craftsman dovetail jig l0807067

8/18/2019 Craftsman Dovetail Jig L0807067

http://slidepdf.com/reader/full/craftsman-dovetail-jig-l0807067 1/48

ModelNo,

171.25450

CRAFT$1VlAK

INDUSTRIAL

DOVETAIL

FIXTURE

• Assembly

• Operation

iMPORTANT;Thefollowingrouterbitsarerequired

for

usewith this fixture: 25414-1/4-in.

Straight Router Bit and

#25415-9/16-in. Dovetail Router Bit which are used

for

THROUGH

or OPEN

JOINTS.

: #25505 or #26318-1/2-in. DovetailRouterBit which

are usedfor a l HALFBLINDJOINTS.

Readandfollow

all instructions

carefully.

KEEPTHIS

MANUALFOR

'

FUTURE

REFERENCE,

Sold bySears,Roebuckand Co,,Hoffman Estates,IL 60179

83463



, i i

FAILURETOHEEDALLSAFETYAND

OPERATING

NSTRUCTIONS

ANDWARNINGSREGARDINGUSEOFTHISPRODUCTCANRESULT

IN SERIOUSBODILYINJURY

1)

KNOWYOURPOWERTOOL

Read

he

owner'smanualcarefully.Learn

its

applicationsand

Iimitatlonsaswell asthespecificpotentialhazardsarticularto

thistool.

2) GROUNDALLTOOLSUNLESSDOUBLENSULATED)

If tool is equippedwithanapproved3-conductorcordand a3-

pronggroundingtypeplug,it shouldbepluggedinto athreehole

electricalreceptaute.t adapters usedtoaccommodate two-

prongreceptacle,he adapterwire mustbeattachedo known

ground,(usuallythescrewsecuringreceptaclecoverplate).

Neverremovehird prong.Neverconnectgreengroundwireto a

terminal.

3) KEEPGUARDSNPLACE

--in workingorder,and

in

properadjustmentandalignment.

4) REMOVEADJUSTINGEYSANDWRENCHES

Forma habitof checkingo seethatkeysandadjustingwrenches

areremovedromtool beforeturningit on.

5) KEEPWORKAREACLEAN

Clutteredareasandbenchesnviteaccidents.Floormustnotbe

slipperydoeto waxor sawdust.

6} AVOIDDANGEROUSNVIRONMENT

Donot usepowertools

in

damporwet

locationsr

exposehornto

rain.Keepwork areawelI lighted.Provideadequatesurrounding

workspace.

7) KEEPCHILDRENWAY

All visitorsshooktbekeptata safedistancefromworkarea.

B) MAKEWORKSHOPHILD-PROOF

--with padlocks,masterswitches,or by removingstarterkeys.

9) DONOTFORCETOOL

It will dothejob betterandsaferattherateforwhichit was

designed.

10)

USEAPPROPRIATEOOL

Donotforcetool or attachmento doajob forwhich

it

wasnot

designed.

11)WEARAPPROPRIATEPPAREL

Donotwearlooseclothing,gloves,necktiesor jewelry(rings,

wristwatches)ogetcaughtin movingparts.Nonslipfootwearis

recommended.Wearprotectivehaircoveringo containlonghair.

Roll longsleevesel;Dyeheelbow.

12)

USESAFETYGOGGLESHeadProtection)

WearSafetyGogglesmustcomptywith ANSIZ87.1 at all times.

Also,usefaceordustmaskif cuttingoperations dusty,andear

protectors(plugsor muffs)duringextendedperiodsofoperation.

13)SECUREWORK

Useclampsora viseto holdworkwhenpractical,it's saferthan

usingyourhandandfreesbothhandsto operateool.

14)

DO

NOT

OVERREACH

Keep

proper

ootingandbalanceat all times.

15)MAINTAINOOLSWITHCARE

Keepools sharpandc]eanfor bestandsafestperformance.Follow

instructionsfor lubricatingandchangingaccessories.

16)

DISCONNECTOOLSBEFOREERVICING

-when changingaccessoriessuchas blades,bits,cutters,etc.

17)AVOIDACCIDENTALTARTING

Makesureswitch

is

in OFFpositionbefore

pluggingn.

18)USERECOMMENDEDCCESSORIES

Consulttheowner'smanualfor recommendedccessories.Follow

the instructionsthataccompanyheaccessories.Theuseof

improperaccessoriesmaycausehazards.

19)NEVER

STANDONTOOL

Serious

injury

couldoccur ;fthetool Istipped

or

thecuttingtool is

accidentallycontacted.0o notstorematerialsaboveor nearthe tool

thatwouldmakeit necessaryo standon thetoolto reachthem.

20)CHECKDAMAGEDARTS

Beforeurtheruseof thetooI,a guardor other

part

hatis damaged

shouldbecarefullycheckedto ensurethatit will operateproperly

andperformits

intended

unction.Checkforalignmentof racy(rig

parts,bindingof movingparts,breakageof parts,mounting,andany

otherconditionsthat mayaffectits operation.Aguardorotherpart

that

is

damagedshouldbeproperlyrepairedorreplaced.

21)DIRECTIONFFEED

Feedworkintoabladeor cutteronly againstthedirectionof rotation

of thebladeor cutter.

22)NEVERLEAVETOOLRUNNINGUNA'n'ENDED

Turnpoweroff.Do notleavetooluntilit comesto a completestop.

23)KEEPHANDSAWAYFROMCUT(1NGAREA

24)STORE

DLE

TOOLS

Whennot in use,toolsshouldbestoredindry,highor Iocked-up

place---outof reachofchildren.

25)O0

HOT

ABUSECORD

Keepcordawayfrom heat,oil, andsharpedges.

28)OUTDOORXTENSIONORDS

Whentoo

is

usedoutdoors,useonlyextensioncordssuitableor

useoutdoors,andso marked.

27)NEVER

USE

IN

ANEXPLOSIVETMOSPHERE

Normalsparkingof the motorcouldignitefumes,flarnmab;eiquids,

or combustibletems.

28)DRUGS,ALCOHOL,MEDICATION

Do notoperateool while underthe influenceof drags,alcohol,or

anymedication.

READ

ANDUNDERSTANDHISCOMPLETENSTRUCTIONBOOK

BEFOREUSINGTHISPRODUCT

2



ADDITIONALSAFETYNSTRUCTIONSORYOUR

INDUSTRIALDOVETAILFIXTURE

1) Alwaysweareyeprotectionhatcomplieswith currentANSI

StandardZ78A.

2) Noiselevelsvarywidely.Toavoidpossiblehearingdamage,wear

earpIugsor muffswhenusingtheDovetailFixtureor hoursata

time.

3) Wearadust maskalongwiththesafetygoggles.

4) Donot usethis DovetailFixturewith routerbitsor guide

bushingsotherthanthosespecifiedorthecuts beingmade.

5) FollowtheinstructionsinyourRouterOwnersManual.

6) Vibrationscausedbytherouterduringusecancauseasteners

to becomeoose.Beforeuseandperiodicallyduringusecheckall

fastenerso makesurethat theyareagtightandsecure.

7) Donot usethis productuntilall assemblynstallationstepshave

beencompleted,andyouhavereadandunderstandnit safetyand

operationalnstructionsn this manual,andtheRouterOwners

ManuaL

8) Makesurethattherouterbit is properlypositionedn therouter

so thatit doesnotcontacthe guidebushingorthetemplatewhen

cutting.

9) TheDovetailFixturemustbe securelymountedto aworkbench

or otherstablesurfacewhenin use.Thefrontof the baseshould

overhanghefrontof theworkbenchbynomerethan1/4" to provide

clearancewhenclampingworkpieceso theDovetailFixture.

10) DonotusetheDovetailFixtureas aworksurface.Doingsomay

causedamageo theDovetailFixture,whichcancauseit to beunsafe

to use.Aworkbenchshouldbeusedfor thispurpose.

11)Thisproductis designedocut

flat

workpieces.

Donotcutor

attemptocutworkpieceshat

are

notflat

or

thatareirregularly

shaped.

12)Thisproductis to beusedforcuttingwoodworkpiecesonly.

Do

not

usethisproductocutmetaloranyothernon-woadmaterial.

13)Thisproducthasbeendesignedo cutworkpieceshaving

thicknessesof 3/8"to 1".Donot useforworkpiecesof anyother

thicknesses.

14)Donotclampanyworkpieceso the DovetailFixtureor makeany

adjustmentso theDovetailFixtureunlessthe routerhasbeenurned

off, therouterbit is notturning,andtheRouterhasbeen

disconnectedromtheelectricaloutlet.

15)Whensetting"lhe-dopth-ot-cut"of the routerbit,makesurethat

theworkplaces clampedothe DovetailFixturen sucha.manner

that

therouterbitdoesnotcut

into the

Dovetailbasecausing

damageoit orpassibleseriousnjurytoyou.

16) ALWAYSNPLUGHEROUTERFROMTHE

ELECTRICALUTLETBEFORENSTALLINGRREMOVINGOUTER

BITSFROMTHEROUTERNDWHENADJUSTINGHECUTTING

DEPTHOFTHEROUTERBIT;ORWHENINSTALLINGRCHANGING

GUIDEBUSHINGS,

17)NEVERLiFTTHEROUTERUPWARDSWHENTHEROUTERS

"ON",THEROUTERIT

IS

ROTATING,NDTHEGUIDEBUSHINGS

NEARORTOUCHINGHETEMPLATE,ECAUSEHISWILLCAUSE

THEROUTERBITTOCUTINTOTHETEMPLATENDDAMAGET.

INTRODUCTION

o Your Sears/Craftsmanindustrial DovetailFixtureis an accessory used with your Routerto allow you to makedrawers, chests, and the like

where dovetail joints are used to join the front, back,and sides of the workpiece.

The Dovetail Fixturewig allow you to make1" spacedflush and flush offset and 318"rabbetedhaif-bfind dovetail joints, in addition you can

make1" spaced (or open) dovetail joints.

• Workplace widths up to 16"can beaccommodated.

Workplacethicknesses between318"and1" can beaccommodated,

The Dovetail Basehas six pockets moldedinto its front which are gaugesto aid you in setting the "depth-of-cut" for commonly used

depths: 3/8", 1/2", 5/8", 3/4'1,7/8", and 1".

The Dovetail Fixturecomes with two templates andtwo guide bushings for making bait-blind and through or openjoints.

Sears/Craftsman router bits,#25414 and#25415, WHICH MUSTBE PURCHASEDSEPARATELY,are requiredto makethe THROUGHor

OPENjoints.

Sears/Craftsman router bit, #25505 or #26318, WHICH MUST BE PURCHASEDSEPARATELY,s required for making the haIf-bIind joints.

• Eachtemplate has a label, describingthe joint that can becut, along with set up information, the bit and guide bushing required, and the

stop block setting for a particular joint.

The Dovetail Fixture can be used with al Sears/Craftsman Routers.

With a separately purchasedSears/Craftsman#25326, UniversalRouter Adapter,the DovetagFixture can be usedwith many non-

Craftsman Routers, such as, Black & Decker,Makita, and SkiL

UNPACKINGNDCHECKINGCONTENTS

in order to simplify handIing and to minimizeany damagethat may occur during shipping, your Industrial Dovetail Fixtureis packaged

unassembled,

Separate all parts from the packing materials and check eachonewith the igustrations and list of parts at the endof this manuaIto make

sure that ag partsare present beforediscarding any packagingmaterial.

• If any parts are missing or cannot beaccounted for, do not attempt to assemble,install, or usethe industrial DovetailFixture

until the missing parts havebeenobtainedand the product has beenassembled correctly.

Contact your localSearsRetail Outletfor a repIacement product or for the missing parts.

3



ASSEMBLYNSTRUCTIONS

Thefollowingoolsare requiredorassembly:

1)

Amediumsized

Phillips

crewdriver,

2) Asmallor mediumsizedadjustablewrench.

ASSEMBLYOFTHERIGHTSIDETEMPLATESUPPORTTOTHEDOVETAILBASE

1). Placehe dovetailbaseopsidedownona flat surface.

2) insertoneof the5/16-18x 2" longroundheadsquareneckboltsinto thes ot inthe right

side

of thebase.(NOTE:Therightsideof the

bases identifiedbythewordsRIGHTSIDEmoldedintoit.)

3) Placea11/32"I.D_x 7/8"O.D.washerontotheboltasshownin Figure1,

4) Threada5/16-18hexnutontothe bolt,asshown,until it bottomsout againsthe washer,

5) Backoffthe nutfromthe washerbetween1/4and1/2turns.Nigh thenutsothatthecornersof thenutareverticallYineduPasshown.

Notethe alignmentof the hexpocket

in

thetemplatesupport.Theboltshouldbefreeto movesidetoside;if it doesnot, loosenthenut1/3

turn or untilthecornersof thenutpointupanddown.

8) Assembleherighttemplatesupportto therightsideof thedovetailbaseso thatthe hexoutlinesupandf ts into thehexpocketinthe

right templatesupport,(NOTE:Therighttemplatesupport

has

thewords RIGHTSIDEmoldedinto it for identification.)

7) Assemblea #10-32x 5/8°ongpanheadmachinescrew,a 13/64" .D.x 9/16"O.D.washer,anda#10"32hexnutt° thebaseassh°wn t°

holdthetemplatesupportin place.Securelyightenthe nut andscrew_

8)

The

templatesupportshouldmovefreelyfrontto backalongthe sideof thebase,If it doesnot,it meanshatthe 5/16-18hexnut is too

tight onthebolt andshould

be

loosened.Todo this, removethefastenersassemblednstepT,andremovethetemplatesupport;repeatsteps

4 through7.

•

ASSEMBLETHE LEFT SIDE TEMPLATESUPPORT TOTHE DOVETAIL BASETHE SAMEAS THE RIGHT SIDE

TEMPLATE SUPPORT WAS ASSEMBLED

Fig. 1

"/8"ongPANHEADACHINECREW

11/32"LO.XT/8"O.D.WASHER

MUSTLINEUP

5/16-18X2"ongROUNDEAD

SQUAREECKBOLT

?HEXNUT

_.D.WASHER

DOVETAILASE

_ BACKOFDOVETAILASE



ASSEMBLYOFTHETOPCLAMPINGBARTOTHEDOVETAILBASE

1)

Assemble

neof theboltsupportsto bothofthe 5/16-18

X3-1/2 long

round

head

squareneckboltsas shown

inFigure2.

2) Alignthe

square

onthebolt

with

the squareholein the boltsupport.Theboltsupport

is

to =bottom-out"againstthe boltasshown

in

Figure3.

FIG.2 5/16-18X3-1/2"IG.3

longROUND

HEADSQUARE _-x

,o,,

FIG. 3a

3) Assembleoneofthespringsto eachof thenylonspring retainersby pushingthespringovertheraisedcylindricalportionof the

springretaineras shownin Figure3aandFigure3b,

4) Positionthedovetailbaseonafiat smoothsurfaceso the backofthe baserestsonthesurface.

NOTE:ALTHOUGHOTHENDSOFTHEDOVETAILASEARESHOWNASSEMBLEDNTHEFOLLOWINGIGURES,THEACTUALASSEM-

BLYSDONEONEENDATATIME.

5) Fromthe bottomofthe base,inserta boltwithbolt supportthroughtheslotin thetopof thebasesothe raisedportionof thebolt

supportgoesinto theslot,asshownin Figure4,

Fig, 4 SLOTN SLOTN

DOVETAIL DOVETAILASE DOVETAIL BOLTANDOLT

EASE / BASE

BOLTAND

BOLTSUPPORT

FRONTOFDOVETAILASE

6) Placea5/16" I.D.X 7/8"O.D.thick nylonwasheroverthe boltso that thecountersinkacesawayfromthedovetailbaseas shownin

Figure6. It will benecessaryor youto holdthebolt in placewhenperforminghis andthe followingsteps.

HELPFULHINTS:Positionhe bolt andtheboltsupportunderthenotchin theribas shownin Figure5, to helpholdthebolt in place,

Fig. 5 _ NOTCHNRIB

SLOTINDOVETAILASE

BOLTANDOLTSUPPORT



7)

Placeaspringandspringretainer,assembled

n

step3, overthebolt so

the

springfits

into

the

countersink

n

the

thick

washer

asshown

In Figure6.

8) Pressdownonthespringretaineruntiljust the

end

of theboltsticksoutpasttheendofthe springretainer.

9) Slidethe clampingbaroverthe boltsothatthespringetainerabutstheinsideof theclampingbarasshownin figure6. NOTE:THE

SPRING

RETAINER

MUST

PUSHAGAINSTTHECLAMPNGBAR.

10)Placean11/32"I.D.X 7/8"

O.D.

thin nylon

washer

andan 11/3Z I.D.X7/8"O.D.washerover thebolt.It will benecessaryor youto

pressdownonthe dampingbar whiledoingthis.

11) Takeone

of

the

clamping

nobsandthread

it

ontotheboltasshown.DONOT

THREAD

he knobcompletelyontothe bolt--just

enough

so

theknob

holds

he clampingbarin place.

SPRINGND

NYLONSPRING

RETAINERIT

INSIDEHEOPEN

SIDEOFTHE

CLAMPINGAR

(SEECLAMPING

BARDETAIL)

\

CLAMPING

Assembleclampingbar,knobs,endcapson bothends asshown

t f/32"LD.X 7/B"O.D.WASHER

11/32"LD.X T/8"O.D.

THINNYLONWASHER

SPRING

31/2 BOLT

BOLl

SUPPORT

FIG. 6

KNOB

CLAMPINGAR

CLAMPINGARENDCAP

OPENIDEOFTHECLAMPING

BARPOINTSOWARDHETOP

SURFACEFTHEDOVETAILASE

11/32"LD.X 7/8"O,D.

t THICKNYLONASHER

/ TOPSURFACEFTHE

DOVETAILASE

-- RIGHTTEMPLATE

SUPPORT

CLAMPINGBARDETAIL

NYLONSPRINGETAINER

11/32"LD.X7/8"O.D. (RETAINERBUTSTHE

WASHER LAMPING SAR)

/

CLAMPING

AR

(SHOWNWITH

/

ENDCUTAWAYANDSECT ONED /

SONYLONSPRINGETAINER /

PLACEMENTANBESEEN) /

COMPRESSION

SPRING

12)Repeatabovesteps4 through11for theotherendof the clampingbar.

13)Assembleheendcapstothe endsof theclampingbarby pressinghemin; theyaredesignedo be"force-fit"intothe barin oneway

only.It maybenecessaryo "tap"themin by gentlyhittingthemwitha rubbermatletora pieceof wood--sincetheyfit verytightly intothe

clampingar,SECARE WHEN DOINGTHISSOAS NOT

TO

DAMAGETHEEND

CAPS,

USECARETHATTHECAPSAREPROPERLYALIGNEDASSHOWN WHEN ASSEMBLINGTHEM TO THEBAR.

fig.

CLAMPINGARPARALLELO

TOPOFBASE

J SPACINGOBE

APPROXIMATELY

1-1/2"

0 0 0

14)Tightenheclampingknobsontotheboltssothatthespacebetweenhebottomof theclampingbarandthetop of thebaseis about

1 1/2".Theciampingbarshouldbeparalletothe topof thebase.

15)Aftercompletinghe abovestepsyourDovetailFixtureshouldlooklikethe illustrationn Figure7.

6



ASSEMBLYOFTHEFRONTCLAMPINGBARTOTHEDOVETAILBASE

1) Assemblehe front clampingbarto thedovetailbasefollowingthesameprocedureusedto assemblehetop clampingbar tothedove-

tail baseas shownin Figure8. The5/16-18X4-1/2"longroundheadsquareneckboltsareused,

Fig. 8

BOLT

0

4 I/2" BOLT / ""

11/32"1.D.7/8"O.D,

THICKNYLONWASHER

COMPRESSIONPRING

CLAMPINGAR

ENDCAP

1 /32"LD.X7/B"O.D,

RETAINER THINNYLONWASHER

CLAMPINGAR

(SHOWNWITH

ENDCUTAWAY

ANDSECTIONED

SONYLONPRING

RETAINERLACE-

MENTCANBE

SEEN)

COMPRESSION

SPRING

NYLONSPRING

RETAINER

(RETAINER

ABUTSTHE

CLAMPINGAR)

11/32".D.X 7/8"O.D.WASHER

ASSEMBLYOFTHECAMHANDLESANDPIVOTSHAFTTOTHEDOVETAILBASE

Afterthecamhandlesandpivotshafthavebeenassembledo thebase,it will be

possible

o accuratelypositionthetemplatesor close

fitting

joints,

Notethat therearesomegraduationsonbothtemplatesupports.

• Rotatinghecamhandlesothat the

pointer

inesup withone of thegraduationspermitsaccurateront-to-backpositioningof the

template.

• Camhandlesaredesignedo provideinfinitetemplateadjustment.

Onegraduationequals1/64"of movementof thetemplate.

• Rotatinghecamhandlesothat thepointer

lever

movestowardthefrontof thebase.causesthetemplateto alsomovetowardsthefront

of thebase.

• Converselyotatingthecamhandlesothat thepointerlevermovestowardthebackof the base,causesthetemplateto alsomove

towardsthebackof thebasealso.

1) Assembleoneof thecamhandlesto thepivotshaftusinga #10-32x 5/8 longpanheadmachinescrewanda 13/64"I.D.x9/16"LD.

washer,asshowninFigure9,

2) Usecaresothatthe pivotshaftfits

into

thehex-shapedholein thecamhandle.Thepivotshaftmayfit tightly intothecamhandle;

this isnormal.

3) Makesurethatthepivotshaftbottoms*outnsidethecamhandle.

Fig. 9

/ CAMHANDLE

13/64".D.X9/16°0.O,WASHER-_,,,,_ _ PIVOTSHAFT

7



14)Assemblehe othercamhandleo theotherendof thepivotshaftusinga 13/64"I,D.x 9/16"O.D,washeranda#10-32X 5/8"long

penheadmachinescrew,asshownin Figure14.

15)Makesurethat thecamhandlelinesupwiththecamhandleat theotherendofthe pivotshaftandthat theendofthe camhandlefitsinto

theholein thebase.

16)Tightenthe screwsecurely, LEFTTEMPLATEUPPORT

Fig. 14

/_ #10-32X5/8"LONG

PANHEADACHINE

SCREW

_" DAMHANDLE

17)Rotateoneof thecamhandtes-ltshoutdrotatefreelyand movethetemplatesupports,

18)If this doesnot happen,oosenthescrewon the retainerandmovetheretainerawayfrom thesidewall slightly,

19)Securelyretightenthescrew.

20)If thereis toomuchside-to-sidemovement(play)of thecamhandles;oosenthescrewin theretainerandmovetheretainerc/oserto the

sidewaltof thebase.

21)Securelyretightenthescrew,

ASSEMBLYOFTHEFRONTSTOPBLOCKSTOTHEDOVETAILBASE

1) Aseemblehefrontstopblocksothefront of thedovetailbase,at eachend,using#10-32x 5/8 long flatheadmachinescrews,13/64_

I.D.x 9/16"O.D.washers,and# 0-32 hexnuts,as shownin Figure15.

2) Makesurethattheopenrib portionfits intothe slotin thefrontof thebase.Thestopblockwglfit intothe slotin onepositiononly,

3) Tightenhescrewsecurelyontothenut.

4) Assembleheotherfrontstopblockto oppositeendo1thedovetagbaseinthesamemanner.

Fig. 15

FORREASONSFCLARITY,THEFRONT

CLAMPINGAR,KNOBS,BOLTSND

SPRINGSRENOTSHOWN

WASHER

DOVETAILASE

SLOT

#10_32XB/8OLONG

FLATHEADMACHINE

SCREW

SUPPORT

#10-32HEX

13/64LD.X9/16°O.D/

WASHER J

FRONTTOPBLOCI_

_ FRONTOFDOVETAtLASE

5/8"LONGFLATHEAD

MACHINESCREW

10



ASSEMBLYOFTHETOPSTOPBLOCKSTOTHEDOVETAILBASE

•

Thetopstopblocksareassembledothetop of thedovetailbasein oneoftwowaysdependinguponwhichstyleofdovetailjointis

to becut:

a) HALF-BLINDLUSHJOINTS--TheA" onthestopblockfacestowardthe"middleof thebase".

b) HALF-BUNDRABBETOINTS_The B onthestopblockfacestowardthe"middleof thebase".

c) THROUGHOINTS--The"A" onthestopblockfacestowardthe"middleof thebase".

• Sincetheflushjoint is themorecommonlyusedjoint,thefollowinginstructionsapplyto theassemblyof thestopblocksfor this

stylejoint.

1) Positionthedovetailfixturerightsideupon aflat surface.

2) Assembleoneof thetop stopblocksto thetop surfaceof thebaseusinga#10-32x 7/8"longflatheadmachinescrew,as shownin

Figure16.Thescrewthreadsintotheholeinthe bottomofthesIot.

3) Makesurethatthe "A" facesthe "middleof thebase".

4) Makesuretheopenribportionof thestopblockfits intotheslot in thetop surfaceof thebase.

Fig.

16

RfBONSTOPLOCK_

#10_32X 7/8_LONG \

MACHINECREW

#t0-32X7/8"L'ONGLAT

HEADMACHINECREW

TOPSTOPBLOCK

SLOTNTOP

OFBASE

SLOTIN TOP

OFBASE

MIDDLEOFTHEBASE

5) Assembleheremainingtopstopblockto theoppositeendof thebaseinthesamemanner.

6) Againmakesurethatthe "A" facesthe"middleof thebase"

7) Tightenbothscrewssecurely.

8) Torepositionthestopblocksfor rabbetoints,simplyloosenthescrewsjustenoughso thattheribson the stopblockscomeout of the

slot,Thestopblockisthenrotated180°to thealternateposition,sothe

B

facesthe middleofthebase,andsecurelyretightenhe screws.

ASSEMBLYOFTHECLAMPINGKNOBSTOTHEDOVETAILBASE

1) Assemb_e1_/32D.x 7/8"____was_ers_ntot_e_/1_-18b_itsat b_thends_f t_ed__etai_aseassh__n in Figure17_

2) AssembleheclampingknobsontotheboItsasshown.

3) Threadtheclampingknobsontothe boltsso that thespacingbetweenhewasherandthetemplatesupportsis approximately1/2".

4) Setthedovetailbaseasidefor thetimebeingandcontinueon withthe nextsection.

ASSEMBLYOFTHETEMPLATES

/ 5/16-18X2" longROUND

Fig. 17 / HEADQUARENEC

BOLT

5/t6- t8 X2°tongROUND

HEADSQUAREECKBOLT\

\

11/32".D.XT/8"

// O.D,WASHER

KNOB

CLAMPING

KNOB

11

/2"SPACINGETWEFNASHERND

TEMPLATEUPPORTBOTHENOS)



•Placethetemplatestiffenerinto therectangularslotin theunderneathideof thetemplate,asshowninFigure18.

NOTE:THETEMPLATEORCUTTINGALF-BLINDOINTSSBEINGUSEDASANILLUSTRATIONNTHEFOLLOWIHGIGURES.

1) Threada #8-36x 3/16"longpanheadmachinescrewthrougheachof the fiveholesin thetemplateandinto thethreadedholesin the

templatesupport,asshowninFigure24andsecurelyightenallof thescrews.

Fig.

18 _ TEMPLATETIFFENER

\ _ _ _ J jRECTANGULARSLOT

TEMPLATE

_ _ MACHINESCREwSLOTTEDINDINGEAD_ _ MA#&3gX3 6"t°ngPANHEADCREW

NOTE:ONSOMEEARLYERSIONSOFTHIS

PRODUCT,

SLOTTEDINDINGHEADMACHINESCREWHASBEENSUBSTITUTEDORTHE

PANHEADCREWSPECIFIEDORASSEMBLINGHETEMPLATEUPPORTSOTHETEMPLATES.SEETHESCREWLLUSTRATIONN

FIGURE18),

2) Assemblehetemplatebracketso thetemplateusingfour #10-32x 3/8°longpanheadmachinescrews_as shownin Figure19.

3) MAKESURETHATTHETEMPLATEBRACKETSREASSEMBLEDOTHEUNDERNEATHIDEOFTHETEMPLATE,SSHOWNN

FIGURE19,ANDTHATTHEAL]GNMENTOFTHEBRACKETSS ALSOASSHOWNNTHEFIGURE.

4) IT IS NOTNECESSARYORTHESCREWSOBETIGHTENEDTTHISSTAGE;HETEMPLATERACKETSHOULDBEFREETOMOVE

WITHRESPECTOTHETEMPLATERELSETWILLNOTBEPOSSIBLEOALIGNTHETEMPLATESDESCRIBEDNTHENEXTSECTION.

5) Theassembledemplateshouldlookliketheillustrationin Figure20.

Fig. 19

#10-32X3/8"tongPANHEADACHINECREW

TEMPLATE

'\

_- TEMPLATERACKET...

6) Assemblehetemplatestiffenerandthetemplatebracketso the TEMPLATEORCUTTINGHROUGHOINTSusingthesamemethod

describednthe precedingsteps1through5, Refero Figure20.

Fig. 20

lg



ALIGNMENTOFTHETEMPLATES

Inorderfor theDovetailFixtureto functionproperly,it is necessaryor thetemplateso bealignedwithrespectto dovetailbase.The

reasonfor this, isthatdovetailcutsareatboth endsof theDovetailFixture.Whenproperlyaligned,he resultbeingall matingcorners

willalwaysbelinedup.

NOTE:THETEMPLATEORCUTTINGHALF-BLINDOINTSSBEINGUSEDASANILLUSTRATIONNTHEFOLLOWINGIGURES,

1) Withthe dovetailbasesti l havingthe 1/2"spacingbetweenhewasherandthetemplatesupports(Referto Figure17),assemblehe

templateassemblyo thedovetailsothat:

a) theslotin thetemplatebracketfits overthebolt,

b) thelegof the templatebrackets betweenhewasherandthetemplatesupport,and

c) thelegsfit intotheslotsinthetemplatesupports,asshownin Figure21.

d) NOTE:THISPROCEDUREUSTBEFOLLOWEDWHENEVERHETEMPLATESINSTALLEDONTHEDOVETAILIXTURE.TISMOST

IMPORTANTHATLEGOFTHETEMPLATERACKETLWAYSEBETWEENHEWASHERNDTHETEMPLATEUPPORTORELSETHE

TEMPLATEWILLNOTBEPROPERLYOSITIONEDORCUTTINGACCURATEOVETAILS.orinitialsetup,Allowthelegsofthe template

bracketto "bottomout" inthe slotsinthe tempiatesupportsasshownin Figure21.

Fig. 21

WASHER

BOLT_

TEMPLATERACKET

SLOTN THETEMPLATERACKET

_ RtGHTTEMPLATEUPPORT

j SLOTINTHETEMPLATESUPPORT

0

"_TEMPLATERACKETBOTTOMS-OUT"AGAINSTHIS

SURFACEBOTHNDSOFDOVETAILASE)

TOREMOVEHETEMPLATEROMTHEDOVETAILIXTURE,LOOSENHECLAMPINGKNOBSSOTHATSPACINGETWEENHE

TEMPLATEBRACKETNDTHEWASHERSABOUT1/2";GENTLYLiFTTHETEMPLATEPWARDFROMTHEDOVETAILASESOTHATTHE

TEMPLATERACKETCLEARSHESLOTSINTHETEMPLATESUPPORTNDSTORENACONVENIENTOCATION,

2) LightIytightentheclampingknobsat bothendsof the baseso that thetemplatebracketsareheldin placeagainstthetemplatesupports

asshowninFigure21.

3) Movethetemplatefrom sideto sideonthe templatebracketsso that it is centeredwith respecto the templatebrackets,Thismeanshat

thetemplateandbracketsshouldlookIikeoneof the followingfigures:Figure22,Figure23,or Figure24,Movetemplateront-to-backsothat

front edgeof templateis parallelwith thefront of the dovetailbase.In eachconditionhetemplateandthetemplatebracketsMUSTbe

symmetricalwith eachother.Thefiguresdonot showthe completedovetailixture,butonly theunderneathsideof thetemplatewithtemplate

bracketscorrectlypositioned,n orderthat thecorrectpositionsof the partscanbeseenclearly.

]3



Fig. 22

I

TEMPLATE

_"DISTANCEETWEENHESEURFACES

MUSTBEEQUALTBOTHENDS

TEMPLATERACKET

CONDITIONONE."EMPLATERACKETSROTRUDEEYONDTEMPLATES

Fig. 23

o

j TEMPLATE

J

F

THESEURFACESUST

BEEQUALTBOTHENDS

_0 0 TEMPLATERACKET

CONDITIONWO;TEMPLATEROTRUDESEYONDTEMPLATESRACKETS

.24

o 0

0

MUSTBEEQUALTBOTHENDS

TEMPLATERACKET

CONDITIONTHREE.TEMPLATEVENWITHTEMPLATERACKETS

14



4) After thetemplatebracketshavebeencorrectlypositionedonthe templatesecurelytightenthefourscrewsholdingthetemptatebrackets

to thetemplate.

5) Removehetemplateassemblyromthebaseandsetit asidefornow.

6) Aligntheothertemplateassemblyn thesamemanner,

ITSHOULDBENOTEDTHATYOUMAYFIND,THATAFTERMAKINGSOMESAMPLECUTS,SLIGHTADJUSTMENTSAYBEREQUIRED.

HOWTOMAKETHESEADJUSTMENTSS EXPLAINEDNTWOOFTHEFOLLOWINGSECTIONS:MAKINGADJUSTMENTSORHALFBLIND

JOINTS"or "MAKINGADJUSTMENTSOROPENTHROUGH)OINTS".

7) Removehetemplateassemblyromthebaseandset it asidefornow.(Figure25 below,is anexampleof INCORRECTLYositioned

templatebrackets,)

CKET

BEYONDHETEMPLATE

BRACKET

0

o

o 0

THETEMPLATERACKETXTENDS

tEMPLATE

CONDITIONOUR:THISCONDITIONSNOTCORRECT--

TEMPLATERACKETXTENDSEYONDHETEMPLATEND

THETEMPLATEXTENDSEYONDHETEMPLATERACKET

• StMPLYMAKESUREBRACKETSREPOSITIONEDHESAMEATACHEND

ASSEMBLY

OF

AGUIDEBUSHINGTOTHEROUTER

ALWAYSMAKESURETHATTHEROUTERS "TURNEDOFF"ANDTHATTHEELECTRICALORDHASBEENUNPLUGGED

FROMTHEELECTRICALUTLETBEFORESSEMBLING GUIDEBUSHINGOTHEROUTERORMAKINGANYADJUSTMENTSR

CHANGINGROUTERBITSINTHEROUTER.

REMOVEANYROUTERBITFROMTHEROUTERBEFOREPROCEEDINGITHTHEASSEMBLYOFA GUIDEBUSHINGOTHEROUTER.

Assembly for Sears routers with three hole baseplates:

1) Placethe'routerupsidedawnonaflat surfaceandremoveanyguidebushingthatmaycurrentlybein the router,

2) Placetheguidebushingrequiredfor thetypeof dovetagoint to becutundertherouterbaseplateasshownin Figure26.

Fig

26

10-32X 3/8°LONGFLATHEAD

MACHINECREW

(1/2"DIAMETERHOWN)

NOTETHEORIENTATIONF"

THEGUIDEUSHING



3) MAKESURETHATTHEORIENTATIONFTHEGUIDEBUSHINGS ASSHOWN,

4) Positiontheguidebushingsothatthethreethreadedholesinthe guidebushingineup withthe countersunkholesinthe baseplate.

5) Threada#10-32x 3/8"longflatheadmachinescrewinte eachonthe holes.

6) SecureIyightenthescrews.

Assembly

for Soars 1/2 Shank Industrial Routers Modal Nos.

27504,

27505 and 27506 or

equivalent:

1) Placeherouterupsideona flatsurfaceandremoveanyguidebushingthat maycurrentlybeinthe router.

2) Placeheguidebushingnthe recessedportionof therouterbaseasshownin Figure27.

3) Alignthecutoutsintheguidebushingwiththe threadedhoIesinthe base.

4) Threadthetwo roundheadcrews,thatcamewiththe router,intothetwo threadedholesinthe base.

5) Tightenthescrewssecurdy.

B) FORADDITIONALNFORMATIONONCERNINGHISMATTER,CONSULTOURROUTEROWNERSMANUAL.

MAKESURETHATTHEROUTER

BITISALIGNEDWITHORCENTEREDN THEHOLE

IN THEGUIDEBUSHING.TODOTHIS,LOOSEN

SCREWSHOLDINGBASEPLATEORADAPTER

PLATETOROUTER,CENTERGUIDEBUSHINGHOLE

WITHRESPECTOROUTERITANDRETIGHTEN

SCREWSSECURELY

Fig, 27 _ - ROUTERBIT

I i I

@

I

TEMPLATEUIDE-

ROUTERA_

Assembly for other brands of routers:

IN

ORDERTOUSETHEDOVETAILIXTUREWiTHOTHERBRANDSOFROUTERS,TWILL BENECESSARYORYOUTOPURCHASE

CRAFTSMANNIVERSALOUTERADAPTERLATE,MODELNO.25326,FROMSEARS,ANDREPLACEHEBASEPLATEONYOURROUTER

WITHTHEADAPTERPLATE.

1) Placethe routerupsideon aflatsurfaceandremoveanyguidebushingthatmaycurrentlybeinthe router,

2) Placetheguidebushingrequiredor thetypeof dovetailjointto becut undertherouterbaseplateas showninFigure2&

3) MAKESURETHATTHERIENTATIONFTHEGUIDEBUSHINGS ASSHOWN,

Fig. 28

NOTETHEORIENTATIONF

THEGUIDEUSHING

MACHINESCREW

(t/2"DIAMETERIlOWN)

MAKESURETHATTHEROUTER

BITtSALIGNEDWITHORCENTEREDNTHEHOLE

IN THEGUIDEBUSHING.TODOTHIS,LOOSEN

SCREWSHOLDINGBASEPLATEORADAPTER

PLATETOROUTER,CENTERGUIDEBUSHING

HOLEWITHRESPECTOROUTERITAND

RETIGHTENCREWSSECURELY

16



9) Applying smallamountofsoaptothe screwthreadswill makeit easierto threadthescrewsintothe holes.

10)Lineupthefront of themountingboardwiththe frontof a workbenchor othersturdysurface,

11)Usingtwo clamps,suchasC-clamps,irmly clampthe DovetailFixtureo theworkbenchbyclampingonthe mountingboardasshownIn

Figure31andFigure31A.

12)Makesurethatthemountingboardinesupwiththe frontof theworkbench.

Fig. 31

CLAMPHERE

\

k

• FRONTURFACEF

THEMOUNTtNG

BOARD

;URFACEF

THEWORKBENCH

FRONTURFACEFTHEBASE

Fig. 31,4

FRONTURFACEF -]

THEBASE

FRONTURFACEFTHE

MOUNTINGOARD

FRONTURFACEF/

THEWORKBENCH

USINGTHEDOVETAILFIXTURE

STYLES OF DOVETAILJOINTS

Fourdifferentstylesofdovetadointscanbemadewiththe DovetailFixtureusingyourrouter.

• Thesejointsaredescribednthefollowingsections.

Half Blind Flush Joint:

• TheHalfBlindFlushJointis usedwhentheheightof boththedrawerront andthedrawerbackisthe sameheightasthedrawersides;

andthe lengthof boththedrawerfrontandthedrawerbackis thesameasthewidthofthedrawer.

SeeFigure32.

18



NOTE:THENORMALDEPTHOFCUTFORAHALFBLINDFLUSHJOINT

IS

3/8 .

_ DRAWERFRONT(PtNPtECE

Fig. 32

DRAWERIDE(TAILIECE)

J

DRAWERACKPiNPIECE)

SIDETAILPIECE)

HALFBILHDFLUSHOINT

HalfBlindFlushOffsetJoint:

TheHaftBlindFlushOffsetJoint is usedwhen:

Theheightof boththedrawerfrontandthedrawerbackisthesameheightasthe drawersides;the tengthof thedrawerfrontis 1/8"

longer(1/16"onaside)thanthewidth of thedrawer;andthe lengthof thedrawerbackis thesameasthewidth of thedrawer.

SeeFigure33.

Toobtaintheoffset,cuta 1t16"deepby 3/8"widerabbetontheoppositeendsonthe insideofthedrawerfront.

NOTE:THENORMALDEPTHOFCUTFORAHALFBLINDFLUSHOFFSETOINTS 3/8 ,

Fig. 33

_ DRAWERRONTPINPIECE)

DRAWERIDETAILPIECE)

DRAWERStDE(TAILPIECE)

TAILS

J

DRAWERACKPINPIECE)_

HALFBILNDFLUSHOFFSETOINT

19



HalfBlindRabbetedJoint:

TheHalfBlindRabbetedointis usedwhen:

thedrawerfrontoverlapsheopeningor thedraweron allfour sidesof the

of

thedraweropening(top bottom andtwosides)thatis;

thelengthof thedrawerfrontis3/4 longer(3/8"on aside)thanthewidthof thedrawer;theheightof thedrawerfrontis also3/4"higher

(3/8°onside)thantheheightofthe drawer;he tengthof thedrawerbackisthesameas thewidthof thedrawer;andtheheightof the

drawerbackisthesameasthe heightof thedrawer

See

Figure

34

Toobtainthis

joint

cuta3/8"deepby3/8"wide rabbetaroundthe

inside

peripheryof

the

drawerfront

NOTE:

THENORMALDEPTHOFCUTFORAHALFBLINDRABBETOINTIS3/8 ,

/DRAWERFRONTPiNPIECE)

Fig. 4

"WIDERABBETAROUNDHE

PERIPHERYFTHEDRAWERRONT

DRAWERIDETAILPIECE)

\

DRAWERSIDE(TAILPIECE)

TAILS

DRAWERACKPINPIECE)

HALFBLINDRABBETEDOINT

Openor ThroughJoint:

• TheOpenorThroughJointis similar to theHalfB{indJoint exceptthatjointseamsarevisibieonthe front, back,andsidesof the

workpiece;on theHalfBlindJoints,theseamsarevisibleonlyonthesidesof theworkpiece,

•

Althoughthisstyleof

joint

canbealsousedfor drawersits mostpopularuseis for makingboxes,andsmallandfargochests

•

Theheightof boththefrontandthe backof thedraweror chestis thesameastheheightasthesidesof thedraweror chest;

andthe lengthof boththefrontandthebackof thedraweror chestIsthesameasthe widthof thedrawerorchest

SeeFigure35

NOTE:THEDEPTH

OF

CUTISDETERMINED

Y

THETHICKNESSES

F

THEFRONT,BACK

AND

SIDEPIECES,

• Thefrontandbackpieces(sometimescalledpin pieces")arecut independentlyrom thesidepieces(sometimescalledtail pieces)

• The'tail piecesarecutfirst usingoneedgeofthetemplateanda dovetailrouterbit Thedepthof cutis equalto thethicknessof the

pin pieces

The'pin pieces'arecutnextusingtheotheredgeof thetemplateanda straightrouterbit Thedepthof cutis equa{o the thicknessof the

taiI pieces Adjustmentsaremadeat thispoint toobtainjoint fit

Fig.

35 _ TAILS ii FRONTPtNPtECE)

TAILS --____ I \ RIDETAILPIECE)

OPENTHROUGH)OINT

_-_-_ BACKPtNPIECE)

2O



ADJUSTINGTHEDEPTH-OF-CUT

OFTHEROUTERBIT

ALWAYSMAKESURETHATTHEROUTERS

"TURNED

OFF ANDTHATTHEELECTRICALORDHAS

BEENUNPLUGGEDROMTHEELECTRICALUTLET

BEFORESSEMBLINGRREMOVINGOUTERBITSTO

THEROUTER,

• Youwill notethattherearesix pocketsalongthefront

surfaceof thedovetailbase,andthat theyareidentified

bya dimensionssuchas3/8, I/2,-up to1.These

pocketsareusedtosetthe depth-of-cutof a routerbit.

Touseproceedasfollows:

DONOTUSEWITHATEMPLATESSEMBLED

TOTHEBASE.

• DONOT

NSTALL

ROUTERBITSTOTHE

ROUTERUNLESSTHECORRECTUIDE

BUSHINGHASBEENASSEMBLEDOTHE

BASEPLATEIRST.

Fig. 36

ROUTERIT

GUIDEBUSHING

_ MAKESUREHATTHEROUTERITISALIGNEDWITHORCENTEREDNTHEHOLENTHEGUIDEUSHING.ODOTHIS,LOOSEN

SCREWSOLDINGASEPLATEORADAPTERLATEOROUTER,ENTERUIDEUSHINGOLEWITHlESPECTOROUTERITANDRETIGHTEN

SCREWSECUREDf

1) InstaIIthe desiredrouterbit to therouterasexp{ainednyour RouterOwner'sManual SeeFigure3B.

A M{NIMUMROUTERBITSHANKENGAGEMENTF3/4"IS REQUIREDNTHECOLLETOFTHEROUTER,

2) TIGHTENHECOLLETNUTSECURELY.

3) Positionthe routeroverthepocketwiththe requireddepth-of-cut,

Fig. 37

Fig.37A

POCKET

2]



4) Graduallymovethe routerbit outward,by usingthedepth-of-cuteatureonthe router,

until

thetipof the routerbit touchesthebottomot

the pocket,as showninFigure37 andFigure37A.

5) Lockthe routerinposition,

Fig. 38 ?FOOT

6) Thedesireddepth-of-cuthasbeenset.

7) Toseta depth-of-cutNOTprovidedfor onthe dovetailbase,simplypJaceheunusedtemplateenthe routerbaseplate,

asshownin Figure38,Theheightfromthetemplateo theendor tip of therouterbitwill thenbethe requireddepthof cut,

WHENETTINGHEDEPTHOFcuT,MAKEABSOLUTELYUREHATTHECOLLETUTDOESNOTCONTACTTOUCH)HEGUIDE

BUSHING.HISCANCAUSEHEGUIDEUSHINGOHEATUPEXCESSIVELYURINGUTTINGWHICHANCAUSEAMAGEOTHETEMPLATE.O

CORRECTHISSITUATIONRPREVENTTFROMOCCURRING,EPOSITIONHEROUTERITNTHEROUTER.

CLAMPINGTHEWORKPIECESOTHEDOVETAILBASE

(ORBACK)FACESP

Fig. 39

TOTHETOPOFTHEBASE

TOP,

OFTHEWORKPIECB

FRONTTOPBLOCK-

FACESOUT

rBECLEAROF

THEWORKPIECES

WORKPtECELAMPEDO

THEFRONTOFTHEBASE

Fig, 40 WORKPIECELAMPEDOTHETOPOFTHEBASE-_-_-/ __i_-_- INSIDESURFACE

TOPC.MPINGB,

TOPSTOPRLOBK

ERO_TLAMPINGBAR-_

WASHER,_,fUSTBE_ORKP_CES¢\ __J_ "_TSTOPBLOCK

INStOESUREADE

_-

'_-'--WORKPIEOECLAMPEO

2,2, THEFRONTOFTHEBASE



• Theclampingarshavebeenspeciallydesignedo allowtheclampingorcestobeappliednextto theworkpiecesormoreefficient

clamping.

his

is

accomplishedbybeingableto positionthe

clamping

nobs

inclose

proximityornextto the

workpieces.

• Figure39 illustratesthepositioningof theclampingarsand theclampingknobswhentheworkpiecesareclampedo the LEFTSIDEof

theDovetailFixture,

Figure40 illustrateshe positioningof theclampingbarsandtheclampingknobswhentheworkpiecesareclampedo the RIGHTSIDEof

the DovetailFixture.

* Notetheclosenessfthe clampingnobsto the workpieces.Whennot inuseclampingknobsandthe supportingboltsandspringsare

freeto bemovedalongthe slotsinthe base,

• CAUTION:WHENCLAMPING,MAKESURETHATTHECLAMPINGKNOBSARENOTPOSITIONEDOCLOSETOTHEWORKPtECESHAT

THEWASHERSBECOMERAPPEDUNDERTHEWORKPIECES.

• FORACCURATEOINTS,THEWORKPIECESUST"Bu]-r-uP" AGAINSTOTHTHETOPANDTHEFRONTSTOPBLOCKSOENSURE

THEEXACTPOSITIONINGFTHEWORKPIECES.

* TOENSUREACCURATEOINTSANDSAFEOPERATION,OODSHAVINGSNDACCUMULATED

UST

MUSTBE

REMOVED

ROMTHE

DOVETAILIXTUREBEFOREACHSETUP,EITHERBYUSINGABRUSHOR BYVACUUMING.

MAKINGDRAWERSWITHHALFBLINDFLUSHJOINTS:

•

The

thicknessof boththe frontandback(pin

pieces)

mustbeat least1/2".

The

thicknessofthe sides(tail

pieces)

mustbeat least3/8".

A partialtailwill becatfor side(tailpiece)thicknessesupto 9/16".Thisisnormalandwill notaffectthejointor its appearance.

Fig. 41

SURFACEINESUPWITH

FRONTTOPBLOCKS

DRAWERIGHTIDE

CORNER1

(CUTATTHELEFTSIDEOF

THEDOVETAILIXTURE)

CORNER4

(CUTATTHERIGHTSIDEOF

THEDOVETAILIXTURE)

DRAWERRONT_

PINS_ /

INSIDEOFDRAWER

STOPBLOCKS

_ DRAWERACK

CORNER2

(CUTATTHERIGHTSIDEOF

THEDOVETAILIXTURE)

CORNER3

(CUTATTHELEFTSIDEOF

THEDOVETAtLIXTURE)

SURFACEINESUPWITH

FRONTTOPBLOCKS

OUTSIDEF

DRAWER

• Figure41 showsa drawerandtheworkpieceshatmaket up.Thisfigureis similartoFigure33,exceptthatit showsthe workpieces

unassembledor anexplodedviewof thedrawer).

23



• Inaddition,thefigure showswherethefourcornersof thedrawerarecutonthe DovetailFixture:

CORNERSAND3 arecotontheLEFTSIDEof the DovetailFixture,

CORNERSAND4 areouton theRIGHTSiDEof the DovetailFixture.

• Trialcutsarestronglyrecommendedsingscrapwoodto ensurethat thefinalworkpieceeareofthe desiredquaIity,

GENERALPREPARATIONS:

a) Theworkpiecesomprisingthedrawer,hat is,front,back,left side,andrightsideshouldbeoutto theproperength,width,and

thickness(es),

Ei#. 42

MARK1"

MARK°DRAWERIOHT /_ _",,

_ MARKDRAWERACKNSIDESURFACE"

_HOWN_DDEN)

MARK4"

SIDETOPSURFACE"

MARKDRAWEREFT

SIDENSIDEURFACE"

(SHOWNIDDEN)

b) Makesurethatallsurfacesaresmoothandsquarewith eachoftheothersurfaces,

c) Lineuptheworkpiecesonaflatsurface,standingonedge,asshownin Figure42.

d) Withasoftleadpencilmarkthefront,back,eftside,andrightside,asshownInFigure42.Thisis to aidyou

workpiecesonthe DovetailFixture,priortocuttingthedovetails•

positioningthe

•40"DIA.GUIDEUSHING

SEARSRAFTSMANOVETAILOUTERIT\ _

#25505OR#26318

24



e) Assemble

he

.40"guidebushingto therouterbaseplate,asdescribedn aprevioussection.Thisthesmallerof thetwoguidebushings

furnishedwiththis product.

f) _nsta__Searsd_vetai_r_uterbit_#255_5_r#26318_t_ther_uterasdescribed_ny_urR__ter_wner_sManuaLShankengagement

shouldbea minimumof 3/4%

_ MAKESURETHATTHEROUTERITtSALIGNEDWITHORCENTEREDNTHEHOLENTHEGUIDEUSHING.ODOTHIS,OOSEN

SCREWSOLDtNGASEPLATEORADAPTERLATETOROUTER,ENTERUIDEUSHINGOLEWITHRESPECTOROUTERtTANDRETtGHTEN

SCREWSECURELY.

_ WHENETTINGHEDEPTHOFCUT,MAKEABSOLUTELYURETHATHECOLLETUTDOESNOTCONTACTTOUCH)HEGUIDE

BUSHING.HISCANCAUSEHEGUIDEUSHINGOHEATUPEXCESSIVELYURINGUTTINGHICHCANCAUSEAMAGEOTHETEMPLATE,O

CORRECTHISSITUATIONRPREVENTTFROMOCCURRING,EPOStTtONHEROUTERITINTHEROUTER.

Fig. 43

' LEFTTOPSTOPLOCK

/"A"FACESOWARDIDDLE

j OFBASE

RIGHTTOPSTOPLOCK

j POINTERPOINTS

TOCENTER

GRADUATION

LEFTFRONTTOPBLOCK

STOPBLOCK

g) Adjust thedepthofcutto 3/8"usingthedepthgaugeonthebaseof theDovetailFixture,asdescribedn a previoussection.

Thissettingis approximateandsomeadjustmentmayberequired.

h) Positionbothof thetopstopbIocksso thatthe"A" facesthe "middleof thebase"asshowninFigure43.

i) Positionthecamhandlesothatthepointerpointsto thecentergraduationasshowninFigure43.

THE FOLLOWING DESCRIBESTHE PROCEDURE

TO

BEFOLLOWEDFORCUTTING CORNERS 1 AND 3:

1) FORCORNER1, positionhe drawerfronton thetopof thebaseso thatit linesupwith thefrontof thebaseandthetop surfaceabuts

the left top stopblock.THEINSIDEOFTHEDRAWERRONTFACESAWAYFROMTHETOPOFTHEBASE.Thewords"INSIDESURFACE"

markedin (d) in theSection,GENERALREPARATIONS,houldbevisible.

2) Lightlyclampthedrawerfront inplace.

Fig. 44

DRAWERRONT

THEENDOFTHEDRAWERIDE

MUSTBELEVELNDF

THENSIDEURFACEFTHE

DRAWERRONTORBACK)

"INSIDESURFACE"HOULDBE

VIStBLEON THISSURFACE

TOPOFTHEBASE _MPLATEUPPORT

(ASNEEDED)

FRONTOF THEBASE

NOTE:WORI(PIECESWILL BEPOSITIONEDONTHEFIXTUREASSHOWN.

"INSIDESURFACE"HOULDBE VISIBLEONTHISSURFACE

25



3) PositionthedrawerRIGHTsideagainstthefront ofthe basesothatthe top surfaceabutstheleft frontstopblock.THEINSIDEOFTHE

DRAWERSIDEFACESAWAYFROMTHEFRONTOFTHEBASE.

Thewords "INSIDESURFACE"markedin (d) Inthe Section,GENERALPREPARATIONS,houldbevisible.

4) Lineuptheworkpieeesso thattheendof thedrawersidelinesupwiththedrawerfront asshownin Figure44.

5) Securelyclamphedrawersideto thebase,

6) Securelyclampthedrawerfrontto thebase.

7) Makesurethatthepartsremaingnedup.

Fig. 45

HALFBLINDOINT

SHORTINGERS WASHER

8) AssembLehe DOVETAILEMPLATEORHALFBLINDJOINTSo the DovetagFixturesothatTHETEMPLATERACKETSITBETWEEN

THEWASHERSNDTHETEMPLATEUPPORTSsshownFigure45.

NOTE:MAKESURETHETEMPLATELAMPINGNOBSARELOOSETOMAKETEMPLATEDJUSTMENT,FTERADJUSTMENTSMADE,

RETIGHTENEMPLATELAMPINGNOBS.

9) Makesurethattheshort

fingers

onthetemplate,as shownin Figure45, facestowardthefront of the base.

10)Makesurethat thetemplates flushandparallelwiththe workpiecesclampedo base.Fornarrowdrawerfronts, the useofanauxifiary

supportfor thetemplates recommended.tspurposes to aidin supportingtherouterwhilecutting.It canbemadefroma pieceof scrap

wood;butits thicknessmustbethe sameasthe drawerfront.(Referto Figure44).

1 ) Clamphe templaten placeby tighteningtheclampingknobs.

12) _ BEFDREMAKINGANYCUTSMAKESURETHATTHEBITWILLNOTCUTINTOTHEBASEORANYOTHERCOMPONENTF

THEDOVETAILIXTURE.THISCANCAUSEDAMAGEOTHEDOVETAILIXTURE;ORLOSSOFCONTROLFTHEROUTERWHICHCAN

RESULTNSERIOUSBODILYNJURY.ATRIALRUNWITHTHEROUTERURNEDOFFANDUNPLUGGEDROMTHEELECTRICALUTLET

ISSTRONGLYECOMMENDED,

13)TURNTHEROUTERON,

Fig. 46

j DRAWERRIGHTSIDE

DOVETAILUTS

26



14)Cutthedovetailby movingthe routerfromLEFTTORIGHT,with theguidehushingfollowingthetemplate,DONOTFORCENYTHING;

MOVETHEROUTERNSLOWANDSMOOTHFASHION.

15)Toensureasmoothanduniformjoint, retracethe previouscutby movingtherouterfrom RIGHTTOLEFTwith theguidebushingagain

followingthe template.

16)_ NEVERLIFTTHEROUTERUPWARDSWHENTHEROUTERSONANDTHEROUTERBITROTATINGRWHENTHEGUIDE

BUSHINGSNEARTOORTOUCHINGHETEMPLATE.HISCANCAUSEDAMAGEOTHEDOVETAILIXTURE;ORLOSSOFCONTROLOF

THEROUTERWHICHCANRESULTNSERIOUSBODILYNJURY,

17)Afterthecut hasbeenmade,heworkpiecesshouldlooklikethoseIllustratedn Figue46.

Fig. 47

/"INSIDESURFACE"HOULDEVISIBLE

_/(,_ /ONTHISSURFADE

TOPOFTHEBASE / AUXILIARYEMPLATEUPPORT

(ASNEEDED)

DRAWERACK

-

_ "

SE

VISIBLENTHISSURFACE

18)Removeheworkpiecesromthe DovetailFixtureandcheckhowtheworkpiecesit together.Someadjustmentsmayberequired,Referto

thesectionMAKINGADJUSTMENTS.

Fig. 48

DOV_A£__

DRAWEREFTSIDE

19)FORCORNER3,positionthedrawerbackonthe topofthebaseso thatit linesupwiththe front of thebaseandthetop edgesurface

abutstheleft topstop block.THEINSIDEOFTHEDRAWERBACKFACESUP.Thewords "iNSIDESURFACE"markedin (d) intheSection,

GENERALREPARATIONS,houldbevisible,SeeFigure47.

20)Lightlyclampthedrawerbackin place.

g?



21)PositionthedrawerLEFTsideagainstthefront of thebaseso thatthetop surfaceabutsthe leftfront stop block.THEINSIDEOFTHE

DRAWERSIDEFACESUP.Thewords"INSIDESURFACE"markedin (d)in theSection,GENERALREPARATIONS,houIdbevisible.

22)Lineupthe workpiecesso thatthe endof thedrawersidelinesup withthedrawerbackasshownin Figure47.

23)Continueas

in

Steps5 through16above.

24)Afterthe cut hasbeenmade,the workpiecesshould looklike thoseillustratedn Figure48.

25)Removehe workpiecesromthe DovetailFixtureandcheckhowtheworkpiecesit together.Someadjustmentsmayberequired.

Referto the sectionMAKINGADJUSTMENTS.

THEFOLLOWING DESCRIBESTHE PROCEDURE TO 8E FOLLOWEDFOR CUTTING CORNERS 2 AND 4:

CORNERSAND4 arecut in thesamewayas 1and3 excepttheyarepositionedonthe rightsideof theDovetailFixtureas shownFig49.

Fig. 49

AUXtLIARYEMPLATEUPPORT

(ASNEEDED)

tNTHISSURFACE

/

FRONTOFTHEBASE

ORAWERtGHTSIDE

"INSIDEURFACE"HOULDEVISIBLENTHISSURFACE

NOTE:WORKPIECESILLBEPOSITIONEDNTHEFIXTUREASSHOWN.

_BEFORE

MAKINGANYCUTSMAKESURETHATTHEBITWILLNOTCUT

INTO

THEBASEORANYOTHERCOMPONENTFTHE

DOVETAILIXTURE.THISCANCAUSEDAMAGEOTHEDOVETAILIXTURE.

_NEVER

LIFT

THE

ROUTERUPWARDSWHENTHEROUTERSONANDTHE

ROUTER

BITROTATINGRWHENTHEGUIDE

BUSHING

SNEAR

TOORTOUCHINGHETEMPLATE.HISCANCAUSEDAMAGEOTHE

DOVETAIL

IXTURE.

Afterthecut hasbeenmade,theworkpieeesshouldlooklikethoseillustratedn Figure45.

Thefinishedfront, back,andsidesshouldlooklikethose in Figure41.

Beforegluingthefront,back,andsidestogethez;omepmvisienmust

be

madefor installinghebottom,suchasdadoingorcatting

e

groovearoundheinsideofthedrawerparts.

Yourdraweris nowreadyto begluedtogether,

MAKINGDRAWERSWITHHALFBLINDFLUSHOFFSETJOINTS:


a) Thelengthof thedrawerfront {s1/8_longerthanthe lengthofthe drawerbeck.

b) Whencuttingcornersl and4;thecam handleis rotatedtwo graduationsowardthebackof thebase,hus movingthe template1/32"

towardthebackof thebase.(Referto Figure50).

NOTE:MAKESURETHETEMPLATELAMPINGKNOBSARELOOSETOMAKETEMPLATEDJUSTMENT.FTERADJUSTMENT

S

MADE,

RETIGHTENEMPLATELAMPINGNOBS.

28



FIG.50

°A FACESfDDLEOFEASE

GRADUAtiONOWARDHEBACK

OFTHEBASEFROMTHECENTER

GRADUAtiON

c) Whencuttingcorners2and3;the camhandleis positionedvertically,asshowninFigure4&

d) All otherGENERALPREPARATIONSrethesameasthoseusedfor "MAKINGDRAWERSWITHHALFBLINDFLUSHJOINTS",

THEPROCEDUREORCUTTINGHESEOINTSSTHESAMEASTHATUSEDFOR"MAKINGDRAWERSWITHHALFBLINDFLUSHJOINTS".

Afteralldovetailcutshavebeenmade,cuta 1/16"deepby3/8"deeprabbetonoppositeendsofthedrawerfront.

• Thefinishedfront, back,andsidesshouldlook likethoseinFigure33.

Beforegluingthefront,back,andsidestogethez;omeprovisionmustbemadeforinstallingthebottom,suchasdadoingorcuttinga

groovearoundheinsideofthedrawerpads.

Yourdrawerisnow readyto begluedtogether.

•

Removehe pencilmarkingsby lightsandingor witha softeraserafterthedrawerpartshavebeengluedtogether.

MAKINGDRAWERSWITHHALFBLINDRABBETEDOINTS:


a) Thelengthof thedrawerfront is 3/4"longerthanthelengthof thedrawerback.

Fig. 51

LEFTTOPSTOPBLOCK

/_"B" FACESOWARDIDDLEOFBASE

/ POINTEROINTSTO

CENTERRADUAtiON

29



b) Theheightofthe drawer

front

is 3/4"higherthanthe heightof the drawerbackanddrawersides.

IT IS EXTREMELYMPORTANTHATTHETEMPLATEEPROPERLYLIGNEDWHENMAKINGTHESEOINTS,ORELSE,N

ADDITIONTOTHEJOINTSPACINGNOTBEINGEQUAL,ASSHOWNNFIGURE5BELOW,HETOPSURFACESFTHESIDES,FRONT,

ANDBACKWILLNOT"LINE-UP"PROPERLYITHER.REFEROTHESECTIONALIGNMENTOFTHETEMPLATES.

(FIGURE5 ILLUSTRATESFLUSHDOVETAILOINT.)

AgotherGENERALREPARATIONS,xceptasnotedbelowntheprocedure,rethe sameasthoseusedfor "MAKINGDRAWERSWITH

HALFBLINDFLUSHJOINTS".

Fi . 52

/ DOVETAILEMPLATEOR

LFBLINDOINTS

THEPROCEDUREORCUTTINGCORNERS1AND4 IS THESAMEASTHATUSEDFOR

"MAKING

DRAWERSWITH HALFBLINDFLUSHJOINTS EXCEPT:

PositionBOTHop stopblocksso thatthe "B" facesthe middieof thebaseasshownin Figure51,

Usethe sideof thetemplatehathasthelongestfingers,

Beforegluingthe Iront,back,andsidestogethez;omeprovisionmustbemadefor installing thebottom,suchasdadoingor cuttinga

groovearoundheinsideofthedrawerparts.

Yourdrawers nowreadyto begluedtogether.

Removehe pencilmarkingsby light sandingorw tha soft eraserafterthe drawerpartshavebeengluedtogether.

TROUBLESHOOTING:

• If thejoint istooloose: iNCREASEhe depthof cut by INCREASINGheamountbywhichtherouterbit extendsbeyondhe basepiateby

1164"to 1/32"andmakea trialcut.Continueadjustinguntil desiredoint fit is attained,

* Ifthe jointis tootight: DECREASEhedepthof cutby DECREASINGheamountbywhichtherouterbit extendsbeyondhe baseplateby

1/64" to 1/32"andmakeatriaI cut.Continueadjustinguntildesiredointfit isattained.

• If the joint is tooshallow:Refero Figure53.LoosenheclampingknobsholdingthetemplatebracketsandmovethetemplateINWARD

halfthe additionaldepthneededby turningthe camhandles.Retightenhe clampingknobs.

• It the joint is toodeep:Refero Figure54.LoosentheclampingknobsholdingthetemplatebracketsandmovethetemplateOUTWARD

by turningthecamhandleshalfthedistanceneeded.Retightenhe dampingknobs.

• If the jnint isnotunilormlyspacedtramtop surfaceofdrawer:Referto Figure55. (Seehe Section"ALIGNMENTOFTHETEMPLATES",)

Withthe templateclampedo the base,loosenthefour screwssecuringhetemplateto thetemplatebrackets,andmovethetemplate

slightlyto the Iuft.Tightenhefourscrewsandmakeatrial cut.If movingthetemplateto the leftdidnotcorrectthecondition,butmadeit

worse,loosenthe screwsandmovethetemplateto the righta smallamount.Tightenthefour screwsandmakeatriai cut.Continue

movingthetemplateto the rightuntilthe conditionis completeIycorrected,MAKESURETOSECURELYIGHTENHEFOURSCREWS.

it movingthe templateo theleft improvesthecondition,continuemovingthe templateo the leftuntiltheconditionis completeiy

corrected.Makesurethetemplateremainsparagelo thefront of thedovetailbase.MAKESURETOSECURELYIGHTENHEFOUR

SCREWS.AFTERTHETEMPLATESAVEBEENCORRECTLYEALIGNED,HEYSHOULDREQUIREOFURTHERDJUSTMENTSF

THEYAREHANDLEDWITHCARE.

3O



Fig. 53

JOINTIS TOOSHALLOW

DRAWERRONT_

FRONT

DRAWEREF:

DRAWERA

\

Fig. 54

JOINTIS TOODEEP

BACKEXTENDS

OUTPASTSIDE

DRAWEREFT

DRAWERA

OUTPASTS_E

Fig.55

JOINTSPACINGS

NOTUNIFORM

DRAWERACKz- L_I_

jJ

DRAWEREFTSIDEj_

J

J

_,/ SPACINGESSTHAN

DRAWERACK

31



Fig. 58

CORNER#1

PROJECTFRONA_

CORNER#4

SURFACEINES

UPWITHFRONT

STOPBLOCKS

PROJECTRtGHTSIDE_._

_ SURFACE

FRONTTOPBLOCK

OUTSIDEF

PROJECT

TAtL_

CORNER2 "" PROJECTACK

PROJECT

CORNER#3

SIDE

MAKINGPROJECTSWITHOPEN(THROUGH)FLUSHJOINTS:

• Thethicknessof boththefront andtheback(pinpieces)mustbebetween3/8"and1".

Thethicknessof the sides(tail pieces)mustalsobebetween3/8"and1".

Figure56showsa projectandthe workpieceshatmakeit up.Thisfigureissimilar toFigure35,exceptthatit showstheworkpieces

unassembled.

Trialcutsarestronglyrecommendedsingscrapwoodto ensurethatthefinalworkpiecesareof the desiredquality.


a) Theworkpiecescomprisingheproject,thatis, front, back,Ieftsideandrightsideshouldbecut to theproperlength,widthandthick

ness(es).

b) Makesurethat allsurfacesaresmoothandsquarewith eachof theothersurfaces.

c) Lineup theworkpiecesona flatsurface,standingon edge,asshownin Figure57,

d)

WITHASOFTLEAD

PENCIL

MARKTHEFRONT,BACKANDTWOSIDES,ASSHOWN

N

FIGURE57, ALSO,THIS

IS

TO

AID

YOU

IN

POSITIONINGHEWORKPIECESNTHEDOVETAILIXTURE,PRIORTOCUTTINGHEDOVETAILS,

e) Positionbothof thetop stopblocksso thatthe "A"facesthe"middleofthe base"asshownin Figure43.

f) Positionthecamhandlesothatthe pointerpointsto thecentergraduationasshownin Figure43.

32



Fig. 57

MARKPROJECTIGHT_

SIDETOPSURFACE

MARK"PROJECTRONTTOPSURFACE"\

MARK" " \,,\\

%

l

--_. SURFACE"SHOWNHIDDEN)

SURFACE"SHOWNHIDDEN)

TOPSURFACE"

MARK4"

TLEFT

SIDE

TOP

SURFACE

MARK

MARK"PROJECTACK

OUTSIDEURFACE"

MARK3"

MARK"PROJECTEFT

SIDEOUTSIDEURFACE"

THEFOLLOWINGDESCRIBESHEPROCEDUREOBEFOLLOWEDFORCUTTINGTHEPROJECT

RIGHTSIDEANDTHEPROJECTLEFTSIDE:

NOTE:THESEWORKPIECESMUST BECUTFIRSTBECAUSEANYJOINTFITADJUSTMENTSTHATMAYBEREQUIREDCANONLYBEMADEWHEN

CUTTINGTHEPROJECTFRONTANDPROJECTSACK-THATS, THEPROJECTFRONTANDTHEPROJECTBACKAREFITTOTHE PROJECTSIDES,

1) Assemblehe 1/2_guidebushingtotherouterbaseplate,sdescribedna previoussection,Thiss thelargerof thetwo guidebushings

furnishedwiththis product.

2) InstallSearsdovetailrouterbit,#25414,to the routerasdescribednyourRouterOwnersManual.Shankengagementshouldbea

minimumof 3/4".

MAKESUREHATTHEROUTERITISALIGNEDWITHORCENTEREDNTHEHOLENTHEGUIDEUSHING.ODOTHIS,LOOSEN

SCREWSOLDINGASEPLATERADAPTERLATEOROUTER,ENTERUIDEUSHINGOLEWITHRESPECTOROUTERITANDRETIGHTEN

SCREWSECURELY

WHENSETTINGTHEDEPTHOFCUT,MAKEABSOLUTELYURETHATTHECOLLETNUTDOESNOTCONTAC(TOUCH)THEGUIDE

BUSHING.THISCANCAUSETHEGUIDEBUSHINGTOHEATUPEXCESSIVELYURINGCUTTINGWHICHCANCAUSEDAMAGETOTHETEMPLATE.O

CORRECTHISSITUATIONORPREVENTTFROMOCCURRING,EPOStTIONHEROUTERITIN THEROUTER.

1/2DIA.GUtDEBUSHtNG_

SEARSCRAFTSMANOVETAtL

ROUTERIT#25414

3) Adjust the depth of cut.The depth of cut for an OPENDOVETAILJOINTis equal to the thickness of the mating part, That is:

FORCORNER#1 OFTHE PROJECTRIGHTSIDEand FORCORNER#4 OFTHE PROJECTLEFTSIDE,THE DEPTHOFCUT IS EQUALTO

THETHICKNESSOFTHEPROJECTFRONT.

FORCORNER#2 OFTHE PROJECTRIGHTSIDEand FORCORNER#3 OFTHE PROJECTLEFTSIDE,THE DEPTHOFCUT IS EQUALTO

THETHICKNESSOFTHEPROJECTBACK.

Use the depth gaugeon the baseof the DovetaiIFixture,as described in a previous section, asa starting point

33



4) Atthis pointit will benecessaryoryou to makeatopback-upboard.Thereasonsor thetopback-upboardareto minimizesplintering

andto providesupportfor thetemplate.Thetopback-upboardis ascrappieceof woodhavingthefollowingdimensions:

LENGTH:6"to 8",sufficientlengthso that it canclampedbythe topclampingbarandbeusedmorethanonce;

WIDTH;2"wider thanthe widthof the projectsides;

THICKNESS:/8"to 1/4"thickerthanthethicknessof theprojectsides;thisto prevent"ACCIDENTALLY"uttinginto thedovetailbase,

Thiscanalsobeaccomplishedby usingmorethan onepieceof scrapas longasthe resultantength,widthandthicknessareasdescribed.

5) TOCUTCORNER10F THEPROJECTIGHTSIDE,positionthetop back-upboardontopofthebasesothatitlinesopwiththe frontof

thebaseandabutstotheright topstopblockasshowninfigure58.

NOTE:BACKUPBOARDSREUSEDTOMINIMIZESPLINTERINGFPROJECTIECESANDTOKEEPROUTERBITFROMDAMAGINGHE

DOVETAILIXTURE,

Fig, 58 TOPBACK-UPOARD

\

AUXILIARYEMPLATE TOPOFTHEBASE\ _ .

SUPPORT(ASNEEDED) _ _ _ _\_ / _ "_','-._

// \ ....\ ,., v

'k ,J

FRONTOFTHEBASE (( _._ .- _ _,L ,

FRONTACK'UPBOARD __

"OUTSIDEURFACE'HOULDEVtSIBLENTHISSURFACE-

BEFOREOSITIONINGHEFRONTACK-UPOARD

6) Lightlyclamptheback-upboardin place,

7) Positionhe projectsideagainsthefront of thebasesothatthetop surfaceabutsthe rightfrontstopblock.Theuseof afrontback'up

boardat thisstepis alsorecommended.t is positionedbetweenheprojectsideandthe clampingbaras shownin Figure58.Thefront back-

upboardshouldhavethefollowingapproximatedimensions:

LENGTH:"to 8",sufficientengthsothatit canbeclampedbythefront clampingbarandbeusedmorethanonce;

WIDTH:1"to 2"widerthanthewidthof thesides;

THICKNESS:/4"to 1/2".

THEOUTSIDEOFTHEPROJECTIDEFACESAWAYFROMTHEFRONTOFTHEBASE.

TEMPLATEOR

Fig. 59 TEMPLATERACKET

CLAMPINGKNOBSI

j CLAMPINGKNOB

\

WASHER

34



Thewords "OUTSIDESURFACE"markedin(d) in theSection,GENERALREPARATIONS,houldhavebeenvisiblebeforehefront back-up

boardwasput in place.

8) Lineuptheworkpiecessothat the endof the projectsideandback-upboardsDineupasshownin Figure58.

9) Securelyclampthe projectsideandthe front back-upboardto the frontof thebase.

10)Secureiydampthetopback-upboardto the topof thebase.

11)Makesurethatthe partsremainlinedup.

12)Assemblehe DOVETAILEMPLATEOROPEN(THROUGH)OINTSo theDovetaiIFixtureso thatTHETEMPLATERACKETSIT

BETWEENHEWASHERSNDTHETEMPLATEUPPORTSs shownFigure59; it will benecessaryoloosentheclampingknobsat theends

of thebasetodothis•

13)Makesurethatthe templates orientedasshownin Fig60.

14)Makesurethatthetemplate

is

flushandparailelwiththe workpiecesclampedo base.Fornarrowprojectsides,the useofanauxiliary

supportforthe templates recommended.tspurposeis toaid insupportinghe routerwhilecutting,Itcanbe madefroma pieceof scrap

wood;

butitsthicknessmustbethesameasthetopback-upboard.

RefertoFigure58).

FIG. 60

TOPB,4CK-UPOARD__

• _

0

FRONTACK-UPOARD

DOVETAILU RIGHTIDEOR

PROJECTEFTSIDE

<>

15)Ciampthetemplateinplaceby tighteninghe clampingknobs.

_ BEFOREMAKINGANYCUTSMAKESURETHATTHEBITWILLNOTCUTINTOTHEBASEORANYOTHERCOMPONENTFTHE

DOVETAILIXTURE.THISCANCAUSEDAMAGEOTHEDOVETAILIXTURE;ORLOSSOFCONTROLFTHEROUTERWHICHCANRESULT

IN SERIOUSBODILYNJURY.ATRIALRUNWITHTHEROUTERURNEDOFFANDUNPLUGGEDROMTHEELECTRICALUTLETS

STRONGLYECOMMENDED,

16)TURNTHEROUTERON.

17)CutthedovetaiIby movingthe routerfrom LEFTTORIGHT,withthe guidebushingoIIowiflgthetemplate.DONOTFORCENYTHING;


18)Toensureasmoothanduniformjoint, retracehe previouscutby movingtherouterfromRIGHTTOLEFTwiththeguidebushingagain

followingthetemplate.

35



NEVERLIFTTHEROUTERUPWARDSWHENTHEROUTERSONANDTHEROUTER

BIT

ROTATINGRWHENTHEGUIDE

BUSHINGSNEARTOORTOUCHINGHETEMPLATE.HISCANCAUSEDAMAGEOTHEDOVETAILIXTURE;ORLOSSOFCONTROLOF

THEROUTERWHICHCANRESULTN SERIOUSBODILYNJURY.

19)Afterthecut hasbeenmade,he workpiecesshouldlook likethoseillustratedn Figure60.

20)Removeheworkpieceandback-upboardsfromthe DovetailFixture.

21) Theback-upboardscanbereused f thecut portionsof boardsarecut off.AFTERBEINGREUSEDUNTILTHEYNOLONGERSERVE

THEIRNTENDEDUNCTION,EWBACK-UPBOARDSMUSTBEMADE.

22)TOCUTCORNER3OFTHEPROJECTEFTSIDE,positionthe topback-upboardontop of the basesothat it lineswiththe frontof the

baseandabutsthe righttopstopblockasshowninFigure58.

23)ContinueasSteps6through20.

24)TOCUTCORNER2 OFTHEPROJECTIGHTSIDE,positionthe top back-upboardontopof thebaseso thatit linesupwith thefront of

thebaseandabutsthe lefttop stopblockasshownin figure61.

TOPBACK-UPBOARD

Fig. 61 / / TOPFTHEASE .

f / AU, ,AR TE , T SBR

.....=. ,./ ., V

,RO,

DT ,ETSIDE....

//.-.

--.-./ 7/ --"

t

%

"OUTSIDEURFACESHOULDEVISIBLE

ONTHtSSURFACEEFOREOSITtONING

THEFRONTACK-UPOARD

Fig. 62

TOPBACK-UPOARD,

FRONTACK-UPOARD

DOVETAIL

36



25) Lightly clamp the back-up board in place.

26) Posit ion the project side against the front of the baseso that the top surface abuts the left front stop bIock,The useof a front back-up

board atthis step is also recommended. It is

positioned

between the project sideand the cIamping bar asshown in Figure61.The front

back-up board is described in Step 7 above.

27) Continueas in Steps 8 through 19 above.

28) After the cuts havebeen made,the workpieces should look like those illustrated in Figure62.

29) Removethe workpiece andthe back-up boards from the Dovetail Fixture.NOTE:THE BACK-UP BOARDSAREREUSABLE.

30) TOCUTCORNER

#4

OFTHEPROJECTLEFTSIDE, position the top back-up board on top of the baseso that it fines up with the front of

the baseand abuts

the

left top stop block asshown is Figure6 .

31) Continueas Steps27 through

32

above.

32) Atthis stage the project sides should look like those iIfustrated in Figure56,

THEFOLLOWINGDESCRIBESTHEPROCEDURETO BEFOLLOWEDFORCUTTINGTHEPROJECT

FRONTANDBACK:

NOTE:Anyjoint fit adjustmentsthatmay be required canonly bemadewhen cuttingthe projectfrontand projectback

pieces. That is, adjustmentsare madeto projectfront endbackpiecesONLYnotto the side pieces,

.40"DIA,GUIDEUSHING

SEARSRAFTSMANTRAIGHT\ _

ROUTERIT#25415 _

1) Assemblehe.40"guidebushingto the routerbaseplate,asdescribedn aprevioussection.Thisis thesmallerof thetwo guidebushings

furnishedwiththis product,

2) InstallSearsstraightrouterbit,#25415,to therouterasdescribedinyourRouterOwnersManualShankengagementhouldbea

minimumof 3/4".

_i MAKESURETHATTHEROUTERITSALIGNEDWITHORCENTEREDNTHEHOLENTHEGUIDEUSHfNG.ODOTHIS,OOSEN

SCREWSOLDINGASEPLATEORADAPTERLATEOROUTER,ENTERUIDEUSHINGOLEWITHRESPECTOROUTERfTANDRETIGHTEN

SCREWSECURELY

_ WHENETTINGHEDEPTHOFCUT,MAKEABSOLTELYURETHATTHECOLLETUTDOESNOTCONTACTTOUCH)HEGUIDE

BUSHING.HISCANCAUSEHEGUIDEUSHtNGOHEATUPEXCESSIVELYURINGUTTINGWHICHCANCAUSEAMAGEOTHETEMPLATE.O

CORRECTHfSSITUATIONRPREVENTTFROMOCCURRING,EPOSITtONHEROUTERITtNTHEROUTER.

3) Adjustthedepthof cut.Thedepthof cutfor anOPENDOVETAILOINTsequaltothethicknessof the matingpart,That

is:

FORCORNER1OFTHEPROJECTRONT,THEDEPTHOFCUTIS EQUALTOTHETHICKNESSFTHEPROJECT IGHTSIDE.

FORCORNER40FTHE PROJECTRONT,THEDEPTHOFCUTIS EQUALTOTHETHICKNESSOFTHEPROJECTEFTSIDE.

FORCORNER2 OFTHEPROJECTACK,THEDEPTHOFCUTIS EQUALTOTHETHICKNESSOFTHEPROJECT IGHTSIDE.

FOR

CORNER

3 OFTHEPROJECTACK,THEDEPTHOFCUTIS EQUALTOTHETHICKNESSOFTHEPROJECTEFTSIDE,

UsethedepthgaugeonthebaseoftheDovetailFixture,as describedn aprevioussection,asa startingpoint.

, 4) Atthisp_intitwi__benecess_ryf_ry_ut_makeat_pb_ck_upb_ard_Thereas_nsf_rthet_pback_upb_ard_ret_minimizesp_intering_

providesupportfor thetemplateandpreventdamageothe DovetailFixlure,Thetop back-upboardis ascrappieceofwood havingthe

followingdimensions:

LENGTH:"to 8",sufficientengthso thatit canbeclampedbythe top clampingbarandbe usedmorethanonce;

WIDTH:2"widerthanthewidthof theprojectfront(or back);

THICKNESS:/8"to 1/# thickerthanthethicknessof the projectfront (orback);THISIS TOPREVENTCCIDENTALLYUTI'INGNTOTHE

DOVETAILIXTURE.

Thiscanalsobeaccomplishedby usingmorethanonepieceof scrapas longasthe resultantength,width,andthicknessareasdescribed,

3?



5) TOCUTCORNER1 OFTHEPROJECTRONT,ositionthe topback-upboardontop of thebasesothat it linesupwiththe frontof the

baseandabutsthe lefttopstopblockasshowninfigure 63.

Fig.83 / TOPACKPOARD

_ / TOPOFTHEBASE /'AUXILIARY TEMPLATEUPPORT

/CASNEEOEO

( .... /

PROJECTACK _ __

<>

FRONTOFTNE


6) Lightlyclamptheback-upboardin place.

7) Positiontheprojectfront(or back)againsthe frontof thebaseso thatthetopsurfaceabutsthe leftfrontstop bIock.Theuseof a front

back-upboardat thisstepisaIso recommended.t is positionedbetweenhe projectfront(or back)andthedampingbarasshownin

Figure63.Thefront back-upboardshouldhavethefollowingapproximatedimensions:

LENGTH:"to 8",sufficientlengthsothat it canclampedbythe frontclampingbarandbeusedmorethanonce;

WIDTH:1"to 2"widerthanthewJdthof thefront (orback);

THICKNESS:/4"to 1/2",

-THEOUTSIDEOFTHEPROJECTRONTORBACK)FACESAWAYFROMTHEFRONTOFTHEBASE,

Fig. 84

___( CLATEMPMTE

BRACKET

MPINGKNOB

_ WASHER

Thewords"OUTSIDESURFACE"arkedin (d) in theSection,GENERALREPARATIONS,houldhavebeenvisiblebeforethefront back-up

boardwasput inplace.

8) Lineuptheworkpiecessothattheendof theprojectfront(orback)andback-upboardslineupasshowninFigure63.

9) Securelyclamptheprojectfront(orback)andfrontback-upboardto thefrontof thebase.

10)Securelyclampthetop back-upboardto the topof thebase,

11)Makesurethatthepartsremainlinedup.

12)AssembleheDOVETAILEMPLATEOROPENTHROUGH)OINTSo theDovetailFixtureso that THETEMPLATERACKETSIT

BETWEENHEWASHERSNDTHETEMPLATEUPPORTSsshownFigure64;it will benecessaryo loosentheclampingknobsat theends

of thebaseto dothis.

13)Makesurethatthe templates orientedasshownin Fig,64,

38



Fig.65

TOPACK-UPOARD

DOVETAIL

DRAWERACK

14)Makesurethatthetemplates flushandparallelwiththeworkptecesdampedto base,Fornarrowprojectfronts(orbacks),he useof an

auxiliarysupportfor the templates recommended.ts purposes toaidin supportingherouterwhilecutting,it canbemadefroma pieceof

scrapwood;butits thicknessmustbethe sameasthetop back-upboard,(Refero Figure63).

15)Clampthetemplaten placebytighteninghe clampingknobs.

BEFOREMAKINGANYCUTSMAKESURETHATTHEBITWILLNOTCUTINT0THEBASEORANYOTHERCOMPONENTFTHE

DOVETAILIXTURE.THISCANCAUSEDAMAGEOTHEDOVETAILIXTURE,

16)TURNTHEROUTERON.

17)Cutthedovetailby movingtherouterfrom LEFFTORIGHT,with the guidebushingfollowingthe template.DONOTFORCEANYTHING;


18)Toensureasmoothanduniformjoint, retracehe previouscutby movingtherouterfrom RIGHTTOLEFTwiththe guidebushingagain

followingthetemplate.

19) MAKESURETHATALL OFTHEMATERIALSCUTAWAY;FREEROUTINGMAYBEREQUIREDOACCOMPLISHHIS.EXTRACARE18

REQUIRED

N

CONTROLLINGHEROUTERMOVEMENTWHILEDOINGFREEROUTING,

Refero Figure65).

Fig. 66

TOPOFTHEBAsE_PBACK-UPBOARD_/_._

A.XILIARY .PLATEU PORT, \

:ASEEDED , - i -: 0

FRONTOETHEBASE_ / ' \

/ v -_PROJECTFRONTR

/

"OUTSIDEURFACE"HOULDEVISIBLENTHISSURFACE PROJECTACK


39



NEVERLIFT THEROUTERUPWARDSWHENTHE ROUTERS ONANDTHEROUTERBITROTATINGORWHEN THEGUIDEBUSH-

ING iS

NEAR

TO

OR

TOUCHING

THE

TEMPLATE.

20) After the cut bas beenmade, the workpiecesshould look like thoseillustrated in Figure65,

21) Removethe workpiece and back-up boards from the Dovetail Fixture.

22) The back-up boardscan bereused if the cut portions of boardsare cut off.AFTERBEINGREUSEDUNTIL THEY NOLONGERSERVE

THEIR INTENDEDFUNCTION,NEW BACK-UPBOARDSMUST BE MADE,

23)TO CUTCORNER#3 OFTHEPROJECTBACK,position the top back-up board on top of the baseso that it lines with the front of the base

and abuts the left top stop block asshown in Figure 63.

24) Continue as Steps 6 through 24.

25) TO CUT CORNER#4 OFTHEPROJECTFRONT,position the top back-up beard on top of the baseso that it lines up with the front of the

baseand abuts the right top stop block asshown infigure 66.

26) Lightly clamp the back-up board in place,

27) Position the project front (or back) againstthe front of the baseso thatthe top surface abuts the right front stop block. The use of a fronl

back-upboardal this step is also recommended,It is positioned betweenthe drawerfront (or back) and the clamping bar asshown in

Figure66. The front back-up board is described in Step7 above,

28) Continue as in Steps 8 through 20 above.

29) After the cuts havemade,the workpieces should Iook like those illustrated in Figure65.

30) Removethe workpiece and the back-up boards from the Dovetail Fixture. NOTE:THEBACK-UPBOARDSAREREUSABLE.

31) TO CUT CORNER#2 OFTHE PROJECTBACK,position the top back-up board on top of the baseso that it lines up with the front of the

baseandabuts the right top stop block as shown is Figure 66.

32) Continue as Steps 28 through 32 above.

33) The finished project front, back,and sides should look like those illustrated in Figure56.

34) Checkhow the workpieces fit together_Some adjustments may be necessary. Referto the Section, MAKINGADJUSTMENTSFOROPEN

(THROUGH)FLUSHJOINTS

Your project is now readyto be gIuedtogether,

Removethe pencil markings by light sanding orwith a soft eraserafter the parts havebeenglued together.

TROUBLESHOOTING:

*

If

thejoint

is too loose:Thisadjustmentcanonlybemadewhencuttingeitherthe front or

the

back(pinpieces).Loosentheclamping

knobsholdingthetemplatebracketsandmovethetemplateOUTWARDyturninghe cam handles,Continueadjustinguntildesiredjoint

fit is attained.Retightenhe clampingknobs.

= tt thejoint is tootight: Thisadjustmentoo canonlybemadewhencuttingeitherthefront ortheback(pin pieces).Loosentheclamping

knobsholdingthetemplatebracketsandmovethetemplateINWARDbyturningthecam handles.Continueadjustingunti desiredoint fit

is attained.Retightenheclampingknobs.

• If the joint

is

too

shallow:

RefertoFigure67,INCREASEhe depthofcutof therouterbit.Thisadjustmentcanbe madewhencuttingthe

front,

the

back,(pin pieces)andthesides(taiI

pieces),

o If t he joint

is

toodeep:Referto Figure68.DECREASEhe depthof cut of therouterbit,Thisadjustmentoocanbemadewhencutting

thefront, theback,(pinpieces)andthesides(tailpieces).

, If the jointisnot uniformlyspacedromtop surfaceof drawer:Referto Figure69.(SeetheSection"ALIGNMENTOFTHETEMPLATES".)

Withthe templateclampedo the base,loosenthefourscrewssecuringhe templateo the templatebrackets,andmovethetemplate

slightlyto theleft. Tightenhe fourscrewsandmakea

trial

cut.If movingthetemplateto the

left

did notcorrectthe condition,butmadet

worse,loosenthe screwsandmovethetemplateto the right aemalIamount.Makesurethetemp[ateremainsparallelto the front of the

dovetailbase.Tightenthefour screwsandmakea trial cut, Continuemovingthetemplateto the right untgthe conditionis completely

corrected.PROPERALIGNMENTOFTHETEMPLATESOTHETEMPLATERACKETSSCRITICALFORJOINTUNIFORMITY.NCETHiS

iSACCOMPLISHEDORRECTLY,TSHOULDNOTNEEDADJUSTMENTSGAIN.MAKESURETOSECURELYIGHTENTHEFOUR

SCREWS.AFTERTHETEMPLATESAVEBEENCORRECTLYEALIGNED,HEYSHOULDREQUIRENOFURTHERDJUSTMENTSF

THEYAREHANDLEDWITHCARE.

4O



Fig. 67

JOINTSTOOSHALLOW

PROJECTRONT__ __.

PROJECTEFTSlOE

PROJECTACI__

/

FRONTXTENDSUTPASTSIDE

_ SIDEEXTENDSUTPASTFRONT

Fi#.68

SIDEEXTENDSUTPASTFRONT

JOINTIS TOODEEP

_ FRONTXTENDSUTPASTSIDE

SIDEEXTENDSOUTPASTBACK

Fig. 69

JOINTSPACINGSNOTEQUAL

FRONTPINPIECE)

SIDETAILPIECE)

BAOK(PINPIECE)

_ SPACtNGREATERHANBACK

SPACINGESSTHANFRONT

41



PARTS LIST for #171.25450 INDUSTRIAL DOVETAIL FIXTURE

KEY OTY PART NO.

I I 29LD-879

2 I 29LD-880

3 I 29LD-8BI

4 I 29LD-882

5 I 29LD-883

6 2 29LD-884

7 2 29LD-885

8 2 29LD-886

9 4 29LD-887

I 0 I 29LD-888

I 4 29LD-889

12 6 29LD-890

13 2 29LD-891

14 I 29LD-892

15 4 29LD-895

16 2 29LD-896

17 I 29LD-899

8 I 29LD-900

I9 4

29LD-901

20 I 45A-350

21 I 45A-351

22 I 45A-352

23 I 45A-353

I 49LD-50

I NONE

24 4 29L-469-13

25 8 29L-469-14

26 I0 29L-469-15

27 2 29LD-841 -2

28 2 29LD-841 -3

29 3 29LD-841-4

30

I

29L-684-6

31 3 29L-684-7

32 2 29A-310-15

33 2 29A-310-16

34 2 29A-310-17

35 4 29A-242-12

36 2 29A-242-I3

37 9 29A-306-37

38 8 29A-306-40

39 4 29LD-930

40 4 29LD-969

4 4 29LCN-IO05

DESCRIPTION

DOVETAIL BASE

DOVETAIL TEMPLATE HALF BLIND JOINT

DOVETAIL TEMPLATE OPEN (THROUGH) JOINT

TEMPLATE SUPPORT (RIGHT SIDE)

TEMPLATE SUPPORT (LEFT SIDE)

CAM HANDLE

FRONT STOP BLOCK

TOP STOP BLOCK

CLAMPING BAR END CAP

RETAINER

BOLT SUPPORT

ICLAMPING KNOB

CLAMPING BAR

PIVOT SHAFT

TEMPLATE BRACKET

TEMPLATE STIFFENER

GUIDE BUSHING ASSEMBLY (.40" DIAMETER)

GUIDE BUSHING ASSEMBLY (I12" DIAMETER)

COMPRESSION SPRING

PRODUCT LABEL (CLAMPING BAR)

LABEL (TEMPLATE-BL IND)

LABEL (TEMPLATE-OPEN

WARNING LABEL (CLAMPING BAR)

INSTRUCTION MANUAL

BAGGED FASTENERS-CONSISTING OF :

#10-32 X 518" Ig. PANHEAD MACHINE SCREW

#I0-32 X 318" Ig. PANHEAD MACHINE SCREW

#8-36 X 3/16" Ig. PANHEAD MACHINE SCREW

#I0-32 X 518" Ig. FLAT HEAD MACHINE SCREW

#I0-32 X 7/8" Ig. FLAT HEAD MACHINE SCREW

_10-32 X 3/8" Ig. FLAT HEAD MACHINE SCREW

#IO-16 X I12" Ig. PANHEAD TAPPING SCREW

#I0-16 X I" 19. PANHEAD TAPPING SCREW

5/16-18 X 4-1/2" Ig. ROUND HEAD SQUARE NECK BOLT

5/16-18 X 3-I/2" Ig. ROUND HEAD SQUARE NECK BOLT

,5/16-18

X 2" Ig. ROUND H EAD SQUARE NECK BOLT

#I0-32 HEX MACHINE SCREWNUT

5ll6-18 HEX MACHINE SCREWNUT

3/64"1.D. X 9/I6"0,D. X 3/64"fhick WASHER

1/32"I.D. X 7/8"0,D. X 1/I6"thick WASHER

1/32"I,D. X 7/8"0,D. THIN NYLON WASHER

5/16"I,D, X 7/8"0.D. THICK NYLON WASHER

NYLON SPRING

RETAINER

42



43



44



1

/ o /_

®

"/

L

. .

®

®

@

45



Notes

46



Notes

47



IIII

I IIit

II

49LD-60

MANUAL

Whencorresponding,alwaysgivethe following

informationas showninthe list.

1. The PARTNUMBER

craftsman dovetail jig l0807067

Documents