Porter-Cable 4113 Saw User Manual
Contents
1. Fig 51B _ c PORTER CABLE 29 SETUP WITH THE TEMPLATE MOUNTED TO A CLAMPING BOARD Step 1 Make an angled clamping board according to the drawing Fig 52B Match the angle of the clamping board to the joint angle Step 2 f necessary create flat places on the clamping board parallel with the opposite side so that the Step 3 clamps can grab Attach the template to the clamping board with 10 wood screws Position the angled surface on the side of the template with the straight fingers Fig 52A Fig 52B DRILL PILOT HOLES FOR 10 WOOD SCREWS BOARDS I LX CUTTING THE TAILS Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Cut the end of the tail board according to the instructions in the drawing Fig 53A You can make these cuts on a table saw with the blade beveled Fig 53B Set the miter gauge at 90 for the first cut then use a tenoning jig for the second cut Fig 53C If you use the template mounted to the base of the jig mount the board with the outside face toward the base of the jig Center the edges of the board between two fingers Fig 53D If you use the board mounted template clamp the board with the outside face toward the angled surface of the clamping board Center the board between two fingers Align the template using the tails line If the angle is steep the tails line may not align with the wo2. Hook the straight clamping block over the front and back of the main clamping board Step 5 Secure the pin board by clamping it between the offset and straight clamping blocks Fig 16E Step 6 Loosen the 410 wood screws align the template lines with the line where the pin board and tail board meet and retighten the 10 wood screws Fig 16F DISCONNECT THE TOOL FROM THE POWER SOURCE Step 7 Set the router bit depth using the bit depth guide Step 8 Cut the joint Fitting the joint is identical to a standard half blind dovetail NOTE You can cut the pin and tail board separately if you prefer USING A ROUTER TABLE You can use board mounted templates with your router table However the templates must be inverted Similarly invert all operations setting the router bit etc Use protective handles to keep your hands away from the router bit Grip the handles only on the opposite side of the workpiece Make the protective handles using the dimensions in the drawing Fig 17B Round over the ends of the handles i 2 so that they are comfortable in your hands 4 pO ROUND OVER EDGES gt MAKE FROM 3 4 STOCK DRILL HOLES FOR SCREWS Fig 17B 13 ALTERNATE ROUTER BITS You are not limited to using the router bits supplied with your jig Other router bits can be used to produce a different look or to work with thicker woods Using alternate bits can
3. Step 4 Use a piece of wood the same thickness as the pin board to mark the router bit depth DISCONNECT THE TOOL FROM THE POWER SOURCE Step 5 Set the router bit depth using the pencil mark from STEP 4 Step 6 Connect your router to the power source and cut the pins as far as the template will allow Step 7 Unclamp the templet slide it down and center the last cut between the two angled fingers and reclamp Fig 11D Step 8 Repeat STEPS 6 and 7 until the pins are cut across the entire board Step 9 Remove the pin board and check the fit with the tailboard FITTING THE JOINT Fitting the joint is identical to the previous section Fig 12A ALTERNATE METHOD THROUGH DOVETAILS WITH UNLIMITED BOARD WIDTH This alternate method may be more accurate for correctly cutting the tail and pin boards Step 1 Clamp the tail and pin boards together with a 2 wide block Fig 13A Step 2 Use a square to align an edge of the tail and pin boards Fig 13B Step 3 Cut the pins and the tails as far as the template will allow Fig 13C Step 4 Slide the template aligning the last cut in between the fingers of the template Fig 13D Step 5 Repeat STEPS 3 and 4 until both boards are completely cut 10 HALF BLIND DOVETAILS WITH CLAMPING BOARDS You can mount your half blind template that comes with the 4210 and 4212 jigs and the 4211 accessory kit to a board This method however limits your workpiece width ca
4. 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 Minneapolis 55429 5522 Lakeland Avenue North Phone 763 561 9080 Fax 763 561 0653 MISSOURI North Kansas City 64116 1141 Swift Avenue Phone 816 221 2070 Fax 816 221 2897 St Louis 63119 7574 Watson Road Phone 314 968 8950 Fax 314 968 2790 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 43214 4560 Indianola Avenue Phone 614 263 0929 Fax 614 263 1238 Cleveland 44125 8001 Sweet Valley Drive Unit 19 Phone 216 447 9030 Fax 216 447 3097 OREGON Portland 97230 4916 NE 122 nd Ave Phone 503 252 0107 Fax 503 252 2123 PENNSYLVANIA Willow Grove 19090 Philadelphia 520 North York Road Phone 215 658 1430 Fax 215 658 1433 TEXAS Carrollton 75006 Dallas 1300 Interstate 35 N Suite 112 Phone 972 446 2996 Fax 972 446 8157 Houston 77043 4321 Sam Houston Parkway West Suite 180 Phone 713 983 9910 Fax 713 983 6645 WASHINGTON Auburn 98001
5. For this method you will need a spacer block equal to the thickness of the saw kerf typically 1 8 on a standard saw blade Also make the boards wider than the final size of the box by the same thickness NOTE This method is very similar to making standard through dovetails 22 CUTTING THE TAILS Step 1 Center and clamp the tailboard as normal but use the spacer on the left side of the board A Fig 38A The spacer will cause the board to move slightly off center to the right Step 2 Mark between the two fingers on the template where you want the kerf to be B Fig 38B Step 3 Cut the tails from the far left to the right Stop at the mark Fig 38C Step 4 Remove the spacer and slide the tail board to the left Step 5 Cut the rest of the tails starting with the tail that has the mark Fig 38D CUTTING THE PINS Step 1 Clamp the pin board with the spacer on the left Fig 39A Step 2 Mark the pin the saw kerf will go through Fig 39B Use the tail board for comparison Step 3 Out the tails from left to right Stop right before the mark Fig 39C 23 Step 4 Remove the spacer and slide the pin board to the left Fig 39D Step 5 Start with the pin to the right of the mark and cut the rest of the pins to the right Fig 39E FITTING AND CUTTING THE JOINT Fitting the joint is the same as fitting the standard dovetail Once the box is glued and dried separate the box lid and botto
6. 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 DELTA SERVICE CENTERS ALBERTA Bay 6 2520 23rd St N E Calgary Alberta 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 MANITOBA 1699 Dublin Avenue Winnipeg Manitoba R3H
7. help you produce more advanced joints inlayed dovetails etc Since 1 2 shank bits are stronger and are much less prone to deflection than the 1 4 shank bits we recommend that you use the 1 2 shank bits with the 4210 and 4212 dovetail jigs and with the 4211 and 4213 accessory kits THROUGH DOVETAIL BITS If you choose to purchase alternate through dovetail bits keep in mind the following 1 dovetail bit must have a 7 angle This angle matches the tapered fingers used to guide the straight bit 2 The sum of the diameters of the dovetail and straight bits must equal 15 16 For example a 5 8 dovetail bit must have a 5 16 straight bit the sum of both equalling 15 16 3 The length of the cutter determines the maximum thickness of wood that be cut The length of the cutter on the dovetail bit is the maximum thickness of the pin board The length of the cutter on the straight bit is the maximum thickness of the tail board If your bits have 1 cutters you can make through dovetails with 1 thick boards 4 Purchase bits that will not cut into the template guides The template guide used with the dovetail bit has an inside diameter of 21 32 Use bits that will fit into this dimension Some larger bits might work but with minimal depth Fig 18 5 The inside diameter of the template guide used with the straight bit is 17 32 Use straight bits that are smaller than that dimension DOVETAIL BIT TEMPLET GUID
8. miter will be cut is to the left Step 4 Adjust the board so that only the triangular part of the half pin will be cut off with the router and straight bit leaving a squared off pin Figs 27A and 27B Step 5 For repeated cuts slide the left offset guide until it touches the pin board and secure it Step 6 Cut the triangular area off Fig 27C MITERING THE PINS Step 1 On the inside surface use a square and pencil to draw a line from the base of the pins to the edge where the miter will be cut Fig 28A Step 2 Use a table saw with the miter gauge set to 45 to miter the squared off half pin Figs 28B and 28C 18 MITERING THE TAILS Step 1 On the inside surface use a square and pencil to draw a line from the base of the tails to the edge where the miter will be cut Fig 29A Step 2 Set the table saw blade so that the height of cut of the saw blade is the same as the thickness of the mitered half pin Step 3 Use a table saw with the miter gauge set to 45 to miter the tails You will need to make several passes to cut out the material Fig 29B NOTE A dado head could be used to make this cut in one pass FITTING THE JOINT You may need to trim the miter cuts by hand for a good fit Files chisels shoulder planes and rabbet planes work well Otherwise adjust the tightness of the joint the same as you would for a normal through dovetail THROUGH DOVETAIL SKIPPED PIN METHOD This metho
9. the first cut and use a tenoning jig for the second cut Fig 56B Step 2 Clamp the workpiece as you did for the obtuse angled joint except face the outside surface of the board away from the base of the jig Step 3 Step 3 is identical to Step 5 in CUTTING THE TAILS of the obtuse angled section Step 4 Set the router bit depth to where the step is in the tail board Step 5 Cut the tails and remove the tail board FIRSTCUT THIRD CUT J IF NECESSARY 127 ANGLE BETWEEN BOARDS ye d P ae NSIDE SURFACE OF BOARD OUTSIDE CUTTING THE PINS Step 1 Cut the end of the pin board according to the instructions on the drawing Fig 57 Steep angles or thin wood will make for a weak joint Make this cut on a table saw with the blade beveled and with the miter gauge set at 90 Step 2 Clamp the workpiece as you did for the obtuse angled joint Step 3 Hold the boards together and mark the end of the pin board at the edges of the tails Step 4 The remainder of the steps including fitting the joint are identical to the obtuse angled joint section 32 MAKE ANGLED CUT ANGLE BETWEEN BOARDS N INSIDE 7 OUTSIDE SURFACE SURFACE OF BOARD OF BOARD Fig 57A SLANTED SIDE JOINTS Two boards joined at 90 with one board slanted to the side is known as a slanted side joint This method is used to make a box with the ends at r
10. the outside surface facing away from the clamping board Fig 7A Align the tail board using the instructions in your basic manual in the section OPERATION Look under POSITIONING THE WOOD STEP 4 Step 2 This step is optional Clamp stop blocks to the clamping board for rapid setups of repeated cuts Step 3 Use a small square and a pencil to draw a line along the bottom of the clamping board Fig 7B Align the line with an edge of the tail board This line will be used to set up the pin board Step 4 Use the width of the pinboard to mark the depth of the router bit on the tailboard Fig 7C DISCONNECT THE TOOL FROM THE POWER SOURCE Step 5 Set the router bit depth using the pencil mark from STEP 4 Step 6 Connect your router to the power source and cut the tails Fig 7D 11 E CUTTING THE PINS Step 1 Clamp the pin board with the outside surface facing away from the clamping board Fig 8A Align the edge of the pin board with the line drawn STEP 3 of CUTTING THE TAILS Step 2 This step is optional Clamp stop blocks to the clamping board for rapid setups of repeated cuts Step 3 Use the width of the tail board to make a pencil mark on the pin board for the depth of the router bit DISCONNECT THE TOOL FROM THE POWER SOURCE Step 4 Set the router bit depth using the pencil mark from STEP 3 Step 5 Connect your router to the power source and cut t
11. to the left of the center of the fingers by that amount Fig 10C EXAMPLE IF the board width is 16 1 2 take the 1 2 divide it by two You would then move the tail board to the left of the center of the fingers by 1 4 and clamp it in place Step 4 Use a piece of wood the same thickness as the pin board to mark the router bit depth DISCONNECT THE TOOL FROM THE POWER SOURCE Step 5 Set the router bit depth using the pencil mark from STEP 4 Step 6 Connect your router to the power source and cut the pins as far as the template will allow ak if 1 le Step 7 Unclamp the templet slide it down and center the last cut between the two straight fingers and reclamp Fig 10D Step 8 Repeat STEPS 6 and 7 until the pins are cut across the entire board CUTTING THE PINS Step 1 Clamp the pin board with the outside surface facing away from the clamping board Step 2 If the board is a width in 1 increments 12 13 etc center the edge of the board exactly in line with the finger of the template farthest to the left Fig 11 Step 3 If the board is not in 1 increments take the fraction of an inch that is greater than 1 and divide it by two Then move the pin board to the left of center of the fingers by that amount EXAMPLE IF the board width is 16 1 2 take the 1 2 divide it by two You would then move the tail board to the left of the leftmost finger by 1 4 and clamp it in place Fig 11B
12. 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 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 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
13. 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 1447 Begin St Laurent Montr al Qu bec 1V8 Phone 604 420 0102 Phone 514 336 8772 Fax 604 420 3522 514 336 3505 The following are trademarks of PORTER CABLE DELTA Las siguientes son marcas registradas de PORTER CABLE DELTA S A Les marques suivantes sont des marques de fabriquant de la PORTER CABLE DELTA Auto Set B O S S 5 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 WORKS 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 11 SAFE 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 PROFESS
14. AIL BOARDS THICKER THAN 7 8 For tail boards thicker than 7 8 you can use the template normally used for through dovetails instead of that used for half blind dovetails to provide deeper pins and tails Fig 24 The procedure is the same as that for a normal half blind dovetail NOTE Use the half blind line for aligning the template Fig 24A With the wood clamped to the base of the jig the maximum thickness will be 1 1 8 By using a templet mounted to a clamping board you can use much thicker wood producing a strong joint 17 MITERED THROUGH DOVETAIL You can make a through dovetail with a mitered edge creating a molded edge that goes the whole way to the joint This joint is very attractive on serving trays or decorative boxes without lids NOTE Depending on the depth of the molded edge you may want to make the boards slightly wider to account for the molded depth If so mount the tail board so that the mitered edge will end with the thicker half pin With the offset guide set against the tail board the pin board will automatically be cut correctly CUTTING THE TAILS Cut the tails as you would a standard through dovetail except do not make the tail cut on the edge from the proposed miter CUTTING THE PINS Step 1 Cut all the pins normally Step 2 Remove the template turn it horizontally so that the straight fingers are facing you Step 3 Adjust the board so that the edge where the
15. E ROUTER SUB BASE 7 DOVETAIL BIT DIAMETER THERE IS A MINIMUM DEPTH OF CUT WHEN THE DIAMETER OF THE ROUTER BIT IS GREATER THAN THE INSIDE i DIAMETER OF THE TEMPLET GUIDE Fig 18A THROUGH DOVETAIL BIT COMBINATIONS READILY AVAILABLE DOVETAIL BIT DIAMETER STRAIGHT BIT DIAMETER HALF BLIND DOVETAIL BITS DOVETAIL BIT TEMPLET GUIDE ROUTER SUB BASE The difference in using alternate bits and standard E gt FARO bits in making half blind dovetails is in the depth of A Uf LT cut 2 DEPTH OF CUT FOR A HALF BLIND JOINT Some items to consider when purchasing alternate bits for half blind dovetails are 1 Ashallow angle of the bit requires a deeper cut A steeper angle requires a shallower cut 2 diameter of the bit should be slightly greater than 1 2 The greater the diameter the deeper the cut 3 bit should have a cutting length at least as long as the cutting depth NOTE When using alternate bits ensure that the pin board drawer front is thicker than the depth of cut NOTE When using alternate bits ensure that the bit will not cut into the base of the jig For deep cuts take out most of the material with a straight bit then follow up with the half blind dovetail bit HALF BLIND DOVETAIL BIT READILY AVAILABLE DOVETAIL BIT APP DEPTH OF CUT 17 32 7 17 32 149 9 16 7 5 8 14 Using two different sized dovetail
16. E BLOCKS Step 4 Make the straight clamping block If the workpiece is thinner than 3 4 you will need to modify the dimension Fig 15D Step 5 Make two thickness blocks the same thickness as the pin board Drill a hole big enough for the wood screw to go through Fig SEEN AE T TU 15E Step 6 Assemble the board mounted half blind 2 template Fig 15F NOTE You will not need to remove the half blind depth bracket 1420 s gt 5 Fig 15F ln DRILLA 1 4 HOLE THROUGH THE BLOCK WOOD GRAIN 12 HALF BLIND TEMPLATE 1 2 THICKNESS ITNUT BLOCKS OFFSETCLAMPINGBLOCK I Lu tH L JH STRAIGHT CLAMPING BLOCK MAIN CLAMPING BOARD RU 4 4 WASHER MAKE THIS DIMENSION THE THICKNESS OF THE PIN BOARD MAKE TWO OF THESE BLOCKS omoes THAT IS TO BE DOVETAILED CUTTING THE JOINT Step 1 Clamp the tail board drawer side to the main clamping board with the outside surface facing the board Fig 16A Step 2 Move the offset clamping block to the right until it touches the tail board Fig 16B Tighten the 1 4 20 x 4 bolt that holds the offset clamping block Step 3 Insert the pin board drawer front flush against the tail board and the offset clamping block Fig 16C 12 Step 4 Slide the straight clamping block to the left so that it contacts the pin board Fig 16D
17. IONAL 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 9 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. 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 Wd 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 result in death or serious injury 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 ONL 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 PNG 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 1 KEEP WORK AREA CLEAN Cluttered areas and benches invite injuries 2 AVOID DANGEROUS ENVIRONMENT Don t expose power tools to rain Don t use power tools in damp or wet locations Keep ar
19. SUPPLEMENTARY INSTRUCTION DOVETAIL JIG MANUAL MODELS 4210 amp 4212 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 housing of the tool Record these numbers in the spaces below and retain for future reference PROFESSIONAL POWER TOOLS http www porter cable com Model No Type Serial No Copyright 2005 Porter Cable Corporation Part No A06477 02 23 05 TABLE OF CONTENTS SAFETY GUIDELINES eene ene Ha b eq d dete ect estet 3 IMPORTANT SAFETY INSTRUCTIONS 3 ADDITIONAL SPECIFIC SAFETY RULES nnne ttt tt ttt tnnt tnnt ttt 4 BACKGROUND INFORMATION 4 ES m E 5 MISCELLANEOUS TECHNIQUES 2 ie HON c ME UR UD NER 5 THROUGH DOVETAILS WITH CLAMPING BOARDS nennen 6 THROUGH DOVETAILS WITH UNLIMITED BOARD WIDTH ntn 8 ALTERNATIVE METHOD THROUGH DOVETAILS WITH UNLIMITED BOARD WIDTH 10 HALF BLIND DOVETAILS WITH CLAMPING BOARDS ennt 11 USING A ROUTER 13 ALTERNATE ROUTER BITS eno pecie ee eee 14 HALF BLIND DOVE
20. TAIL TAILBOARDS THICKER THAN 7 8 ntt 17 MITERED THROUGH DOVETAILS ttti 18 THROUGH DOVETAIL SKIPPED PIN METHOD tnnt 19 HALF BLIND DOVETAIL SKIPPED PIN METHOD nnne 20 SAW KERF ALLOWANCE METHOD 22 MULTIPLE SPACER METHOD REA LL En Hee d ra 24 END TO END JOINTS cies ees UEM AME UI MEUM LAM MEE 24 DRAWERS WITH DOVETAIL DADOS teen ttt tttennnni tt tetnennittttteenni tnnt 25 WOODEN HINGES m ee eee eee eas tend 26 ANGLED JOINTS oot steerer AN UHR RUD 29 ACUTE ANGLED JOINTS ee Un NM RUM UE 32 SLANTED SIDE JOINTS ceto dL btt R abandona EE 33 COMPOUND ANGLED JOINTS Rn 34 INLAYED THROUGH DOVE TAILS 37 INLAYED HALF BLIND DOVETAIL JOINTS nnne ttt ttt 38 INLAYED BOX JOINTS R etur aE ud itus 40 TABLES OF COMMONLY AVAILABLE ROUTER BIT SIZES n 41 TROUBLESHOOTING mettent tetti iniiis Kissi AiE as SEEKERS 42 MAINTENANCE EN 42 SERVICE S ERU RR RC MERIDIE MM EUM 42 ACCESSORIES EIL m 42 WARRANTY SERVICE CENTER LOCATIONS nnne 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
21. Use the set with the smaller dovetail bit for the second joint Make sure that the length of the cutter is at least the thickness of the pin board At the same time make sure that the length of the cutter on the straight bit is at least the thickness of the tail board plus the thickness of the inlay line Plane the inlay board the same thickness as the thickness of the pin board plus the thickness of the inlay line from the table above MAKE THE FIRST JOINT Make the first joint the same way that you would make a standard through dovetail Fig 68A If the jig is set up to make through dovetails with the tails and pins slightly protruding or recessed use the alternate method of setting the router bit depth found in the section on MISCELLANEOUS TECHNIQUES Glue the joint together and let it dry 37 CUT OFF THE INLAY BOARD After the joint has dried cut the inlay board to an amount equal to the thickness of the inlay Fig 68B If desired you can cut off the small area shown from the remainder of the inlay wood Fig 68C If left on the completed joint will have an extra amount of material on the inside another alternative is to bevel this extra material Fig 68D MAKE THE SECOND JOINT Make the second joint the same way as you would a standard through dovetail HINT Do not move the offset guides after making the first joint EN i INLAYED HALF BLIND DOVETAIL Make this joint by producing two half blin
22. ard in one of the dados Step 3 Glue a second workpiece to the first Fig 48B Step 4 Repeat Steps two and three for the other half of the hinge Step 5 After the glue dries remove the metal rod Step 6 Round over the ends of the glued boards Step 7 Make the rest of the hinge the same as you would with the 180 Hinge With a Drilled Hole 27 270 HINGES WITH ROUTER MADE GROOVES This method uses two pieces of wood glued together for each hinge half One of the pieces is very short Step 1 Use router to make a half round dado near the end of a board Make the diameter of the groove equal to the diameter of the hinge pin and the depth of cut half the diameter of the hinge pin Fig 49B Round over the ends of the boards Fig 49C Step 2 Cut off the ends of the boards The length of the cut off should be twice the thickness of the board Fig 49D Step 3 Repeat Step 1 for the remaining longer boards Step 4 For both hinge halves glue the short board to the long board with the metal hinge rod in the grooves and sticking out both sides of the wood Fig 49E Step 5 After the glue dries remove the metal rod Step 6 Make the rest of the hinge the same as you would with the 180 Hinge With a Drilled Hole ev 19 PORTER cable R 7 p a E 28 ANGLED JOINTS You can join boards at angles other than 90 Four different methods are shown below by using the through do
23. at described in the section on Half Blind Dovetail Bits with the Pins and Tails Cut Separately under the chapter ALTERNATE ROUTER BITS Use the board from the previous section as the tail board Cut the tail board with the smaller dovetail bit and the pin board with the larger dovetail bit HINT Using two routers to make these joints will make your work easier INLAYED BOX JOINT This joint is made by cutting two box joints on top of each other SETUP Select one set of dovetail bits from the table for Box Joint Bit Combinations in the section TABLES OF COMMONLY AVAILABLE ROUTER BIT SIZES Use the following table to determine the thickness of the inlay line Straight Bit Set Thickness of Inlay Line NOTE If the thickness of the inlay line is very thin you may have difficulty in cutting the inlay correctly You must plane the inlay board to the thickness of the second board plus the thickness of the inlay line MAKE THE FIRST JOINT The first joint is identical to a box joint with alternate router bit sizes as found in the section ALTERNATE ROUTER BITS Make a box joint with the first board and the inlay board Use the larger straight bit with the first board and the smaller bit with the inlay board If the jig is set up to make through dovetails with the tails and pins slightly protruding or recessed use the alternate method of setting the router bit depth found in the section on MISCELLANEOUS TECHNIQUES NOTE Fo
24. base of the jig Step 8 Cut the pins and remove the pin board BLADE TILT ANGLE MAKE ANGLED CUT INSIDE OUTSIDE SURFACE SURFACE OF BOARD OF BOARD FITTING THE JOINT Fitting the joint is the same as fitting the standard dovetail HINT Use pieces of scrap wood the same thickness and species of wood to make test pin boards until the template is adjusted for a perfect fit INLAYED JOINTS The 4200 series dovetail jigs will allow you to make joints with inlays of different colored wood for a very unique look INLAYED THROUGH DOVETAIL The inlayed through dovetail is produced by utilizing 2 through dovetails one on top of the other SETUP Fig 67A Fig Select two sets of router bit combinations from the table for Through Dovetail Router Bit Combinations in the section TABLES OF COMMONLY AVAILABLE ROUTER BIT SIZES Use the following table to determine the thickness of the inlay line Router Bit Set Combinations Thickness of Inlay Line in Approximate Thickness Decimal Measurements in Fractional Measurements T1 amp T2 0 056 7 128 T1 amp T8 0 083 11 128 Use the set with the bigger dovetail bit for the first joint Make sure that the length of the cutter on the bit is at least the thickness of the pin board plus the thickness of the inlay line At the same time make sure that the length of the cutter on the straight bit is at least the thickness of the tail board
25. bits to make half blind dovetails requires separate cuts similar to cutting the rabbeted half blind dovetail This method provides a more hand cut look and is an important step in creating inlayed half blind dovetails Some items to consider 1 The two bits must have the same angle 2 Ashallower angle requires a deeper cut while a steeper angle requires a shallower cut 3 When the diameters of the two bits are added together the sum must be slightly greater than 1 The closer the sum is to 1 the shallower the depth of cut will be The larger the sum the deeper the cut BIT COMBINATIONS FOR SEPARATE HALF BLIND CUTS READILY AVAILABLE LARGER BIT SMALLER BIT APPROX DEPTH OF CUT 3 4 14 1 2 14 9 16 5 8 14 1 2 14 3 8 5 8 7 17 32 7 7 8 5 8 7 9 16 7 1 9 16 7 17 32 7 SETUP The only difference between cutting this joint and cutting the standard half blind is the use of two router bits If you use one router you will have to set the depth of cut for each router bit You can make a simple depth guide as illustrated in Fig 21A If you have two routers you will not have to go through the process of changing the bit each time you make a different cut This method requires however two 3 4 OD template guides and two template guide locknuts available from Porter Cable 15 CUTTING THE TAILS Cut the tail board drawer side similar to cutting the rabbeted half blind dovetail but re
26. cific legal rights and you may also have other legal rights which vary from state to state 43 PORTER CABLE e DELTA SERVICE CENTERS CENTROS DE SERVICIO DE PORTER CABLE 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 Tempe 85282 Phoenix 2400 West Southern Avenue Suite 105 Phone 602 437 1200 Fax 602 437 2200 CALIFORNIA Ontario 91761 Los Angeles 3949A East Guasti Road Phone 909 390 5555 Fax 909 390 5554 San Diego 92111 7638 Clairemnot Blvd Phone 858 277 9595 Fax 858 277 9696 San Leandro 94577 Oakland 3039 Teagarden Street Phone 510 357 9762 Fax 510 357 7939 COLORADO Arvada 80003 Denver 8175 Sheridan Blvd Unit S Phone 803 487 1809 Fax 303 487 1868 FLORIDA Davie 33314 Miami 4343 South State Rd 7 441 Unit 107 Phone 954 321 6635 Fax 954 321 6638 Tampa 33609 4538 W Kennedy Boulevard Phone 813 877 9585 Fax 813 289 7948 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 Woodridge 60517 Chicago 2033 West 75th Street Phone 630 910 9200 Fax 630 910 0360 MARYLAND Elkridge 21075 Baltimore
27. d dovetails on top of each other 38 SETUP Select one set of dovetail bits from the table for Combinations for Half blind dovetails with the pins and the tails cut separately in the section TABLES OF COMMONLY AVAILABLE ROUTER BIT SIZES Use the following table to determine the thickness of the inlay line Dovetail Bit Set Thickness of Inlay Line in Approximate Thickness Decimal Measurements in Fractional Measurements 0 100 13 128 0 050 3 64 0 048 SE 0 028 1 32 SE NOTE If the thickness of the inlay line is very thin you may have difficulty cutting the inlay correctly MAKE THE FIRST JOINT The first joint is identical to that described in the section on Half Blind Dovetail Bits with the Pins and Tails Cut Separately under the chapter ALTERNATE ROUTER BITS Use the inlay material as the pin board normally the drawer front For the first joint cut the tail board with the larger dovetail bit and the pin board with the smaller dovetail bit Glue the joint and let it dry CUT OFF THE INLAY BOARD After the joint has dried cut off the inlay board Cut off the pin board flush with the inside edge of the tail board Fig 71B Then cut off the front edge of the inlay board Fig 71C making sure that the remainder of the inlay A Fig 71D is cut so that the thickness is equal to the thickness found in the table on the previous page 39 MAKE THE SECOND JOINT The second joint is also identical to th
28. d is very similar to cutting standard through dovetails Fig 30A CUTTING THE TAILS Cut the tails as normal except do not cut into the areas where you do not want a pin to appear 19 CUTTING THE PINS Step 1 Hold the pin board against the tail board and mark the edges of the tails on the end of the pin board Step Shade in the areas on the end of the pin board where the tails will be Fig 32B Step 4 Cut all the pins Fig 32C Step 5 Slide the pin board to the right 1 4 Fig 32D Step 6 Cut in between the fingers of the template to cut only in the shaded area A Fig 32D Repeat STEPS 4 and 5 until all of the material between the pins has been removed FITTING THE JOINT Fit the joint the same as you would a standard through dovetail HALF BLIND DOVETAIL SKIPPED PIN METHOD This method is similar to making standard half blind dovetails except that the tails and pins are cut separately Cut the tails first Use a scrap workpiece thick enough to prevent contact with the base of the jig to support the template 20 Step 1 Make a climb cut from right to left Step 2 Cut only between the fingers where you want the pins to be Fig 34A Step 3 Use the router to round over the ends of the cuts Fig 34B Step 4 The joint will hide any accidental excess material cut A Fig 34C Step 5 Use a pencil to mark the location of the ends of the templet fingers on
29. d of the board between the angled fingers of the template Use the PINS line to align the template with the edge of the pin board Set the router bit depth slightly more than the thickness of the tail board Make sure that the bit does not contact the base of the jig Cut the pins and remove the pin board MAKE ANGLED CUT ANGLE BETWEEN BOARDS NS N OUTSIDE INSIDE SURFACE SURFACE OF BOARD OF BOARD FITTING THE JOINT Fitting the joint is the same as fitting the standard dovetail With the angled template fingers facing you move the template toward you for a tighter joint or away for a looser joint 31 ACUTE ANGLED JOINTS An acute angle joint joins two boards together at an angle less than 90 The acute angled joint is very similar in construction to the the obtuse angled joint and can be used with the obtuse angled joint to make boxes with angles other than 90 SETUP Use the same setup as you would for the obtuse angled joint Use 180 minus the joint angle for the insert angle when you make your angled insert or your angled clamping board NOTE If the acute angle and the obtuse angle add up to 180 use the same setup for both joints CUTTING THE TAILS Step 1 Cut the end of the tail board according to the instructions on the drawing Fig 56A Steep angles or thin wood will make for a weak joint Make this cut on a table saw with the blade beveled Set the miter gauge at 90 for
30. dges can make the joints go together easier and may prevent damage to the pins Fig 1B Make the chamfers with a file or a chisel Since the chamfers are located on the inside of the joint they will be invisible ALTERNATE THROUGH DOVETAIL AND BOX JOINT BIT DEPTH SETTING This method of setting your router bit depth on through dovetails or box joints is very accurate for creating pins or tails that are flush and is especially good for inlay work Use a board that is the same thickness as your workpiece to be joined and draw a line Set the router on the template and lower the router bit until it reaches the line Make sure that the scrap material used in the horizontal position to support the template is at least as thick as the router bit depth of cut STOP NUT FOR BRASS ADJUSTMENT KNOB If using the same setup repeatedly you can use a 3 8 16 nut A Fig 3A not supplied to keep the brass adjustment knobs from moving TEMPLATES MOUNTED TO CLAMPING BOARDS You can mount the jig templates to clamping boards and take the templates to the workpiece to make the joint The benefits of this operation are 1 You can maneuver a mounted template onto a large workpiece easier than clamping a large workpiece to the jig This process allows you to join boards wider than 12 by routing a part of the joint sliding the mounted template just past the original cut and routing the remainder of the joint 2 Byusin
31. ea well lit Avoid chemical or corrosive environment Do not use tool in presence of flammable liquids or gases 3 GUARD AGAINST ELECTRIC SHOCK Prevent body contact with grounded surfaces For example pipes radiators ranges refrigerator enclosures 4 KEEP CHILDREN AWAY Do not let visitors contact tool or extension cord All visitors should be kept away from work area 5 STORE IDLE TOOLS When not in use tools should be stored in dry and high or locked up place out of reach of children 6 DON T FORCE TOOL It will do the job better and safer at the rate for which it was intended 7 USE RIGHT TOOL Don t force small tool or attachment to do the job of a heavy duty tool Don t use tool for purpose not intended for example do not use a circular saw for cutting tree limbs or logs 8 DRESS PROPERLY Do not wear loose clothing or jewelry Loose clothing draw strings and jewelry can be caught in moving parts Rubber gloves and non skid footwear are recommended when working outdoors Wear protective hair covering to contain long hair 9 USE ANSI Z87 1 SAFETY GLASSES Wear safety glasses or goggles while operating power tools Also face or dust mask if operation creates dust All persons in the area where power tools are being operated should also wear safety glasses and face or dust mask 10 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
32. en the fingers of the template Fig 64D Step 3 Align the template using the Tails alignment line If the angle is so steep that the Tails alignment line will not work you may have to use an angled clamping board However as long as the rounded part of the fingers go past the edge of the wood the set up will work fine as is Step 4 Set the router bit depth to where the sides of the board go off at a slight angle Fig 64E Step 5 Cut the tails and remove the tail board Fig 64D CUTTING THE PINS Step 1 Cut the end of the tail board according to the drawing Fig 65A Set the miter gauge and tilt the blade to the values in the previous table Remember that the miter gauge for the tailboard must be tilted opposite for the pin board Step 2 If you are using the 12 long angled insert remove it from the jig Step 3 Hold the outside surfaces of the boards together and mark the pin board at the edges of the tail Fig 65B Step 4 Rotate the template so that the angled fingers for cutting the pins is facing you Step 5 Mount the pin board with the outside surface facing away from the base of the jig Center the marks the end of the board between the angled fingers of the template A Fig 65C Step 6 Use the PINS alignment line to align the template with the edge of the pin board Step 7 Set the router bit depth to slightly more than the thickness of the tail board but prevent the bit from contacting the
33. ers can be made with dovetailed dados sliding dovetails Lay out the parts as shown is Fig 44A Assembled the drawers will look the same as Fig 44B The drawer front will have two dados one for each drawer side The drawer sides will have a tenon on the front end and a dado near the rear facing the center of the drawer The drawer back will have a tenon on each end The drawer front and sides will have a cut groove to accept the drawer bottom The drawer back will be cut narrower for ease of inserting the drawer bottom into the drawer Use brads up through the drawer back to fix the drawer bottom in place To hide the joint cut the dado normally but stop before you reach the top Fig 44C NOTE You can clamp a stop to the template if you are making multiple cuts Fig 44C To further hide the joint you can cut the top corner of the tenon off Fig 44A NOTE If the sides and back are the same thickness you can cut all of the tenons with one setup 25 WOODEN HINGES A wooden hinge can be used to make hinged table leafs or hinged legs for a collapsible table The hinge pins are normally are made of stainless steel but you can use other materials including wood for that purpose 180 HINGES WITH A DRILLED HOLE The workpiece for this simple hinge must be narrow enough to make the hole for the hinge pin with a drill bit This hinge has at least a range of motion of 180 Figs 45A and 45B Step 1 R
34. g the clamping boards you can rout boards that are too short to clamp in the jig base allowing you to dovetail small decorative boxes You can make half blind joints in thicker wood than the jig can handle You can make steeply angled joints with the clamping boards 5 You can make joints using a router table by inverting the mounted templates Bo THROUGH DOVETAILS WITH CLAMPING BOARDS You can use both the normal through dovetail template included with the 4212 Jig and the 4213 Accessory Kit and the miniature through dovetail template included with the 4215 Accessory Kit with a clamping board NOTE You can modify these clamping board methods to make box joints SETUP Step 1 Make a clamping board 2 x 3 x 19 Make sure that all four sides are square You may need to glue thinner sections of wood together and rorstowoop screws plane them to make the 2 board Step 2 Drill the pilot holes for 10 screws on the face of the board as indicated in the drawing Fig 6A Step 3 Remove the brackets from the template Fig 6B Step 4 Align the lines of the template with the edges of the clamping board You should be able to see the pilot holes in the elongated slot of the template Fig 6C Step 5 Drive two 10 wood screws through the elongated slots of the template into the clamping board Fig 6D CUTTING THE TAILS Step 1 Clamp the tail board with
35. he pins Fig 8C Step 6 Remove the pin board and check the fit with the tail board Fig 8D FITTING THE JOINT Step 1 Orient the template so that the PINS side is facing you Fig 9A Step 2 Loosen the two 10 screws Step 3 f the joint is too loose move the template toward you slightly Step 4 If the joint is too tight move the template away from you slightly Step 5 Tighten the screws loosened in STEP 2 Step 6 Cut the pin board again and check for fit THROUGH DOVETAILS WITH UNLIMITED BOARD WIDTH You can cut dovetails in boards wider than the templates mounted on clamping boards by cutting the first part of the joint sliding the templet down the workpiece and cutting the rest of the joint NOTE Become familiar with the procedure for cutting through dovetails with a template on a clamping board before attempting working with unlimited board width SETUP Remove the half blind depth bracket Other than that the setup is identical to the previous setup CUTTING THE TAILS Step 1 Clamp the tail board with the outside surface facing away from the clamping board Fig 10A Step 2 If the board is a width in 1 increments 12 13 etc center the edge of the board exactly between the two fingers of the template farthest to the left Fig 10B Step 3 If the board is not in 1 increments take the fraction of an inch that is greater than 1 and divide it by two Then move the tailboard
36. ight angles to the table but with the sides tilted outward cradles planters magazine racks NOTE Usually the tails are cut into the ends and the pins are cut into the sides CUTTING THE TAILS Step 1 Cut the ends of the tail board at the desired angle Note that when the angle is approaching 15 that the tails weaken Fig 59A Step 2 Mount the board so that the outside surface faces the base of the jig and the edge is against the template Fig 59B Step 3 Cut the tails in the same manner as you would the standard dovetails Fg 59B 33 CUTTING THE PINS Step 1 Cut the pin board according to Fig 60A Step 2 Hold the boards together and mark the pin board at the edges of the tails Fig 60B Step 3 Rotate the template so that the tapered fingers for cutting the pins is facing you Step 4 Mount the pin board with the outside surface facing away from the base of the jig Center the marks from STEP 2 between the tapered fingers A Fig 60C Step 5 Out the pins in the same manner as you would with standard dovetails Fig 60A FITTING THE JOINT Fitting the joint is the same as fitting the standard dovetail HINT Use pieces of scrap wood the same thickness and species of wood to make test pin boards until the template is adjusted for a perfect fit COMPOUND ANGLE JOINTS Two boards joined at 90 with both boards slanted to the side is known as a compound angle joint This
37. m with a table saw MULTIPLE SPACER METHOD The saw kerf allowance method can be modified by using multiple spacers on the same joint to create more varied spacing of the pins and tails However when removing or adding a spacer continue cutting the NEXT tail instead of cutting the SAME tail as described in CUTTING THE TAILS STEP 5 and continue with the SAME pin instead of cutting the NEXT pin as described in CUTTING THE PINS STEP 5 END TO END JOINTS You can use the 4200 series dovetail jigs to join boards end to end to increase length and to make visually interesting larger panels BOX END TO END JOINTS End to end and standard box joints are the same except in the joining of the boards You can use any depth of cut with your router as long as you use the same depth on both boards NOTE When you set your depth of cut set it so that the bit won t cut into the base of the jig 24 The standard joint is shown is Fig 42B and the end to end joint is shown in Fig 42C DOVETAIL END TO END JOINTS A dovetail end to end joint is a combination of a box joint and a half blind dovetail joint the workpieces are mounted to the jig in the same way as for a box joint However the router bit and bit depth are set up for a half blind dovetail NOTE The tightness of the joint is adjusted by the depth of the router bit eee ro co mme E DRAWERS WITH DOVETAIL DADOS Draw
38. method is used to make serving trays or planters NOTE The instructions given here are for templates mounted to the base of the jig However this joint can also be made with templates mounted to angled clamping boards You must use the angled clamping board for steeper angles Use the following table for setting up your table saw for these cuts DESIRED SIDE ANGLE MITER gauge ANGLE BLADE TILT ANGLE 85 85 0 89 6 80 80 1 88 3 75 75 5 86 2 70 71 1 83 3 65 67 1 79 7 SETUP Use the same setup as you would for the obtuse angled joint Use the blade tilt angle for making the angle insert or the angled clamping block Bevel the edges according to the drawing Fig 63A N FIRST OUTS aR BLADE TILT ANGLE BEVEL THE EDGES OF THE TAIL AND PIN BOARDS i THICKNESS OF PIN BOARD SECOND CUT 1 OUTSIDE SURFACE OF BOARD Fig 63A Fig 64A Step 1 Cut the end of the tail board according to the drawing Fig 64A Set the miter gauge and tilt the blade to the values in the above table Make the first cut with the board flat on the table surface and guide it with the miter gauge Fig 64B Make the second cut with a tenoning jig Fig 64C TS 0 a ww 35 CUTTING THE TAILS Step 2 With the angled insert attached to the base of the jig mount the tail board with the outside surface of the board facing the jig and with the board centered betwe
39. move the spacer and move the left offset guide directly against the tail board NOTE Support the template with a scrap workpiece thick enough to prevent the cutter from contacting the base CUTTING THE PINS Cut the pin board drawer front similar to cutting the rabbeted half blind dovetail If you use the alternate method of aligning the pin board with secondary board Make sure the secondary board does not have a rabbet NOTE Ensure that the pin board drawer front is thicker than the depth of cut to prevent the cutter from contacting the base FITTING THE JOINT Fit the joint the same as you would a standard rabbeted half blind dovetail NOTE If a change in depth of cut is required change it on both bits BOX JOINT BITS You can make box joints with different diameter router bits for the two workpieces The process is identical to making standard box joints except that you will need to change the bit for the second board Two routers will make this job easier However this two router method will require two 3 4 OD template guides and two template guide lock nuts available from Porter Cable In selecting straight bits for these modified box joints keep in mind the following 1 The sum of the diameters of the two straight bits must equal 1 2 The length of the bit used to cut the first board determines the maximum thickness of the second board Example if a 3 8 diameter bit used on the first board has a 1 2 long cu
40. 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 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 NO PON 2 REPLACEMENT PARTS When servicing use only identical replacement parts BACKGROUND INFORMATION The details for basic joints are found in the instruction manual for the 4212 Dovetail Jig along with information regarding the use of various router bits and or templet guides and will not be repeated in this supplemental manual The purpose of this document is to provide you with an advanced knowledge of the jig and to promote that knowledge along with your creativity to produce beautiful woodworking projects that can stand the test of time OPERATION MISCELLANEOUS TECHNIQUES Using these techniques can simplify your dovetailing projects USE A DEAD BLOW HAMMER Use a plastic dead blow hammer to join your workpieces together to help prevent the marring of wood Fig 1A CHAMFER THE TAIL EDGES Chamfering the inner tail e
41. od The joint will be fine if you place the straight portion of the template fingers directly over the tail board A Fig 53E Otherwise you may have to use an angled clamping board Set the router bit depth where the sides of the board are at a slight angle Fig 53F Cut the tails and remove the tail board THICKNESS OF PIN BOARD FIRST CUT AM SECOND CUT ANGLE BETWEEN BOARDS PA OUTSIDE INSIDE SURFACE SURFACE OF BOARD OF BOARD Fig 53A 30 CUTTING THE PINS Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Cut the end of the pin board according to the drawing 54A If you use the template mounted to the base of the jig and a 12 angled insert remove the small front knobs clamping rod and clamping U channel Then remove the angled insert and reinstall the hardware Hold the boards together and mark the end of the pin board along the edges of the tails Fig 54B Rotate the template so that the angled fingers are facing toward you If you use the template mounted to the base of the jig mount the pin board with the outside surface facing away from the base of the jig Center the marks on the end of the board between the angled fingers of the template Fig 54C If you use the template mounted on a clamping board clamp the pin board with the outside surface facing away from the straight surface of the clamping board Center the marks on the en
42. ound over the ends of the two workpieces Fig 45C Step 2 Use a drill press to drill a hole in the center of each board for the hinge pin Fig 45D Step 3 Make an end to end box cut Make the depth of cut slightly deeper than the thickness of the boards Fig 45E Step 4 Make the length of the hinge pin narrower than the width of the boards Step 5 Hold the boards together align the holes and insert the pin Fig 45F Step 6 Glue wooden plugs in the workpiece to hold the pins in place Fig 45G Step 7 Cut off the protruding part of the plugs and sand Fig 45H 26 270 HINGES WITH A DRILLED HOLE Follow the previous directions for 180 Hinge and use the following photos to help you make a hinge that will have 270 or more range of motion Cut the boards as shown in Fig 46A Fig 46A Fig 46B Fig 46C 180 HINGES WITH ROUTER MADE GROOVES When the width of the workpieces are too wide for a drill bit to make the hole use this method Two boards compose each hinge half Make a half round dado at the end of the workpieces When you glue the boards together these two dados make the hole for the hinge pin Step 1 Use a router to make a half round dado near the end of each of the four boards Make the diameter of the Drs equal to the diameter of the hinge pin and the depth of cut half the diameter of the hinge pin Fig 48A Step 2 Insert the metal rod long enough to stick out of both ends of the bo
43. pacity to 8 SETUP Items needed to setup for the half blind dovetails Wood to make the clamping board parts Clamps 2 10 wood screws 2 1 4 20 threaded T nut 1 4 20 x 4 bolt 1 4 washer O01 onmce NOTE These instructions can be modified for making half blind dovetails with the through dovetail template and for the miniature dovetail template See the section HALF BLIND DOVETAILS WITH TAIL BOARDS THICKER THAN 7 8 Step 1 Make a main clamping board 1 1 2 x 3 1 4 x 16 Square all of the sides Make a mortise through the board and drill pilot holes for 10 wood screws Fig 15 NOTE Threaded inserts and 10 flathead machine screws can be used in place of the 10 wood screws Step 2 Make the offset clamping block Make a counterbore for the threaded T nut Fig 15B NOTE If your pin board is thinner than 3 4 modify the dimension You may need to use extra washers to prevent the bolt from sticking out Fig 15B 2 318 WIDE MORTISE GOES THROUGH BLOCK MORTISE IS CENTERED ON BLOCK ra 5 4834 DRILL PILOT HOLES FOR 10 WOOD SCREWS WOOD GRAIN block Fig 15C 11 112 5 WOOD m 14 HOLE THROUGH THE BLOCK P MAKE THIS DIMENSION THE THICKNESS OF THE PIN BOARD THAT IS TO BE DOVETAILED MAKE TWO OF THES
44. r the tails and pins to be flush be careful to make the bit depth very precise CUT OFF THE INLAY BOARD After the joint has dried cut off most of the inlay board Leave an amount equal to the thickness of the inlay MAKE THE SECOND JOINT The second joint is also identical to a box joint with alternate router bit sizes as found in the section ROUTER BITS Make a box joint with the board from the previous section and the second board Use the smaller straight bit with the board from the previous section and the larger bit with the second board HINT this section of your project aligning the joint is easier if you do not move the offset guides after making the first joint 40 TABLES OF COMMONLY AVAILABLE ROUTER BIT SIZES THROUGH DOVETAIL ROUTER BIT COMBINATIONS Combination Number 7 Dovetail Bit Straight Bit 3 4 3 16 T1 T2 5 8 5 16 HALF BLIND DOVETAIL BITS Bit Diameter and Angle Approximate Depth of Cut 17 32 72 13 32 17 32 14 3 16 9 16 7 3 4 5 8 14 9 16 WITH THE PINS AND THE TAILS CUT SEPARATELY Combination Large Dovetail Bit Small Dovetail Bit pproximate Number Diameter and Angle Diameter and Angle Depth of Cut 3 4 1 2 9 16 5 8 1 2 3 8 5 8 17 32 7 8 5 8 9 16 1 9 16 17 32 5 8 The actual depth of cut may be a little deeper or shallower than what appears on this table Since vendors use different manufacturing tolerances on bit dimension
45. s use the manufacturer s advertised bit dimensions only as a guide Remember that a small amount of variation within tolerances can have a large impact on the final depth of cut BOX JOINT BIT COMBINATIONS Combination Number Larger Straight Bit Smaller Straight Bit B1 1 2 1 2 B2 9 16 7 16 B3 5 8 3 8 41 TROUBLESHOOTING For assistance with your tool visit our website at www porter cable com for a list of service centers or call the Porter Cable help line at 1 800 487 8665 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
46. 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 to determine that it will operate properly and perform its intended function Check for alignment of moving parts binding of moving parts breakage of parts mounting and any other conditions that may affect its operation A guard or other part that is damaged should be properly repaired or replaced by an authorized service center unless otherwise indicated elsewhere in this instruction manual Have defective switches replaced by 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
47. the wood Fig 34D Step 6 Remove the templet Install the half blind templet so that its straight edge is facing you Step 7 Adjust the template back and forth to align the edge of the template with the marks on the wood B Fig 34E CUTTING THE PINS Step 1 Cut the tails Clean out all of the areas between the fingers Fig 35A Step 2 Use a pencil to mark the location of the half circle between the fingers of the templates C Fig 35B Step 3 Remove the pin board and hold it next to the tail board 21 Step 4 Shade the pins that will be removed Fig 35C Step 5 Place the pin board back in the jig Step 6 Install the half blind template so that its straight edge faces you Step 7 Adjust the pin board so that the marks align with the straight edge of the templet D Fig 35D Step 8 Make the cuts with the router to remove the shaded pins Fig 35E Step 9 Remove all excess material Step 10 If you remove a bit more material than necessary remember that it will be hidden in the joint E Fig 35F FITTING THE JOINT Fit the joint the same as you would the half blind dovetail SAW KERF ALLOWANCE METHOD An effective way to match the grain in a decorative box is to make the box from one piece of wood and then cut the lid with a table saw However if the dovetails are evenly spaced they may be unattractive because the saw kerf removed needed material Fig 37A NOTE
48. tter the maximum thickness of the second board would be 1 2 BOX JOINT BITS READILY AVAILABLE LARGER STRAIGHT BIT SMALLER STRAIGHT BIT DOVETAIL DADO BITS Any dovetail bit can be used to make dovetail dados sliding dovetails as long as the bit does not cut into the template guide or the base of the jig The process is identical to that of the standard dovetail dado Also you can use template guides smaller than 3 4 OD which will have the effect of making the dado slot wider than the bit diameter NOTE Any template guide bushing surface must not extend more than 1 4 from the base 16 DOVETAIL BIT TEMPLET GUIDE j n 7 E 1 0 OF TEMPLET GUIDE 7 7 LOC SSS c d DOVETAIL BIT DIAMETER A MINIMUM DEPTH OF CUT HEN THE DIAMETER OF THE ROUTER Wi BIT IS GREATER THAN THE INSIDE DIAMETER OF THE TEMPLET GUIDE 7 THERE IS Cutting a dado with a templet guide that has an OD smaller than 3 4 requires two passes 1 Start on the left side Keep the router toward the back edge of the dado slot and cut to the right until you have completed the cut 2 Start on the right side Keep the router towards the front edge of the dado slot and cut to the left until you complete the cut 3 Leave the router in the dado slot until the bit stops spinning NOTE For deep cuts use a straight bit first NOTE Cut the tenon just as you would a standard tenon HALF BLIND DOVETAILS WITH T
49. vetail procedure OBTUSE ANGLED JOINTS The simplest of these angled joints is the obtuse angled dovetail In this joint two boards are joined together at an angle greater than 90 This joint can be made with either the template mounted to the base of the jig or to a clamping board If the angle is 100 or greater you must use the clamping board method Fig 50A SETUP WITH THE TEMPLATE MOUNTED TO THE BASE OF THE JIG Step 1 Make an angled insert according to one of the drawings Figs 51A 51B Match the angle of the insert with the joint angle If the workpiece is wider than 6 use the 12 insert Step 2 Make sure that the 1 4 20 flat head screw does not protrude A Fig 51C Step 3 Remove the small front knobs the front clamping rod and the front clamping U channel Leave the springs Step 4 Use two 1 2 1 4 20 flat head screws to secure the angled insert to the front of the base of the jig with the thicker edge of the insert up If you are using the 6 insert install it in the 2 holes on the right Fig 51C Step 5 Replace the hardware that was removed in STEP 3 MAKE TWO COUNTERSINKS FOR j 14 20 FLATHEAD SCREWS m c PROTRUDEPAST THE OUTER J S20 FLATHEAD SCREWS DRILLTWO 14 HOLES PROTA PAST HE OUTER x SURFACE OF THE INSERT SURFACE OF THE INSERT DRLLTWO 14 HOLES N INSERT ANGLE A T I V pb Dr 3 Tam M INSERT ANGLE
50. 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 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 spe
51. your tool model number type serial number etc SERVICE REPLACEMENT PARTS When servicing use only identical replacement parts 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 Cable Delta Supplier Porter Cable Delta Factory Service Centers and Porter Cable Authorized Service Stations Please visit our Web Site www porter cable com for a catalog or for the name of your nearest supplier Since accessories other than those offered by Porter Cable Delta have not been tested with this product use of such accessories could be hazardous For safest operation only Porter Cable Delta recommended accessories should be used with this product 42 WARRANTY PORTER CABLE LIMITED ONE YEAR WARRANTY Porter Cable
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