Porter-Cable 4212 (29550) Saw User Manual
Contents
1. DRAWERS Tips for making drawers Tails A Fig O1 are cut into the sides of the drawers while pins B Fig O1 are cut into the fronts and backs of drawers You can use either solid wood or plywood for the drawer bottoms A Fig O2 Insert the bottoms in a groove along the bottom of the 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 O2 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 Figs O5 and O6 HALF BLIND DOVETAILS HALF BLIND DOVETAILS RIGHT WRONG GROOVE ALIGNED WITH TAIL GROOVE NOT ALIGNED WITH TAIL 14 BASIC JOINTS THROUGH DOVETAILS The through dovetail has a look that is visually appealing especially in boxes and chests NOTE For miniature through dovetails use the 4215 accessory kit Cut both the pins and tails in the vertical position Cut the tails first Use two routers if possible one for the pins and the other for the tails to make the process quicker and easier If you are using the 4210 dovetail jig you will need the 4213 accessory kit2. GEORGIA Forest Park 30297 Atlanta 5442 Frontage Road Suite 112 Phone 404 608 0006 Fax 404 608 1123 ILLINOIS Addison 60101 Chicago 400 South Rohlwing Rd Phone 630 424 8805 Fax 630 424 8895 KANSAS Overland Park 66214 9201 Quivira Road Phone 913 495 4330 Fax 913 495 4378 MARYLAND Elkridge 21075 Baltimore 7397 102 Washington Blvd Phone 410 799 9394 Fax 410 799 9398 MASSACHUSETTS Franklin 02038 Boston Franklin Industrial Park 101E Constitution Blvd Phone 508 520 8802 Fax 508 528 8089 MICHIGAN Madison Heights 48071 Detroit 30475 Stephenson Highway Phone 248 597 5000 Fax 248 597 5004 MINNESOTA Eden Prairie 55344 9709 Valley View Road Phone 952 884 9191 Fax 952 884 3750 MISSOURI St Louis 63146 11477 Page Service Drive Phone 314 997 9100 Fax 314 997 9183 NEW YORK Flushing 11365 1595 N Y C 175 25 Horace Harding Expwy Phone 718 225 2040 Fax 718 423 9619 NORTH CAROLINA Charlotte 28270 9129 Monroe Road Suite 115 Phone 704 841 1176 Fax 704 708 4625 OHIO Columbus 43229 1948 Schrock Road Phone 614 895 3112 Fax 614 895 3187 Parma Heights OH 44130 6485 Pearl Road Phone 440 842 9100 Fax 440 884 3430 OREGON Portland 97230 14811 North East Airport Way Phone 503 255 6556 Fax 503 255 6543 PENNSYLVANIA Willow Grove 19090 Philadelphia 520 North York Road Phone 215 658 1430 Fax 2
3. Note Rockler may not carry all products and or sizes listed in this vendor s publication INSTRUCTION ESPANOL PAGINA 27 MANUAL FRANGAISE PAGE 51 DOVETAIL JIG MODELS 4210 amp 4212 29550 To learn more about Porter Cable IMPORTANT visit our website at Please make certain that the person who is to use this equipment carefully reads and understands these instructions before starting operations The Model and Serial No plate is located on the main e housing of the tool Record these numbers in the spaces below and retain for future reference PROFESSIONAL POWER TOOLS Model No http www porter cable com Type Serial No Copyright 2004 Porter Cable Corporation RTD10000210AA Part No A05065 05 27 05 TABLE OF CONTENTS SAFETY GUIDELINES 1c en ddd Ee eee cedi eene egy 3 IMPORTANT SAFETY INSTRUCTIONS o 0 scssesssssesssecescscesessessessessecsccuccuccucessssessessececceccuccuecaseneensecsececceceeeeseententenensess 3 ADDITIONAL SPECIFIC SAFETY RULES cccccccscsssesssessseseseseseseseseseseseseseeeseseseceeeseeeseueeseeeeseseeesceeeeseneaeecseaeaeaeaeaeaeaes 4 BACKGROUND INFORMATION Dovetail and Box Joint OvervieW usvssssscssssesssssssessesessessssessessssessscsssessecscsessecussessesussessecussessesussessesusseenesussesseaussecusausseaneeesaeeneans 5 Product Capabilities icsn bonesas aieiaa AAR n R AR R RARE i 6 4200 Series Dovetail Jig Over
4. S SOLE LIABILITY UNDER THIS OR ANY IMPLIED WARRANTY AND UNDER NO CIRCUMSTANCES SHALL PORTER CABLE BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other legal rights which vary from state to state 26 PORTER CABLE e DELTA SERVICE CENTERS CENTROS DE SERVICIO DE PORTER CABLE e DELTA Parts and Repair Service for Porter Cable Delta Machinery are Available at These Locations Obtenga Refaccion de Partes o Servicio para su Herramienta en los Siguientes Centros de Porter Cable Delta ARIZONA Phoenix 85013 2906 4501 N 7th Ave Phone 602 279 6414 Fax 602 279 5470 CALIFORNIA Ontario 91761 Los Angeles 3949A East Guasti Road Phone 909 390 5555 Fax 909 390 5554 San Diego 92111 7290 Clairemont Mesa Blvd Phone 858 279 2011 Fax 858 279 0362 San Leandro 94577 Oakland 3039 Teagarden Street Phone 510 357 9762 Fax 510 357 7939 COLORADO Denver 80223 700 West Mississippi Ave Phone 303 922 8325 Fax 303 922 0245 FLORIDA Davie 33314 Miami 4343 South State Rd 7 441 Unit 107 Phone 954 321 6635 Fax 954 321 6638 Tampa 33634 4909 West Waters Ave Phone 813 884 0434 Fax 813 888 5997
5. on the far right A Fig H5 11 TEMPLATE GUIDES Use the correct template guides provided with this unit to guide the router against the template fingers To determine the proper guide for a given joint place the template guide in the slot on the left side of the corresponding template The guide should have a snug fit in the slot ROUTER BIT DEPTH DISCONNECT THE ROUTER FROM THE POWER SOURCE BEFORE MAKING ANY CHANGES OR ADJUSTMENTS The depth of cut for the router bits is critical for a good fitting joint The 4200 series jigs have patented router bit depth guides that allow the user to quickly and easily set the bit to the correct depth without measuring Rest the router on the left side of the template and gently lower the router bit until it touches the guide Multiple depth guides are provided on the jig because different joints require different depth settings NOTE Attach the templet guide with the lock nut and the bit to your router using the instructions in your router s operating manual Step 1 Lower the bit just past the edge of the templet guide Fig K1 Step 2 Use the slot with the corresponding scribed text on the template that matches the joint you will cut Fig K2 Step 3 Place the router on the template with the guide and bit in the selected slot Fig K3 Step4 Lower the router bit A Fig K4 on the depth guide B and lock the position on your router wee Tails Box Depth I Li lox
6. 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 14 DISCONNECT TOOLS when not in use before servicing and when changing accessories such as blades bits cutters etc 15 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 3 16 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 17 OUTDOOR USE EXTENSION CORDS When tool is used outdoors use only extension cords marked Suitable for use with outdoor appliances store indoors when not in use If an extension cord is to be used outdoors it must be marked with the suffix W A or w following the cord type designation 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 t
7. amp Box Template 4 Template Guide 4 Dovetail Bit 5 Lock nut 5 Straight Bit 6 T handle Hex Wrench 6 Template Guide 2 7 Lock Nuts 2 8 T handle Hex Wrench 10 11 1 Half blind amp Dado Template 1 Through and Box Joint 2 Brackets 2 Template 3 Dado Depth Bracket 2 Brackets 2 4 Half blind Depth Bracket 3 Half Blind Depth Bracket 5 Dovetail Bit 4 Straight Bit 6 Depth Knob 5 Template Guide and Lock Nut 7T Screws 8 6 Hex Nuts 1 8 Hex Nuts 1 7 Screws 6 9 Wrench 8 Depth Knob 10 Template Guide and Lock Nut 9 Wrench Miniature Half blind Through amp Box Template Brackets 2 Template Guide and Lock Nut 2 Half blind Depth Bracket Offset Guide 2 Depth Knob Dovetail Bit Straight Bit Hex Nuts 1 10 Screws 6 11 Wrench ASSEMBLY The 4200 series dovetail jigs come fully assembled from the factory However the accessory templates 4211 4213 4215 require assembly The supplied hex wrench can be used to attach the brackets and router bit depth guides to the template A 3 8 wrench is required to adjust the height of the router bit depth guide ASSEMBLED JIG HEIGHT ADJUSTMENT ADDITIONAL TOOLS REQUIRED The router that you use with this jig must accept the Porter Cable
8. in template guide 9 TIGHTEN TEMPLATE GUIDE LOCKNUT SECURELY 10 SOME WOOD CONTAINS PRESERVATIVES WHICH CAN BE TOXIC Take extra care to prevent inhalation and skin contact when working with these materials Request and follow any safety information available from your material supplier NoOogaPoOnd sa REPLACEMENT PARTS When servicing use only identical replacement parts BACKGROUND INFORMATION DOVETAIL AND BOX JOINT OVERVIEW The dovetail joint is a traditional joint that is both strong and visually appealing This joint has flared protrusions tails that are cut into one board drawer side and protrusions with slanted sides pins that are cut in the other board drawer front or back When the two pieces are joined the tails and pins lock together mechanically so that 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 even made stronger by glue Types of dovetails include through dovetails half blind dovetails rabbeted half blind dovetails mitered through dovetails blind dovetails and mitered dovetails Of these joints the through half blind and rabbeted half blind are the most common NOTE This manual includes instruction for the basic dovetail jig operations Please visit our Web Site at www porter cable com jigs for the supplementary manual that gives instruction for more advan
9. left to right Step 5 Remove the boards from the jig and test for fit NOTE Alternate method for aligning the pin board Use a board with a rabbet the same width as the rabbet on the workpiece R12 FITTING AND TROUBLESHOOTING Fitting and troubleshooting methods for the lipped front half blind dovetail are the same as for the regular half blind dovetail 20 BOX JOINTS Box joints have straight protrusions that interlock and must be held together by glue The large amount of gluing surface provides the strength necessary for large projects NOTE f you are using the 4210 dovetail jig you will need the 4213 accessory kit to make this joint You will need the 4215 accessory kit for the miniature box joints Box joint fingers are spaced in 1 increments 1 2 for miniature ITEMS NEEDED ITEMS NEEDED FOR MINIATURE Through Dovetail and Box Joint Template Miniature Dovetail Template e 1 2 diameter straight bit not provided e 1 4 diameter straight bit not provided Length of the cutter must be at least At least 1 2 long cutter the thickness of the workpiece e 3 8 O D Template Guide 42037 3 4 O D Template Guide 42040 Template Guide Lock Nut 42239 Template Guide Lock Nut 42239 CUTTING THE FIRST WORKPIECE Step 1 Clamp a scrap board A Fig S1 in the upper clamp horizontal mounting position that is the same thickness as the second workpiece Step 2 Use the T handle wrenc
10. lind Depth 12 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 L1 Cuts that are off even one degree will not align correctly Fig L2 Also your workpieces must be flat and not cupped Orient your wood so that end grain is joined to end grain Fig L3 to make the joint strong Using the long grain Fig L4 in the workpiece will result in a weak joint BOARD THICKNESS NOTE You can join two workpieces that are different thicknesses Fig M1 The clamps on the 4200 series jigs will hold wood from 1 4 to 1 1 8 thick Use the following information as a guide to help you decide the thickness of wood for your projects Standard through dovetails cesses Tail Board Range 1 4 to 1 Pin Board Range 1 4 to 3 4 Miniature through dovetails Both Tails and Pins 1 4 to 1 2 Half blind dovetails Standard and Miniature 1 2 to 1 1 8 Half blind dovetail with a lipped front Pin board will change depending on the size of the lip 1 2 to 1 1 8 Standard Box Joints Limited by router bit length ses 1 4 to 1 1 8 Miniature Box Joints 1 4 to 1 2 Dovetail Dados te Cc LR Lee Rete tra 1 4 to 1 1 8 OPTIMAL BOARD WIDTHS Th
11. result in death or serious injury yXe WI Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury Used without the safety alert symbol indicates potentially hazardous situation which if not avoided may result in property damage IMPORTANT SAFETY INSTRUCTIONS Publici Read and understand all instructions Failure to follow all instructions listed below may result in electric shock fire and or serious personal injury SAVE THESE INSTRUCTIONS liti There are certain applications for which this tool was designed Porter Cable strongly recommends that this tool NOT be modified and or used for any application 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 Technical Service Manager Porter Cable Corporation 4825 Highway 45 North Jackson TN 38305 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 extensi
12. then move the horizontal board accordingly The procedure is the same with the 4215 Miniature template except that you move the boards 1 4 TEAROUT REDUCTION Tearout is unwanted splintering of the wood fibers that occurs when a router bit enters exits or skims the edge of wood and is common to all dovetail jigs Tearout cannot be eliminated but it can be reduced by the insertion of additional scrap wood against the workpiece ALIGNING THE TEMPLATES For proper operation you must align the templates correctly from front to back The 4200 series jigs have patented alignment lines to help you align the templates without measuring Some templates have one line Fig H1 while others have several lines to produce multiple types of joints Fig H2 Porter Cable has scribed icons on the templates to indicate which lines go with which joints 3 9 PAlla G Adjust the templates front to back until the alignment line is directly over the point where the horizontal board and the vertical board meet NOTE To be accurate lean over the template and look straight down to align the lines Fig H3 For the joint to be produced correctly loosen the knobs on both sides of the template align the lines hold the template flat with one hand and tighten the knobs with the other Fig H4 NOTE To help align both ends of the template when you are using a narrow workpiece mount an additional piece of wood of the same thickness
13. to make this joint ITEMS NEEDED ITEMS NEEDED FOR MINIATURE Through Dovetail and Box Joint Template Miniature Dovetail Template 17 32 7 Dovetail Bit 43776PC 9 32 7 Dovetail Bit 43777PC 13 32 Straight Bit 43743PC 3 16 Straight Bit 43014PC 3 4 O D Template Guide 42040 with dovetail bit 3 8 O D Template Guide 42037 with dovetail bit 5 8 O D Template Guide 42046 with straight bit 5 16 O D Template Guide 42055 with straight bit Template Guide Lock Nut 42239 Template Guide Lock Nut 42239 CUTTING THE TAILS Step 1 Clamp a spacer board A Fig P1 equal to the thickness of your pinboard in the upper clamp Mount the through dovetail template B on the base with the tails side facing you Step 2 Move the offset guide A Fig P2 to the far left Step 3 Clamp the tailboard A Fig P3 in the lower clamp with the outside surface of the board facing the jig See the section POSITIONING THE WOOD in this manual 15 Step 4 Reposition the offset guide A Fig P4 flush to the vertical board and secure it Step 5 Reposition the scrap board A Fig P5 so that it is flush with the rear edge of the vertical board B Step 6 Align the template using the tails box line A Fig P6 with the line formed where the scrap board B and the vertical board meet C and secure it Step 7 Mount the dovetail bit and 3 4 template guide on the router and set the router bit depth usi
14. 15 658 1433 TEXAS Carrollton 75006 Dallas 1300 Interstate 35 N Suite 112 Phone 972 446 2996 Fax 972 446 8157 Houston 77022 2122 536 East Tidwell Rd Phone 713 692 7111 Fax 713 692 1107 WASHINGTON Auburn 98001 Seattle 3320 West Valley HWY North Building D Suite 111 Phone 253 333 8353 Fax 253 333 9613 Authorized Service Stations are located in many large cities Telephone 800 438 2486 or 731 541 6042 for assistance locating one Parts and accessories for Porter Cable Delta products should be obtained by contacting any Porter Cable Delta Distributor Authorized Service Center or Porter Cable Delta Factory Service Center If you do not have access to any of these call 800 223 7278 and you will be directed to the nearest Porter Cable Delta Factory Service Center Las Estaciones de Servicio Autorizadas est n ubicadas en muchas grandes ciudades Llame al 800 438 2486 6 al 731 541 6042 para obtener asistencia a fin de localizar una Las piezas y los accesorios para los productos Porter Cable Delta deben obtenerse poni ndose en contacto con cualquier distribuidor Porter Cable Delta Centro de Servicio Autorizado o Centro de Servicio de Fabrica Porter Cable Delta Si no tiene acceso a ninguna de estas opciones llame al 800 223 7278 y le dirigir n al Centro de Servicio de Fabrica Porter Cable Delta m s cercano CANADIAN PORTER CABLE e DELTA SERVICE CENTERS ALBERTA Bay 6 2520 23rd St N E Calgary A
15. 42239 for this cut in both the 4210 and 4212 jigs ITEMS NEEDED Mark the centerline A Fig T1 of the dado location on the workpiece Make two marks 3 8 from the centerline of the dado B Fig T1 Insert the workpiece A Fig T2 in the upper clamp horizontal clamping position and place the dado template B on the jig with the dado side facing you Adjust the template so that the lines that you drew in STEP 2 C are aligned exactly with the edges of the slot 23 Step 4 Step 5 Step 6 Set your router bit depth by using either of the three choices A B or C Fig T3 on the left side of the template or by manually setting the router to another depth Slowly rout along the slot from left to right Fig T4 Some deep dadoes may require cutting the bulk of the material with a straight bit Remove the workpiece CUTTING THE TENON BOARD Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Mount a scrap board A Fig T6 in the upper clamp horizontal mounting position Mount the tenon board B Fig T6 in the lower clamp vertical mounting position Make a climb cut from right to left on the front edge of the template Make another cut from left to right along the front edge of the template Remove the tenon board Keep the same end up and turn the board so that the cut side of the board faces the base Repeat STEPS 3 and 4 Remove the tenon board and fit the joint F
16. Cutting the TAS nii reb qoe tr dee a tr a en trn n prie Dti P IC Pi De EH IG RETENTO es codd 19 Cutting Ma Mla m uL 20 Fitting and Troubleshooting 20 BOX QRITo IRI EDT DILDO 21 Cutting the First workpiece PERIE NEN PR PETE CREPE eee eee Ve eT wee aye scere vvv ta vec METS dee eee ee ae ce eve a vue e Ee E Eee CTE Reet 21 Cutting the Second Workpiece d e 22 Dovetail Dados Sliding Dovetails 23 Dado Board 23 TOON BOA M LLL LL LLLI LLL LU LI 24 Fitting and Troubleshooting INNO MA Pe D ED CUI SER C MOM MC TUM IE AEN AMD D CE 24 MAINTENANCE 25 SERVICE 25 ACCESSORIES 25 WARRANTY Vea ex eie e da era OE eoa Peso io 26 ESPANOL ME X 27 FRANGAISE ene acento creer ere rear 51 SERVICE CENTER LOCATIONS Wege s essa se aue eee ce eges a ter E cae ETA ve ees a eoe ea ev aeg eve e bae vae Voy ves esa A ANE E A Back cover SAFETY GUIDELINES DEFINITIONS This manual contains information that is important for you to know and understand This information relates to pro tecting YOUR SAFETY and PREVENTING EQUIPMENT PROBLEMS To help you recognize this information we use the symbols to the left Please read the manual and pay attention to these sections PW Wi Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could
17. FE LOC Sanding Center SANDTRAP amp design SAW BOSS Sawbuck Sidekick SPEED BLOC SPEEDMATIC SPEEDTRONIC STAIR EASE The American Woodshop amp design The Lumber Company amp design THE PROFESSIONAL EDGE THE PROFESSIONAL SELECT THIN LINE TIGER TIGER CUB TIGER SAW TORQBUSTER TORQ BUSTER TRU MATCH TWIN LITE UNIGUARD Unifence UNIFEEDER Unihead Uniplane Unirip Unisaw Univise Versa Feeder VERSA PLANE WHISPER SERIES WOODWORKER S CHOICE Trademarks noted with and are registered in the United States Patent and Trademark Office and may also be registered in other countries Las Marcas Registradas con el signo de y son registradas por la Oficina de Registros y Patentes de los Estados Unidos y tambi n pueden estar registradas en otros pa ses PC7 2 0105 149
18. IND DOVETAILS To produce rabbeted half blind dovetails drawer front cut the pins for a half blind joint after the drawer front has been rabbeted The depth of the rabbet must be deeper than the half blind router bit depth guide NOTE Cut the tails first For miniature half blinds use the 4215 accessory kit Use scrap wood until you are comfortable with the jig Mount the correct offset guides black for the standard and silver for the miniature ITEMS NEEDED ITEMS NEEDED FOR MINIATURE Miniature Dovetail Template 9 32 7 Dovetail Bit 43777PC 3 8 O D Template Guide 42037 with dovetail bit Template Guide Lock Nut 42239 Miniature Offset Guides silver Half blind Dovetail Template 17 32 7 Dovetail Bit 43776PC 3 4 O D Template Guide 42040 Template Guide Lock Nut 42239 CUTTING THE TAILS Step 1 Clamp a scrap board A Fig R1 in the upper clamp horizontal mounting position Use scrap board that is thick enough to prevent the bit from contacting the base 1 2 will work Secure the template B on top of the scrap board Fig R1 Ensure the flatness by holding one hand on the board and using the other to tighten the template knobs Step 2 Move the left offset guide all the way to the left Fig R2 Use the black offset guides for the standard cut and the silver for the miniature cut Step 3 Position and clamp the tail board in the lower clamp vertical mounting position with the outside surface a
19. ITTING AND TROUBLESHOOTING For joints that are too loose move the template toward you and recut the tenon board For joints that are too tight move the template away from you and recut the tenon board 24 MAINTENANCE KEEP TOOL CLEAN Periodically blow out all air passages with dry compressed air Clean all plastic parts with a soft damp cloth NEVER use solvents to clean plastic parts They could possibly dissolve or otherwise damage the material WEAR ANSI Z87 1 SAFETY GLASSES WHILE USING COMPRESSED AIR SERVICE AND REPAIRS All quality tools will eventually require servicing or replacement of parts due to wear from normal use These operations including brush inspection and replacement should ONLY be performed by either an AUTHORIZED PORTER CABLE SERVICE STATION or a PORTER CABLE DELTA FACTORY SERVICE CENTER All repairs made by these agencies are fully guaranteed against defective material and workmanship We cannot guarantee repairs made or attempted by anyone other than these agencies Should you have any questions about your tool feel free to write us at any time In any communications please give all information shown on the nameplate of your tool model number type serial number etc ACCESSORIES A complete line of accessories is available from your Porter CableeDelta Supplier Porter CableeDelta Factory Service Centers and Porter Cable Authorized Service Stations Please visit our Web Site www porter cable com for a c
20. atalog or for the name of your nearest supplier Since accessories other than those offered by Porter CableeDelta have not been tested with this product use of such accessories could be hazardous For safest operation only Porter CableeDelta recommended accessories should be used with this product WARRANTY PORTER CABLE LIMITED ONE YEAR WARRANTY Porter Cable warrants its Professional Power Tools for a period of one year from the date of original purchase We will repair or replace at our option any part or parts of the product and accessories covered under this warranty which after examination proves to be defective in workmanship or material during the warranty period For repair or replacement return the complete tool or accessory transportation prepaid to your nearest Porter Cable Service Center or Authorized Service Station Proof of purchase may be required This warranty does not apply to repair or replacement required due to misuse abuse normal wear and tear or repairs attempted or made by other than our Service Centers or Authorized Service Stations ANY IMPLIED WARRANTY INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WILL LAST ONLY FOR ONE 1 YEAR FROM THE DATE OF PURCHASE To obtain information on warranty performance please write to PORTER CABLE CORPORATION 4825 Highway 45 North Jackson Tennessee 38305 Attention Product Service THE FOREGOING OBLIGATION IS PORTER CABLE
21. ced procedures THROUGH DOVETAILS HALF BLIND DOVETAILS GT RABBETED HALF BLIND DOVETAILS BOX FINGER JOINT A similar joint called a box or finger joint 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 DOVETAIL DADO SLIDING DOVETAIL Tenon The Dovetail Dado or Sliding Dovetail consists of a dovetail shaped dado in one EZ board and a dovetail shaped tenon in the T other board This method is a strong way of connecting fixed shelves to walls PRODUCT CAPABILITIES The Porter Cable 4200 series dovetail jig will help you cut these joints efficiently An accessory kit will enable you to cut miniature versions of these joints for small gift boxes or cubbyhole drawers on a roll top desk The 4200 series also has the capability to cut more advanced joints dovetails that skip pins wood hinges end to end joints various types of angle joints and joints with inlays The specific model capabilities are Jigs 4210 Dovetail Jig half blind half blind with a lipped front and dovetail dados 4212 Deluxe Dovetail Jig through dovetail box joint half blind half blind with a lipped front and dovetail dados Accessories 4211 Accessory Kit includes the template router bit and templet guide included with the mod
22. e 4200 series dovetail jigs are capable of making joints up to 12 However some widths will produce a more attractive joint than others The optimal widths for creating dovetails are in 1 increments plus 1 4 1 1 4 2 1 4 3 1 4 etc Other widths will work but will not be as attractive NOTE If you are using the 4215 miniature accessory kit the optimal widths are in 1 2 increments plus 1 8 5 8 1 1 8 1 5 8 etc BOARD LENGTHS For through dovetails and box joints cut your workpieces to the same length as the outside dimension of your final project However cut the drawer sides tail board of half blind joints as indicated below because the wood does not go all the way through the joint To calculate the length of the half blind tail board take the inside dimension of the final project and add the router bit depth of cut If the tail board has a half blind on both ends double the added dimension The length of the pin boards drawer front remains the same 13 PROJECT LAY OUT 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 N1 Step 2 Label the corners A B C and D Fig N2 Step 3 Label the tail boards drawer sides with a T Fig N3 Step 4 Label the pin boards drawer fronts with a P Fig N4
23. el 4210 4213 Accessory kit incudes all items necessary to provide the 4210 jig with the same capabilities as the 4212 deluxe dovetail jig 4215 Accessory kit contains the template router bits and templet guides to make miniature through dovetails and half blind dovetails JIG OVERVIEW The 4200 series dovetail jigs come equipped with an easy to mount heavy duty steel base A Fig A1 featuring a clamping system designed to hold wood and minimize board slippage during cuts Troubleshooting tips B are provided on each side of the base Three different machined aluminum templates Fig A2 can be used on the jig system to create all joints described in this manual The fingers on each template are used in combination with the template guides Fig A3 to guide the router in the proper motion Additionally each template aids in setting proper board alignment and router bit depth Dovetail bits and straight bits Figs A4 and A5 are used with this jig system CARTON CONTENTS 4210 DOVETAIL JIGS ACCESSORY KITS 4211 4212 1 Base 1 Base 2 Half blind amp Dado Template 2 Half blind amp Dado Template 3 Dovetail Bit 3 Through
24. f blind dovetail is one of the most common types of joints and is the ideal choice for the drawer construction In typical half blind drawer construction the joint is not visible from the front and is invisible when the drawer is closed NOTE For miniature half blinds use the 4215 accessory kit Use scrap wood until you are comfortable with the jig You can cut half blind pins and tails simultaneously on the 4200 series jigs Mount the correct offset guides black for the standard and silver for the miniature ITEMS NEEDED ITEMS NEEDED FOR MINIATURE e Half blind Dovetail Template e Miniature Dovetail Template e 17 32 7 Dovetail Bit 43776PC e 9 32 7 Dovetail Bit 43777PC e 3 4 O D Template Guide 42040 e 3 8 O D Template Guide 42037 with dovetail bit e Template Guide Lock Nut 42239 Template Guide Lock Nut 42239 Miniature Offset Guides silver CUTTING HALF BLIND DOVETAILS Step 1 Clamp the pin board drawer front A Fig Q1 in the upper clamp horizontal mounting position with the outside of the board facing the jig Step 2 Secure the template B on top of the pin board Ensure the flatness by holding one hand on the template and using the other to tighten the template knobs Step 3 Move the left offset guide all the way to the left Use the black offset guides for the standard cut and the silver for the miniature cut 17 Step 4 Clamp the tailboard drawer side in lower clamp vertical positio
25. gainst the jig base Fig R3 Step 4 Make a spacer equal to the rabbet s width Put the spacer A Fig R4 against the left edge of the tail board move the left offset guide B flush against the spacer and secure the offset guide Step 5 Reposition the scrap board C so that it is flush against the offset guide and the back edge of the vertical board Step 6 Align the half blind temp plate line A Fig R5 with the line formed where the scrap board B and the vertical board C meet Step 7 Mount the dovetail bit and template guide to the router and set the router bit depth using the half blind bit depth guide Fig R6 Step 8 Make a climb cut from right to left across the outer edge of the tail board to reduce tear out Fig R7 Step 9 Rout in and out of the fingers of the template from left to right Fig R8 Remove the boards CUTTING THE PINS Step 1 Clamp the pin board in the upper clamp horizontal mounting position with the outside surface against the jig s base Step 2 Secure the template on top of the pin board making sure that it is flat Fig R9 Step 3 Reposition the pin board A Fig R10 so that it is flush to the left offset guide B and the inside edge of the rabbet A Fig R11 is aligned with the half blind alignment line B Lower the router bit on the depth guide and lock the position on your router Step 4 Rout in and out of the fingers of the template from
26. h A Fig S2 to loosen the screw on the left offset guide B Move the guide to the far left Step 3 Mount the workpiece A Fig S3 in the lower clamp vertical mounting position with the outside surface against the jig base 21 Step 4 Step 5 Step 6 Step 7 Step 8 Reposition the left offset guide A Fig S4 flush against the workpiece B Align the template using the tails Box template line with the line formed where the scrap board and the workpiece meet Mount the straight bit and template guide on the router and set the router bit depth using the tails box bit depth guide Rout between the fingers of the jig with the templet guide against the left side of the fingers both in and out This light pressure toward the left will help to prevent loose joints Remove the workpiece from the jig CUTTING THE SECOND WORKPIECE NOTE Step 1 Step 2 Step 3 Step 4 If the thickness is different between the first and second workpiece replace the scrap piece in the upper clamp horizontal Mounting position with another that is the same thickness as the first workpiece Use the T handle wrench A Fig S8 to loosen the screw on the right offset guide B Fig S10 Move the guide to the far right Clamp the first board in the lower clamp on the right side of the jig with the fingers protruding past the template Fig S9 Center the protrusions of the wood in betwee
27. lberta T2E 8L2 Phone 403 735 6166 Fax 403 735 6144 QUEBEC 1515 ave St Jean Baptiste Suite 160 Qu bec Qu bec G2E 5E2 Phone 418 877 7112 Fax 418 877 7123 1447 Begin St Laurent Montr al Qu bec H4R 1V8 Phone 514 336 8772 514 MANITOBA 1699 Dublin Avenue Winnipeg Manitoba R3H 0H2 Phone 204 633 9259 Fax 204 632 1976 ONTARIO 505 Southgate Drive Guelph Ontario N1H 6M7 Phone 519 767 4132 Fax 519 767 4131 BRITISH COLUMBIA 8520 Baxter Place Burnaby B C V5A 4T8 Phone 604 420 0102 604 420 3522 The following are trademarks of PORTER CABLE DELTA Las siguientes son marcas registradas de PORTER CABLE e DELTA S A Les marques suivantes sont des marques de fabriquant de la PORTER CABLE DELTA Auto Set BAMMEF B O S S Builder s Saw Contractor s Saw Contractor s Saw II Delta DELTACRAFT DELTAGRAM Delta Series 20007 DURATRONIC Emc FLEX Flying Chips FRAME SAW Grip Vac Homecraft INNOVATION THAT WORKSS Jet Lock JETSTREAM kickstand LASERLOC MICRO SET Micro Set MIDI LATHE MORTEN NETWORK OMNIJIG POCKET CUTTER PORTA BAND PORTA PLANE PORTER CABLE amp design PORTER CABLE PROFESSIONAL POWER TOOLS PORTER CABLE REDEFINING PERFORMANCE Posi Matic Q 3 amp design QUICKSAND amp design QUICKSET QUICKSET II QUICKSET PLUS RIPTIDE amp design SAFE GUARD II SA
28. n on the left side of the base with the outside of the board facing the jig A Fig Q3 Step 5 Center the board between the farthest finger on the left and the nearest finger on the right of the board Step 6 Move the left offset guide A Fig Q4 flush against the vertical board B and secure it Step 7 Reposition the pin board B Fig Q5 so that it is flush against the offset guide A and the back edge of the vertical board C Step 8 Align the template lines with the intersection of the pin board A Fig Q6 and tail board B Step 9 Set the router bit depth using the bit depth guide A Fig Q7 Step 10 Climb cut from right to left the outer edge of the vertical board Fig Q8 to reduce tearout Step 11 Rout along the fingers of the template Fig Q9 Remove the boards from the jig and test for fit FITTING AND TROUBLESHOOTING For joints that are too loose adjust your router to make a deeper cut Measure the gap A Fig Q10 in the test cut and adjust the router for that amount For joints that are too tight adjust your router to make a more shallow cut Once you achieve the correct depth secure the router bit depth guide in place with a 3 8 wrench If the drawer front overlaps the drawer side reposition the template toward you Fig Q1 1 If the drawer front is recessed from the edge of the drawer side Fig Q12 reposition the template away from you 18 RABBETED HALF BL
29. n the fingers of the templet Move the right offset guide flush against the workpiece and secure it with the T handle wrench Fig S10 Remove the first workpiece 22 Clamp the second workpiece A Fig S11 in the lower clamp vertical mounting position on the right side of the jig flush against both the template B and against the right offset guide C with the outside surface facing away from the jig If the first and second workpieces are of different thicknesses reset the router bit depth using the tails box bit depth guide Rout between the fingers of the jig with the templet guide against the left side of the fingers both in and out This light pressure toward the left will help to prevent loose joints Fig S12 Remove the second workpiece and assemble the joint Fig S13 NOTE The fit tightness of the box joint cannot be adjusted DOVETAIL DADOS SLIDING DOVETAILS Dovetail dadoes sliding dovetails are used primarily in the construction of cabinets entertainment centers and shelving The 4200 series jigs have three preset depths for dadoes 1 4 3 8 and 1 2 but you can manually set your router bit depth to any setting NOTE Becertain that the router bit will not cut into the base or offset guides during this cut Everything is provided CUTTING THE DADO BOARD Step 1 Step 2 Step 3 Dado Template 17 32 7 Dovetail Bit 43776PC 3 4 O D Template Guide 42040 Template Guide Lock Nut
30. ng the tail box depth guide A Fig P7 Step 8 Rout along the template fingers Fig P8 When the cut is complete remove the vertical board NOTE f you prefer for your pins to protrude slightly for easier sanding Adjust your router for a slightly deeper cut Once your optimum depth has been achieved adjust the bit height guide with a 3 8 wrench CUTTING THE PINS NOTE Ifthe pin board is not the same thickness as the tail board replace the scrap piece in the horizontal clamp with a scrap board the same thickness as your tail board Step 1 Remove the template and rotate it 180 degrees so that the pins side is facing you Clamp the pin board in the lower clamp flush against the left offset guide with the outside of the board facing away from the jig Step 2 Align the pins line see the arrows Fig P10 on the template with the line formed where the scrap board and pin board meet and tighten the template in place Step 3 Mount the straight bit and the 5 8 templet guide on the router and set the router bit depth using the pins bit depth guide Fig P11 16 Step 5 Rout between the fingers of the template Fig P12 Step 6 Remove the pin board and check the fit with the tailboard Fig P13 THROUGH DOVETAIL TROUBLESHOOTING For joints that are too loose move the template toward you slightly For joints that are too tight move the template away from you slightly HALF BLIND DOVETAILS The hal
31. o 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 authorized service center Do not use tool if switch does not turn it on and off 20 WEAR ANSI S3 19 EAR PROTECTION to safeguard against possible hearing loss ADDITIONAL SAFETY RULES FAILURE TO FOLLOW THESE RULES MAY RESULT IN SERIOUS PERSONAL INJURY READ AND FOLLOW ALL SAFETY INSTRUCTIONS in the instruction manual supplied with your router SECURE WORK Be sure Dovetail Fixture Jig and work is anchored securely to prevent movement BE SURE CORD SET IS FREE and will not hang up during routing operations KEEP HANDS CLEAR of cutter when motor is running to prevent personal injury MAINTAIN FIRM GRIP on router when starting motor to resist starting torque STAY ALERT and keep cutter free clear of all foreign objects while motor is running BE SURE MOTOR HAS COMPLETELY STOPPED before removing router from Dovetail Fixture Jig and setting Dovetail Fixture Jig down between operations 8 NEVER REMOVE ROUTER MOTOR from router base while template guide and dovetail bit are installed dovetail bit may not fit through hole
32. on 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 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 11 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 12 DON T OVERREACH Keep proper footing and balance at all times 13 MAINTAIN TOOLS WITH CARE
33. rkpieces NOTE Use a scrap board A Fig C2 to prevent misalignment A Fig C3 TEMPLATE MOUNTING You can mount the templates in two positions on the jig s which allows the production of multiple types of joints with each template To reverse a template loosen the template knobs C Fig D1 remove the template B from the base rotate it 180 degrees horizontally replace it on the base and tighten the template knobs NOTE Secure the templates by inserting the template brackets A Fig D2 between the large template knobs B Fig D2 and the brass adjustment knobs C You can then make front to back adjustments by loosening the large template knobs B and rotating the brass adjustment knobs C TEMPLATE SUPPORT For every type of joint place wood in the top clamp whether a workpiece or a scrap piece to provide support for the router on the template You can add extra support by inserting a second board A Fig E1 of the same thickness in the top clamp to ensure that the template is parallel to the base across its length This practice works very well for narrow workpieces PORTER CRBLE _ _ EE Supported Unsupported POSITIONING THE WOOD You must position the workpiece correctly to produce attractive symmetrical joints Use the offset guides to consistently po
34. sition the workpiece for optimal alignment and symmetry Step 1 Clamp the workpiece or spacer board A Fig F1 in the horizontal position The position is not critical but the workpiece must not extend beyond the front edge of the base Step 2 Mount the template Fig F2 on top of the horizontal workpiece Press down on the template A with one hand and tighten the template knobs with the other Step 3 Loosen the left offset guide A Fig F3 with the T handle hex wrench B and move it to the far left position Step 4 Align the vertical workpiece A Fig F4 flush against the bottom side of the template Center and clamp the workpiece between the farthest finger to the left and the nearest finger to the right of the template Step 5 Move the left offset guide A Fig F5 to the right so that it is flush against the vertical workpiece B Tighten the left offset guide with the T handle wrench C Step 6 Unclamp the horizontal workpiece and slide it forward so that it is flush against the vertical workpiece and flush against the left offset guide Fig F6 NOTE The template has been removed for clarity 10 HALF PINS VS HALF TAILS Traditionally dovetails have half pins cut on both ends Fig G1 Half tails will be just as strong but will not be as attractive Fig G2 If your joints are half tails and you want half pins move the vertical board 1 2 either left or right
35. template guides supplied with the jig Adapters and sub bases are available for most routers must have a 1 2 collet for use with 4210 and 4212 jigs and the 4211 and 4213 accessory kits must have a 1 4 collet for use with the 4215 accessory kit NOTE While the jigs and accessory kits include the router bits and template guides to make the basic dovetail joints additional router bits are required to make box joints MOUNTING INSTRUCTIONS NOTE Always mount your jig to a solid work surface You can mount your jig permanently Fig B1 by using the pre drilled holes A Fig B1 on each side of the base or you can mount the base to your work surface using clamps Fig B2 OPERATION Mount your workpiece in the jig properly If the workpiece is not secure it can be damaged when it moves The jigs utilize two mounting positions for workpieces horizontal and vertical Some joints require both while others require the use of a scrap board in the horizontal position upper clamp and the workpiece in the vertical position lower clamp Position your workpiece correctly left to right to produce symmetrical and tight fitting joints Tear out from the router bit can be reduced when scrap wood is positioned properly against the workpiece CLAMPS The 4200 series jigs are equipped with two cam action clamps A Fig C1 with knobs B to adjust for workpiece thickness and levers C for quick clamping and releasing of wo
36. view 7 Carton Contents 7 Assembly ss 8 Additional Tools Required 8 Mounting IniStictlOlS o SERRE me heats US 8 OPERATION lO e 9 Template Mounting I 9 Template Support s 10 Positioning the WOO MH 10 HalfsPinis Vs Half TAil e teta ta e det n Eie RE tti re rin OO 11 Tearout Reduction 11 Aligning the Templates XM AM EIU M MMC UD E ML DM MARI A M RUN D M M M UE 11 RI uel RC Uo lt gt surance ee ep en en rer E gee Renan eer TR Cte ne 12 Router Bit Deepthi 12 WOOD PREPARATION Grain Directi n ote tele RR i ee e eee aca e b e e EH eren 13 Board THICKNESS EE 13 Optimal Board With eects etecessseeessssnecsssnnecsssnsecsssnnecsesnssecssssecssssusrecessnerecsonsestsonerecesaueseetonsncetanenecnsannecessnans 13 Board Lengths ve 13 Project Layout 14 Drawers 14 BASIC JOINTS Through DOVEtAIIS MERC 15 Cutting the Tails mnes nnne enne ntneentnneetnnennnnettineetnne 15 Cutting the Pins 16 Fitting and Troubleshooting RODEO ODER 17 Half Blind Dovetails MERECE 17 Cutting a HalfsBlind Dovetail 5 ttt tete tetto ant trente a aenea roe a sedo 17 Fitting and Troubleshooting S 18 Half Blind Dovetail with a Lipped Front 19
Download Pdf Manuals
Related Search