1
7900C 2 pc. Bracket Set. . . . . . . . . . . . . . . . . . . 1
7900E Work Stop ........................2
7900G Plate Guide .......................1
7900P Router Plate .......................1
4973 Router Plate Hardware . . . . . . . . . . . . . 1
Part# Description Qty.
5540 Knob 6
Part# Description Qty.
BUSH002 1/4" Spacer 14
Part# Description Qty.
5785 5/32” Allen Wrench 1
Part# Description Qty.
MF015 1” Screw 4

ATTACH BRACKETS
 AttachtheBrackets(7900C - 2 pc. set) toeachendofthe36”UltraTrack(4436 - Stationary
Track) asshown.Inserta1/2”screw(MB020)throughthe6holesindicatedon
eachBracketandstartanovalnut(5760B - flat side first) oneachscrew.
TheendofeachBracketshouldbeflushwiththeendofthetrackandsquaretothe
longedgeofthetrack.TightenthescrewsusingtheAllenWrench(5785).
1
ATTACH MDF SUB-FENCES
 Identifythe36”UltraTrack(7900T) withaholeinthecenterslotneareitherend.
ThisistheAdjustableTrackandshouldbeplacedontherighthandside.Attach
anMDFSub-fence(7900A) toeach36”UltraTrack(4436 & 7900T).
Inserta1/2”screw(MB020)throughtheholesindicatedoneach
Sub-fenceandstartanovalnut(5760B - flat side first) oneach
screw. AttachtheSub-fencestotheUltraTracksasshown,
withtheovalnutscapturedinaT-slotclosesttothe
longedgeofthetracks.RoughlycentertheSub-
fencesonthelengthofthetrackandsnug
thescrewsusingtheAllenWrench
(5785).SettheAdjustable
Trackasidefornow.
4436 - Stationary Track
Stationary Track
Brackets x2
7900T - Adjustable Track
7900A x2
MB020 x4
5760B x4
Thru Hole
Thru Hole
MB020 x6
5760B x6
90°
90°
5864 x2
BUSH002 x4
5760B x2
ATTACH ADJUSTABLE TRACK
LaytheAdjustableTrackontheBracketsandaligntheholeneareachendoftheAdjustable
TrackwiththeslotineachBracket.TheoverhangingedgesoftheMDFSub-fencesshould
befacingeachotherbetweentheAdjustable&StationaryTracks.Iftheholesinthe
AdjustableTrackdon’tlineupwiththeslotsintheBrackets,loosenandreadjust
oneoftheBracketsontheStationaryTrack(keeping it square to the
Stationary Track) untiltheholes&slotsalign.Installtwo1/4”bushings
(BUSH002) oneachRatchetHandle(5864).InserttheRatchet
HandlethroughtheholeintheAdjustableTrackandthruthe
slotintheBracket.SecureitwithanOvalNut(5760B -
flat side first)capturedintheslotoftheBracket.
Adjustable Track
1
2
3

2
6.5”
MB020 x16
5760B x16
Work Stops x2
MF015 x4
7900B x1
5760B x4
HB030 x2
7900E x2
BUSH002 x2
5540 x2
ATTACH BACK & FRONT FENCES
Install1/2”screws(MB020)throughthe8countersunkholesineachTrackBracket(reposition the
Adjustable Fence as necessary)andstartanovalnut(5760B - flat side first) oneachend.
Installthe12”BackFence(4412) and24”FrontFence(4424) UltraTrackstothe
BracketsasshownbycapturingtheovalnutsintheT-slotsinthetrackfacesand
slidingthemintoplace.Centerthe12”BackFenceend-toendontheBracket.
KeeptheinnerlongedgeoftheUltraTrackflushwiththelongedgeof
theBracketandtightenthescrewsusingtheAllenWrench(5785).
Locatetheendofthe24”FrontFence6-1/2”fromtheendof
theBracketneartheStationaryFence.
AligntheinnerlongedgeoftheFront
Fenceflushwiththelonginneredge
oftheBracketandtightenthescrews
usingtheAllenWrench(5785).
ATTACH WORK STOPS & EDGE FENCE
TheWorkStopsattachtotheedgesofthe36”UltraTracksasshown.
Slidetheheadofa1”hexbolt(HB030) intotheoutsideT-slotontheedgeofeach36”Ultra
Track.PlacetheWorkStop(7900E - raised side first & overhanging end facing down)
oneachbolt,a1/4”bushing(BUSH002) andaKnob(5540),thentighten.
Installthefour1”flatheadscrews(MF015)thruthefour
countersunkholesinEdgeFence(7900B) andstartanoval
nut(5760B - flat side first) oneachscrewend.
InstalltheEdgeFenceintheT-slot
inthefrontedgeofthe24”Front
Fenceasshown.Centerend-to-end,then
tightenthescrewsusingaPhillips
screwdriver(not provided).
24”
Front
Fence
12” Back
Fence
HB030 x4
BUSH002 x8
5540 x4
ATTACH ROUTER PLATE STOPS
 AttachtheRouterPlateStopsbyslidingtheheadoftwo1”hexbolts(HB030) into
theinnermostT-slotofeach36”UltraTrack.Placetwo1/4”bushings(BUSH002)
oneachbolt,thenstartaKnob(5540)oneachboltandtighten.
5
4
6

3
ATTACH PLATE GUIDE & ROUTER TO PLATE
 AttachthePlateGuide(7900G) totheRouterPlate(7900P)usingthe1/2”
screws(MF035) andaPhillipsscrewdriver(not provided).Followthedirections
inthe4973 Plate HardwareandattachyourroutertotheRouterPlate(7900P).
Anytypeofroutercanbeusedbut,tocutstoppeddadoes(dadoes that don’t
exit the edge(s) of the workpiece),you’llneedtouseaplungerouter.
 AnoptionaldrillstyleRouterPlate(PN 7900PD)is
availableforsemi-permanentmountingofyourrouter,but
itrequiresdrillingmountingholesintheRouterPlate.
7
8
SIZE 1/4” FENCES
Loosenthe1/4”MDFFences,re-positionthemsotheirfrontendsareslightly
overlappingthefrontoftheEdgeFenceandtightenthescrews.

SELECT ROUTER BIT - IMPORTANT!!!
 Forbestresultswerecommendour13700 1/2” Downshear bitforusewiththisjig,
howeveranybitupto3/4”diameterwillwork.Tocutthedadointwopasses,thebit
diametercan’tbelessthenhalfthewidthofthedado.Ifyourdadoiswiderthan
twicethebitdiameter,you’llhavetomakeextrapasses.
A3/4”bitwillcutdadoesupto1-1/2”wide,a1/2”
bitupto1”,andsoforth.Smallerdiameterbits
maylimitthedepthofthedadoyou’reabletocut.
Once you select a bit, the jig should never be used with
another bit without A) Installing another set of 1/4” MDF
Fences (7900A) and going through the sizing operation. Or B)
Removing & rotating the 7900A’s 180º and sizing the new edge.Install
thebitinyourrouterandsetthedepthofcuttojustbelowthe1/4”Fences.
SIZE 1/4” FENCES - CONT
  Ripapieceof3/4”thickscraproughly1-1/2”widex24”long.Place
itbetweentheStationaryandAdjustableTracks,restingontopofthe1/4”MDF
Fences.LoosentheknobsontheAdjustableTrackandslideitovertowardsthe
StationaryTrack,withthe1-1/2”widescrapbetweenthem.Tightenthe
knobsateachendoftheAdjustableTrackandremovethescrap.
1-1/2”
Wide
Scrap installed
between
tracks, on
top of fences
MF035 x2
7900G
7900P
4973

4
1
4
2
3
SIZE 1/4” FENCES - CONT
 TemporailaryremovetheEdgeFence.PlacetheRouter/RouterPlateontheTrackswith
thePlateGuidebetweenthe36”UltraTracks.AdjustthefrontandbackStopssotherouter
bitwon’tstriketheFrontorBackFences.

ClamptheDadoJigtoaworkbenchusingclamps(not provided).
Temporarilyplacesomescrapsof3/4”thickmaterialunderthe
centerportionoftheStationary&AdjustableTracks/1/4”Fences
tosupportthemasyouusetheroutertosizethe1/4”Fences.
Re-installtheEdgeFence
oncecompleted.
SIZE 1/4” FENCES - CONT
1.PlacetheRouter/RouterPlateontheDadoJigagainstthebackRouterPlate
Stops(make sure bit is not touching the 1/4” MDF Fence).
2.WiththePlateGuidebetweentheStationary&AdjustableUltraTracks,turntherouteron
and,whileholdingtheedgeofthePlateGuideagainsttheinsideedgeofthe
AdjustableTrack,pulltherouterforwardalongtheAdjustableTrack.
3.WhenyoucontactthefrontRouterPlateStops,slidetherouterto
theleftsothePlateGuideisagainsttheStationaryTrack.
4.WhileholdingtheedgeofthePlateGuideagainsttheinside
edgeoftheStationaryTrack,pushtherouterrearwardalong
theStationaryTracktothebackRouterPlateStops.
The1/4”MDFfencesarenowsizedtoyourrouterbitand
youarenowreadytocutdadoeswiththeDadoJig.
ReattachtheEdgeFencetothe
FrontFence.

5
SETUP FOR DADO WIDTH
 Clamp,orbolt,theFront&BackFencesoftheDado
Jigtotheworkbench.AlwayscheckthattheFrontFenceis
squaretotheStationaryTrackbeforebeginning.

Selectthesetupworkpieceyouwanttocutthedadofor.
LoosentheAdjustableTrackandplacethesetup
workpieceonedgeverticallybetweenthesized
1/4”MDFFences.PositiontheAdjustable
Tracksotheworkpieceissandwiched
snuglybetweenthesized1/4”MDF
Fences,tightenthetwoknobs
ontheAdjustableFenceand
removethesetupworkpiece.
Workpiece sets dado
width by indexing
between 1/4” Fences
ButtthetwoWorkStopsagainstthebackedgeof
theworkpiecetobedadoedandtightentheknobs.
TheseholdtheworkpieceagainsttheEdgeFence.
Clamptheworkpiecetotheworkbench,orclamp
stopstotheworkbenchoneithersideofthe
workpiece,toholdit’spositionwhiledadoing.

6
DADO JIG OPERATION
1.PlacetheRouter/RouterPlateontheDadoJigagainstthebackRouterPlateStops(make sure the bit
doesn’t touch the workpiece),withthePlateGuidebetweentheStationary&AdjustableUltraTracks.
2.Turntherouteronand,holdtheedgeofthePlateGuideagainsttheedge
oftheAdjustableTrackasyoupulltherouterforward.
3.WhenyoucontactthefrontRouterPlateStop,slidetheroutertotheleftso
thePlateGuideisnowheldagainsttheStationaryTrack.
4.PushtherouterrearwardtothebackRouterPlateStop.
1
4
2
3

7
DADO JIG STOP ACCESSORIES
 TheFrontTrackoftheDadoJigcanbeextendedononeorbothends.TheExtensioncanbeorderedasa24”inch
Extension(7924 shown)ora48”Extension(7948).BothExtensionsincludeaTrackConnector(4536).TheExtensionallows
youtoattachWorkStopstotheextralengthoftracktomakecuttingmultipledadoesonsamesizeworkpieceseasier.
 TheExtension(7924 or 7948) doesnotincludeanyFlipStops,(789S)whichcanbeorderedseparately. Anaccessory
totheFlipStopistheMicroAdjuster(4523). ItattachesdirectlytotheFlipStopandallowsupto5/8"offineadjustment.
©Copyright WOODHAVEN INC. 5/21/15
[phone] or WWW.WOODHAVEN.COM
7924 24”
Fence
Extension
4536 Track
Connector
789S Flip Stop
789S Flip Stop
789S Flip Stop
with 4523
Micro Adjuster