Woodstock D2796, Operating Manual

Page 1: ...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 DOVETAIL JIG D2796 OPERATING MANUAL P O Box 2309 Bellingham WA 98227 ...

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Page 3: ...ENCE ADJUSTMENT 12 FENCE ADJUSTMENT TABLE 13 OPERATIONS 14 HALF BLIND JOINTS 14 RABBETED DRAWER FRONTS 16 TROUBLESHOOTING 17 TEAR OUT 17 EXCESSIVE FIT 17 INCOMPLETE FIT 17 OFFSET EDGES 18 FIT TOO TIGHT OR TOO LOOSE 18 UNEVEN FIT 19 WARRANTY 20 CLOSURE 20 PARTS DIAGRAM 21 PARTS LIST 22 TOOL DATA 22 COPYRIGHT BY WOODSTOCK INTERNATIONAL INC TX 4 085 998 WARNING NO PORTION OF THIS MANUAL MAY BE REPROD...

Page 4: ...sary to become acquainted with the Model D2796 Dovetail Jig The time you invest before you use it will be time well spent Also read and follow all of the safety procedures noted in this manual If you do not understand any of the operations or safety guidelines discussed in this manual please get answers to all your questions before attempting to use this jig The specifications drawings and photogr...

Page 5: ...r other protective head wear if your hair is long 11 NEVER STAND OR LEAN ON TOOL 12 USE SAFETY GLASSES AND EAR PRO TECTION Also use a DUST MASK if the cut ting operation is dusty 13 DO NOT OVERREACH Keep proper footing and balance at all times 14 MAINTAIN TOOLS IN TOP CONDITION Keep tools sharp and clean for best and safest per formance Follow instructions for lubricating and changing accessories ...

Page 6: ...he threaded end of each hand lever into the clamping rods located on the top and front of the dovetail jig as shown in Figure 1 Tighten until secure 3 Secure the jig to your bench top See Figure 2 Hint If you do not wish to permanently devote bench space to the dovetail jig mount the jig to a piece of 3 4 plywood that can be clamped to your bench top Dovetail Jig Hand Lever Hand Lever Figure 2 Jig...

Page 7: ...rude exactly 9 16 below the router base See Figure 4 3 The maximum router base size that can be used with this jig is 7 in diameter 4 The guide bushing should protrude 1 8 to 3 16 below the base of the router and have a 7 16 out side diameter O D Figure 5 shows the pin widths produced by different sized templates Your jig comes with a 1 2 template Other templates are available from your local Wood...

Page 8: ...g strength After all the pieces have been cut to size and checked to ensure squareness set them on a bench in the order that they will be fitted together Lay each piece down so the inside faces up Label each piece on the inside as shown in Figure 6 When planning the dimensions of your dovetail joints it is important to consider how the tails and pins will be aligned across the joint You want to av...

Page 9: ...pressure knobs control the height of the clamping bar and adjust cam clamping pres sure Hand Lever Fence Knob Clamping Pressure Knob Template Knob Hand Lever Clamping Pressure Knob Figure 7 shows the adjustment locations for the dovetail jig Upper Side Stops Front Side Stops ADJUSTMENT LOCATIONS NOTICE When describing adjustments and operations in this manual reference is made to the pieces being ...

Page 10: ... you clamp your top workpiece to ensure that subsequent cuts are consistent The clamping pressure should be adjusted so the work piece can be easily slid under the bar when the hand lever is up Push the hand lever down to hold the work piece in place See Figure 8 Do not use excessive force when pushing the lever If the lever will not lock firm ly under average pressure loosen the clamping pressure...

Page 11: ... edges are flush against the side stops 10 Your jig set up should look like Figure 10 NOTICE The dovetail jig is capable of processing 2 sets of joints at one time if the sum of the widths of both sets is less than 12 If you wish to make 2 sets of joints at one time adjust both sets of side stops at each end of the jig Refer to Steps 1 9 above IMPORTANT For the best results we recommend using 3 4 ...

Page 12: ...oosening the two template lock knobs Do not adjust the screws holding the template To adjust the template to the proper position 1 Mount your drawer pieces in the jig The horizon tal piece must be tight and flush with the top of the vertical piece When mounted correctly the top edge of the vertical piece sits flush with the top of the horizontal piece See Figure 11 1 8 7 8 or Less Figure 12 Correc...

Page 13: ...ke adjust ments to the template and re measure both posi tions 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 y...

Page 14: ...owing steps to determine the correct amount 1 Measure the distance x from the edge of your router base to the outside edge of the guide bush ing See Figure 16 2 Measure the thickness in inches of the vertical drawer piece in the jig 3 Use the chart on the next page Find where the two axes meet for your specific measurements This is the distance in inches that should be between the fence and the fr...

Page 15: ... 13 Woodstock Intl Inc D2796 ADJUSTMENTS FENCE ADJUSTMENT TABLE Thickness of Vertical Piece Measurement x from Fig 16 Distance from Edge of Bushing to Edge of Router Base ...

Page 16: ...he fit With the jig completely adjusted you should be ready to test it out Review all safety guide lines on Page 2 if you are not sure about the risks asso ciated with operating a router in conjunction with this jig HALF BLIND JOINTS To use the dovetail jig 1 Position the mated pieces in the jig so the insides face out and up Each piece must be tight against the side stops The back piece is positi...

Page 17: ...outer 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 Hint If you are using material thicker than 7 8 cut it in two stages First remove the m...

Page 18: ...e width of the spacer must be the same width as the rabbet See Figure 21 2 The fence must also be set back an additional amount equal to the width of the rabbet 3 Since the side piece is unsupported by the front piece the rabbet created a void behind the side piece it is likely that the router bit will cause tear out each time the bit exits the side piece To pre vent tear out place a wood spacer c...

Page 19: ...front or back piece the cut is too deep See Figure 22 Cause The distance between the edge of the side piece and fence is set too wide Remedy Adjust the fence forward by the same amount that the pins are exposed Refer to the procedure described above for fence adjustment See Figure 23 Figure 22 shows excessive fit Figure 23 Adjust fence towards template TROUBLE SHOOTING INCOMPLETE FIT An incomplete...

Page 20: ...e stop by the exact width of the fingers on the template you are using Ensure that the front side stop remains square to the workpiece mounted on top of the jig See Figure 27 FIT TOO TIGHT OR TOO LOOSE If you find the fit to be about right in every other aspect but it is simply a little too tight or too loose the depth of the router bit is probably maladjusted See Figure 28 1 If the fit is too tig...

Page 21: ...el to the front of the template See Figure 31 3 The template is not parallel to the drawer edges See Figure 32 Remedy Make sure that the drawer edges fence and template are all parallel to one another Figure 30 The wood stock must be clamped parallel to one another and tight against the side stops Figure 29 shows uneven fit Figure 31 Adjust the fence so that it is parallel to the front edge of the...

Page 22: ... or for incidental contingent special or consequential damages arising from the use of our products To take advantage of this warranty the product or part must be returned to the original place of purchase Proof of purchase must accompany the merchandise Woodstock reserves the right to change specifications at any time since we constantly strive to achieve better quality equipment We make every ef...

Page 23: ...dstock Intl Inc D2796 PARTS 5 5 23 23 8 23 8 23 17 7 7 8 8 3 14 14 14 14 16 12A 21 21 11 11 18 18 18 18 16 16 9 2 2 2 4 4 2 9 10 16 1 3 17 7 7 6 6 13 13 13 13 19 19 19 19 20 20 20 20 22 22 22 22 PARTS DIAGRAM ...

Page 24: ...am Template Aluminum Router Specifications Maximum Router Base Size 7 Router Bit Required 14 1 2 Dovetail with 1 4 Shank Guide Bushing Required 7 16 O D Specifications while deemed accurate are not guaranteed 12B TEMPLATE 7 16 12C TEMPLATE 9 16 13 SIDE STOP 14 HUB 16 SPRING 17 CLAMPING ROD 18 T NUT 19 T NUT 20 FLAT WASHER 21 FLAT HD SCREW M6 1 0 x 8 22 HEX HEAD BOLT 23 PHLP HD SCREW M5 0 8 x 12 RE...

Page 25: ...NOTES 23 Woodstock Intl Inc D2796 ...