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P.O. Box 2309
Bellingham, WA 98227
DOVETAIL JIG
D2796 OPERATING MANUAL
COPYRIGHT © BY WOODSTOCK INTERNATIONAL, INC. TX 4-085-998
WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE
OR FORM WITHOUT THE WRITTEN APPROVAL OF WOODSTOCK INTERNATIONAL, INC.
REPRINTED APRIL 2001, PRINTED IN CHINA
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INTRODUCTION SAFETY ASSEMBLY ADJUSTMENTS OPERATIONS PARTS TABLE OF CONTENTS INTRODUCTION ............................................................................................................................................2 COMMENTARY..............................................................................................................................................2 SAFETY RULES FOR ALL TOOLS ........................................................................................
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INTRODUCTION COMMENTARY Woodstock International, Inc. is proud to offer the To operate this or any tool safely and efficiently, it is Model D2796 12" Dovetail Jig. Suitable for production essential to become as familiar with its characteristics work or small scale dovetail joinery, the Model D2796 as possible. Take as much time as necessary to become 5 enables you to simultaneously cut /8" half-blind dove- acquainted with the Model D2796 Dovetail Jig. The 7 1 tails and pins with a router, /16" g
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SAFETY SAFETY RULES FOR ALL TOOLS 1. KNOW YOUR POWER TOOL. Read the 12. USE SAFETY GLASSES AND EAR PRO- owner’s manual carefully. Learn the tool’s appli- TECTION. Also use a DUST MASK if the cut- cations and limitations, as well as its particular ting operation is dusty. hazards. 13. DO NOT OVERREACH. Keep proper footing 2. KEEP ALL GUARDS IN PLACE and in work- and balance at all times. ing order. 14. MAINTAIN TOOLS IN TOP CONDITION. 3. GROUND ALL TOOLS. If an adapter is used to Keep tools sharp
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UNPACKING Wear safety glasses dur- Remove the items packed in the carton. It may be a ing the entire assembly good idea to save the carton and packing material in process. Failure to com- case they might be needed in the future. Upon removal ply may result in serious of all items from the package, you should have: personal injury. 1. Dovetail Jig 2. Hand Levers (2) HAND LEVERS 3. Manual The jig is shipped fully assembled except for the two hand levers. Hand Lever Dovetail Jig 1. Screw the threa
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ASSEMBLY CAPACITIES 5 The Model D2796 is designed to produce ⁄8" half-blind 7 dovetail joints with a router, /16" O.D. guide bushing 1 (Figure 3), and a 14°, /2" dovetail router bit. Two 1 3 optional templates are available for making ⁄2" and ⁄4" half-blind dovetails and pins. Half-blind dovetails are very strong and are commonly used in fine drawer con- struction. The term “half-blind” refers to the fact that the pins and tails can only be seen from the side. 1. The Model D2796 is capable of h
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PREPARATION It is important to plan your work before starting! If joining multiple pieces for a drawer or series of draw- ers, it is best to label the pieces as front, back and sides and which face will be inside or outside. It is also best to label the ends so it is clear which end mates with another. Labeling will save setup time and avoid costly mistakes in the long run. 3 A typical drawer has a /4" thick front with sides made 1 of /2" material. Your drawer fronts and backs must be 5 at leas
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ADJUSTMENTS ADJUSTMENT LOCATIONS 1. The hand levers clamp your workpiece in place. 2. The fence knobs hold the fence in place. Loosen these knobs to adjust fence position. NOTICE 3. The upper side stops align the workpiece hori- When describing adjustments and operations in zontally under the template. this manual, reference is made to the pieces being joined as fronts, backs or sides. These pieces indi- 4. The front side stops align the vertical workpiece cate drawer fronts, backs, and sides.
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CLAMP ADJUSTING NOTICE All work pieces must be cut perfectly square for The clamping pressure should be adjusted so the work- the dovetail joints to fit properly. piece can be easily slid under the bar when the hand lever is up. Push the hand lever down to hold the work- To Adjust: piece in place. See Figure 8. Do not use excessive force 1. Loosen the fence and slide to the rear. Slide the when pushing the lever. If the lever will not lock firm- drawer piece horizontally under the top clamp and
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ADJUSTMENTS 4. Insert a drawer side under the front clamp. This piece will be vertical. Adjust the height so the top NOTICE end of the vertical piece overlaps the end of the hor- The dovetail jig is capable of processing (2) sets of izontal piece. At this point, it is not critical that the joints at one time if the sum of the widths of both pieces be flush. sets is less than 12". If you wish to make (2) sets of joints at one time, adjust both sets of side stops 5. Clamp the side in place. at ea
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TEMPLATE ADJUSTMENT 7 1 3. For side pieces thicker than /8", add /8" to the The template is adjustable from front to back so that the 7 amount that the board exceeds /8". Then, set the joint will be hidden when the dovetails are complete. front edge of the template fingers back from the Adjustment is made by loosening the two template lock edge by that sum. See Figure 13 and 14. knobs. Do not adjust the screws holding the template. To adjust the template to the proper position: 1. Mount your dra
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ADJUSTMENTS 4. To measure at both ends of the jig, try shifting the vertical piece to the other end of the jig or clamp two pieces at each end of the jig as shown in See Figure 15. It is not necessary to simultaneously measure with two rulers. The two rulers only rep- resent two measurement locations. 5. Tighten the two template lock knobs and re-check your measurements. Figure 15. Make sure template is parallel to drawer edges. NOTICE Ensure that the front edge of the template is par- allel to
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FENCE ADJUSTMENT (x") Once the side stops have been accurately set up, the fence needs to be properly adjusted. The fence is designed to control how far back into the template the router will cut. If the fence is not set back far enough, Guide Bushing the drawer pieces will not fit all the way together. If the fence is set too far back, the drawer pieces will slide into one another too far leaving excess material on the joint. On the next page is a chart used to determine how far back from the t
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ADJUSTMENTS FENCE ADJUSTMENT TABLE Thickness of Vertical Piece (Measurement x" from Fig.16) Woodstock Intl., Inc. D2796 - 13 - Distance from Edge of Bushing to Edge of Router Base
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OPERATIONS HALF-BLIND JOINTS To use the dovetail jig: Keep loose clothing rolled up and out of the 1. Position the mated pieces in the jig so the insides way of machinery and face out and up. Each piece must be tight against keep hair pulled back. the side stops. The back piece is positioned hori- zontally on top of the jig. The mating side piece positioned vertically in the front of the jig. Secure the drawer pieces with the clamps. The end of the side piece must be flush with the top face of t
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OPERATIONS Turn the router on and gently ease the bit into the work, letting the guide bushing gently contact the template. Facing the dovetail jig, start at your left side and work to the right, following each template finger in and out. Ensure that the router base and guide bushing stay in firm contact with the tem- plate. See Figure 19. 7 Hint: If you are using material thicker than /8", cut it in two stages. First, remove the material IN FRONT OF the fingers. Second, remove the material BETW
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HALF-BLIND JOINTS ON RABBET- ED DRAWER FRONTS Rabbet spacers Drawer fronts that have been rabbeted around the inside edge to create a lip to restrict drawer travel in the closed position require some additional setup. To produce half-blind dovetails on rabbeted drawer fronts: 1. A spacer must be added to the vertical side stop in the front of the jig to compensate for the rabbet. The width of the spacer must be the same width as Figure 21 shows lining up a rabbeted board and where to the rabbet
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OPERATIONS TROUBLE SHOOTING TEAR-OUT When cutting across the grain of the wood, tear-out or splintering may occur when the router bit exits the workpiece. To prevent tear-out, you may scribe a line on the side piece with a sharp knife or awl at the same distance down that router bit will cut. Tear-out can be eliminated or reduced by backing up the workpiece with a scrap piece or simply using extra care when operating the router. EXCESSIVE FIT If the pins on the side piece fit too deeply in the t
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Figure 25. Adjust fence away from template. Figure 27. Edge of vertical piece must be offset from edge of horizontal piece by exactly the width of (1) template fin- OFFSET EDGES 1 ger. Included template finger is ⁄2". If the side piece edge is not aligned with the front or FIT TOO TIGHT OR TOO LOOSE back piece edge, the edges are offset. See Figure 26. If you find the fit to be about right in every other aspect, Cause: The side stops are not set correctly. but it is simply a little too tight or
