Set the router on the template, making sure the cutter is not in
contact with the template or the stock. Turn the router on and
start cutting on the left edge of the work piece. Keeping the
guide bushing tight against the template, cut the tail by plung-
ing in on the left edge, across the back side and coming back
out on the right side of the tail. Always keep the guide bush-
ing tight against the template fingers, and guide the router in a
clockwise rotation around the tail (Fig. 21).
Flip the piece end for end, keeping the inside face toward the
operator and continue cutting the remaining tails using the
same procedure. Cut all remaining tailboards in the same way.
WARNING:
Do not lift the router off the template while the
motor is running. If you do, the bit may ruin your template.
Cutting the Pin Pieces
Cutting the pins determines how tight your joint will be. To
get the jig set up correctly, use a test board exactly the same
dimension as the pin boards used in the project. All pin boards
are cut with the inside face (marked “P”) towards the jig.
Remove the 1/2", 8º dovetail bit and install the 5/16" straight
bit. Remove the tail template and install the pin template. Set
the back edge of the template to the “F” setting (Fig. 22) for
both 1/2" and 3/4" material.
Set the depth of cut the same way as you did cutting the
tailpieces, but this time use the tail stock to scribe your line.
Proceed to cut the joint in the same fashion as you did
the tail boards.
Test Fit
Test fit the pin board to the tail board. If the joint is too tight,
you will need to loosen the two T-bolt knobs and move the tem-
plate away from you approximately 1/16". NOTE: Moving the
template towards you will give you a tighter joint; moving the
template away from you will loosen the joint (as indicated on
the template). Be sure the front edge of the template remains
parallel with the front of the jig body.
Cut off the previously routed pins, and reinstall the same test
piece again, keeping it tight against the left side stop. Then
re-cut the pin test piece.
Follow this process until you produce an acceptable fit.
Proceed to cut all pin boards. Remember to always have the
inside face toward the jig when cutting the pins.
Figure 21
Figure 22
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