DOVETAIL JIG No. 860 - Test Equipment Depot
Contents
1. I1 i iB QTY 1 14 1 2 x1 4 Included bearings are 1 2 outside diameter OD Router sleeves or bushings can be substituted as long as they are also 1 2 OD Included router bit is 14 x 1 2 Other bits can be substituted providing they are also 1 2 diameter and their length is no greater than 3 4 USING THE DEPTH GAUGE The depth Gauge is used to set the depth of the Dovetail Cutter during router setup It is also used to control the length of the pins during cutting 1 Loosen the two screws A on the face of the depth gauge 2 Align the top surface B with the desired measurement on the ruled edges C 3 Tighten the two screws A to lock the depth stop in position ROUTER SETUP 1 Install both bearings onto dovetail cutter and insert into Router FIG 5 2 Set the height of the Dovetail Cutter Bit using the Depth Gauge FIG 6 For instructions on setting the depth gauge see USING THE DEPTH GAUGE on page 2 3 FIG 7 shows the dimension of the dovetail joint that the cutter height affects 4 The tightness of the joint the fit between the two boards can be adjusted by raising or lowering the height of the cutter as show in FIG 8 This will be described in greater detail later ral Goms Setting a HIGHER bit height will produce a TIGHTER joint Setting a LOWER bit height will produce a LOOSER joint CUTTING A HALF BLIND DOVETAIL JOINT The PINS side of the joint must be thicke2. HOP CHILDPROOF Use pad locks master switches or remove start keys 9 DON T FORCE THE ROUTER It will do the job better and safer at the rate for which it was designed 10 WEAR PROPER APPAREL No loose clothing gloves neckties or jewelry to get caught in moving parts Nonslip footwear is recommended Wear protective hair covering to contain long hair 11 USE SAFETY GLASSES 12 USE A FACE OR DUST MASK 13 DON T OVERREACH Keep your proper footing and balance at all times 14 MAINTAIN YOUR ROUTER IN TOP CONDITION Keep router bits sharp and clean for best and safest performance Follow instructions for lubricating and changing accessories 15 DISCONNECT YOUR ROUTER BEFORE SERVICING Also when changing bits blades cutters and other accessories 16 USE ONLY RECOMMENDED ACCESSORIES Consult the owner s manual for recommended accessories The use of improper accessories may cause hazards 17 AVOID ACCIDENTAL STARTING Make sure switch is in OFF position before plugging in cord 18 NEVER STAND ON A TOOL Serious injury could occur if the tool is tipped or if the cutting tool is accidentally contacted 19 CHECK FOR DAMAGED PARTS Before further use of the router a guard or other part that is damaged should be carefully checked to ensure that it will operate properly and perform its intended function Check for alignment of moving parts breakage of parts mounting and any other conditions that may affect its operation A guar
3. Test Equipment 99 Washington Street s Melrose MA 02176 oH Phone 781 665 1400 1 800 517 8431 Toll Free 1 800 517 8431 GENERAL La Visit us at www TestequipmentDepot com DOVEIA LER DOVETAIL JIG No 860 USER S MANUAL INTRODUCTION Thank you for purchasing General s DOVETAILER Dovetail Jig A simple and easy way to make professional furniture joints SAFETY RULES FOR A HANDHELD ROUTER AND ROUTERS USED WITH A ROUTER TABLE 1 KNOW YOUR ROUTER Read the owner s manual carefully before use Learn the router s applications and limitations as well as the specific potential hazards involved in its use 2 KEEP GUARDS IN PLACE and in working order 3 GROUND ALL TOOLS Most routers are equipped with a three prong plug and it should be plugged into a three hole electrical outlet If an adapter is used to accommodate a two prong outlet the adapter lug must be attached to a known ground such as the outlet holding screw Never remove the third prong 4 REMOVE ANY ADJUSTING KEYS AND WRENCHES Make it a habit to check that keys and adjusting wrenches are removed from the router before operating 5 KEEP WORK AREA CLEAN Cluttered areas and benches invite accidents 6 AVOID POTENTIAL DANGERS Don t use your router in damp or wet locations or expose them to rain Keep work area well lighted 7 KEEP CHILDREN AND VISITORS AWAY Distractions can easily lead to accidents your own or others 8 MAKE YOUR WORKS
4. cut in multiple segments To align the jig with the previous cut the aligning tool must be used 1 Move the wood in the jig and position the last slot from the previous cut in the last channel of the jig 2 Loosely clamp the wood in the jig 3 Insert the aligning tool into the slot to properly center the wood with the jig FIG 17 4 Tighten the thumbscrews CAUTION DO NOT OVERTIGHTEN and continue cutting 5 Repeat as necessary ROUND OVER FACE JOINTING 1 In order to join two pieces of wood using a Dovetail Joint the round over created by the dovetail jig must be avoided FIG 18 2 Insert the first board into the TAILS section of the Dovetail Jig along with a thin piece of scrap to offset the first board and the jig FIG 19 3 Align one edge of the board to be cut with the outside edge of the jig FIG 20 4 Tighten the thumbscrews CAUTION DO NOT OVERTIGHTEN and make all cuts 5 Insert the second board into the jig along with the scrap wood and offset one edge of the board 1 2 from the outside edge of the jig This spacing will offset the TAILS of the second board so that they align with the slots cut into the first board FIG 21 en e SS ee Test Equipment Depot 800 517 8431 99 Washington Street Melrose MA 02176 FAX 781 665 0780 TestEquipmentDepot com 5
5. d or other part that is damaged should be properly repaired or replaced 20 ROUTER TABLE DIRECTION OF FEED Feed work into the cutter 21 NEVER LEAVE THE ROUTER RUNNING UNATTENDED Turn power off and stay with router until it comes to a complete stop Before leaving assure that power cannot be turned on accidentally Use pad locks master switches or remove start keys 22 AVOID DRUGS ALCOHOL AND MEDICATION Do not operate the a router while under the influence of drugs alcohol or medication 1 POINTS TO NOTE BEFORE STARTING e Ensure that the bit is sharp Blunt tools cannot produce good quality work and increase the risk of a kickback and machine overload e Advance the bit evenly and at a moderate pace to ensure longer bit life and to protect against overloads e Cut long sockets in stages if necessary to avoid any buildup of chips e After installation of a new milling bit make sure that it turns easily in the milling position e Check the operation and setting of the tool on a sample piece before using on good wood e Make sure both pieces of wood to be joined are perfectly flat by placing them against one another Warped wood will cause an unsatisfactory joint DOVETAIL JIG ASSEMBLY 1 Remove all components from hardware bag and ensure that all are present and undamaged FIG 1 2 Install thumb screws into tapped holes as shown Screw locations may be adjusted as needed FIG 2 3 Press non marring ends onto thumbscrews FIG 3
6. f adjuster plate Position the wood to be cut by lining up the sides with the first piece FIG 13 12 With the edges of both boards aligned tighten the thumbscrews NOTE THE CAUTION FROM STEP 5 and secure the stock to the bench Remove the TAILS board before proceeding 13 Make all cuts For this cut the router should ride on the surface of the depth plate as shown in FIG 14 Be sure to follow the jig profile as the slots are wider than the cutter bearings This is to allow for a rough and a finish pass 14 Before gluing fit the two sections together The joint should be tight and even with no gaps If problems arise file or trim the joint to improve the fit CUTTING A FULL THROUGH DOVETAIL JOINT This requires a dovetail cutter bit with a greater depth than the wood you are cutting The steps required to cut a full through joint FIG 15 are very similar to those described in the previous section CUTTING A HALF BLIND DOVETAIL JOINT With the following exceptions 1 When cutting the TAILS FIG 15 portion of the joint set the bit depth to slightly greater than the thickness of the PINS board This will ensure that the tails are slightly proud when fit and can be sanded down for a flush fit FIG 16 2 When cutting the PINS portion of the joint set the cutter depth deeper tighter first and adjust to the desired joint fit CUTTING JOINTS WIDER THAN 6 Joints over 6 wide must be
7. r than 1 2 for Half Blind Joints 1 When cutting a half blind dovetail joint use the included 1 2 x 1 2 cutter and start with a bit height setting of 1 2 2 Cut a test joint with scrap wood to confirm the fit of the joint If the boards do not fit together easily the joint may be too tight The joint can be made looser or tighter by setting the cutter depth shallower or deeper as shown in FIG 8 3 Begin with the TAILS side of the joint 4 Center the board in the TAILS portion of the jig with the outside face of the board facing inward FIG 10 5 Tighten the thumbscrews CAUTION DO NOT OVERTIGHTEN THE THUMBSCREWS AS THIS HAS THE ABILITY TO WARP THE JIG 6 Clamp the board to a workbench or secure it in a vice as shown FIG 11 7 Cut the TAILS portion of the joint Be sure to follow the jig profile as the slots are wider than the cutter bearings This is to allow for a rough and a finish pass 8 Now it is time to make the PINS side of the joint 9 Set the depth gauge to the desired length of the PINS This should be slightly greater than the thickness of the wood used for the TAILS board FIG 12 3 Test Equipment Depot 800 517 8431 99 Washington Street Melrose MA 02176 FAX 781 665 0780 TestEquiomentDepot com 10 Loosely clamp the PINS wood into the jig with the outside face pointing inward 11 Insert the TAILS from previous cut into the teeth on the bottom o
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