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Note: Rockler may not carry all products and/or sizes listed in this vendor's publication
INSTRUCTION
ESPAÑOL: PÁGINA 27
FRANÇAISE : PAGE 51
MANUAL
DOVETAIL JIG
MODELS 4210 & 4212
(29550)
IMPORTANT
To learn more about Porter-Cable
visit our website at: Please make certain that the person who is
to use this equipment carefully reads and
http://www.porter-cable.com
understands these instructions before
starting operations.
The Model and Serial No. plate is located on the main
housing of the tool
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TABLE OF CONTENTS SAFETY GUIDELINES 3 IMPORTANT SAFETY INSTRUCTIONS 3 ADDITIONAL SPECIFIC SAFETY RULES 4 BACKGROUND INFORMATION Dovetail and Box Joint Overview 5 Product Capabilities 6 4200 Series Dovetail Jig Overview 7 Carton Contents 7 Assembly 8 Additional Tools Required 8 Mounting Instructions 8 OPERATION Clamps 9 Template Mounting 9 Template Support 10 Positioning the Wood 10 Half-Pins Vs. Half- Tails 11 Tearout Reduction 11 Aligning the Templates 11 Template Guides 12 Router Bit Depth 12
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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. Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which, if not
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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
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THROUGH DOVETAILS Tails Pins HALF-BLIND DOVETAILS 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 board and a dovetail-shaped tenon in the other b
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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,
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CARTON CONTENTS DOVETAIL JIGS 4210 4212 3 2 2 1 1 4 6 3 5 4 5 6 7 8 1. Base 1. Base 2. Half-blind & Dado Template 2. Half-blind & Dado Template 3. Through & Box Template 3. Dovetail Bit 4. Dovetail Bit 4. Template Guide 5. Straight Bit 5. Lock nut 6. Template Guide (2) 6. T-handle Hex Wrench 7. Lock Nuts (2) 8. T-handle Hex Wrench ACCESSORY KITS 4211 4213 4215 1 1 1 5 4 3 2 5 4 3 2 5 4 3 2 10 6 6 7 6 7 8 7 8 10 9 9 9 8 11 1. Half-blind & Dado Template 1. Through and Box Joint 1. Miniature Half-b
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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. 3/8" ASSEMBLED JIG HEIGHT ADJUSTMENT ADDITIONAL TOOLS REQUIRED The router that you use with this jig must accept the Porter-Cable template guides supplied with the jig.
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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
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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. A E1 E2 Supported Unsupported POSITIONING THE WOOD You must position the workpiece correctly to produce attra
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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, then move the horizontal board accordingly. The procedure is the same with the 4215 Miniature template, except that you move the boards 1/4". G1 G2 TEAROUT REDUCTION Tearout is unwanted splintering of the wood fibers that occu
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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. J1 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 j
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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. L2 L1 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. L3 L4 BOARD THICKNESS NO
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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) I B C C B I I T T D A D A I N1 N2 N3 DRAWERS Tips for making drawers
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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 kit to make this joint. ITEMS NEEDED ITEMS
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Reposition the offset guide (A) Fig. P4 flush to the vertical board and secure it. Step 4 - Step 5 - Reposition the scrap board(A) Fig. P5 so that it is flush with the rear edge of the vertical board (B). Align the template using the “tails/box” line (A) Fig. P6 with the line formed where the scrap board (B) and Step 6- the vertical board meet (C) and secure it. A A C B B A P4 P5 P6 Step 7 - Mount the dovetail bit and 3/4" template guide on the router and set the router bit depth using the “tail
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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). P12 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 half-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 constru
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Clamp the tailboard (drawer side) in lower clamp (vertical Step 4 - position) on the left side of the base with the outside of the board facing the jig (A) Fig. Q3. CENTER 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 - A Reposition the pin board (B) Fig. Q5 so that it is flush against the offset guide (A) and the back e
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RABBETED HALF-BLIND 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 FO
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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. R6 R7 R8 CUTTING THE PINS Step 1 - Clamp the pin board in the upper clamp (horizontal mounting position) with the outside surface agains
