General Tools Woodworking Dovetail Jig Instruction Manual

Introduction

This manual provides comprehensive instructions for the safe and effective use of your General Tools 861 Woodworking Dovetail Jig. This 12-inch template kit is designed to help you create professional-quality dovetail joints, including half-blinded, edge-to-edge, square, and through joints, for furniture and cabinet making.

The integrated clamping design accommodates various board widths, and the jig allows for easy adjustment to create loose or tight joints.

What's Included

• 1 Aluminum Dovetail Jig
• 14-degree, 1/2-inch Dovetail Router Bit
• Alignment Tool
• Allen Wrench
• Four Face Clamps and Thumb Screws
• User Manual (this document)

Setup

Before first use, ensure all components listed in the 'What's Included' section are present. Familiarize yourself with the jig's parts, including the main aluminum body, the adjustable guides for cutting pins and tails, and the clamping mechanisms.

The jig is designed for use with either a hand-held router or a router table. Ensure your router is compatible with a 1/2-inch shank dovetail bit.

Operating Instructions

General Safety Precautions

• Always wear appropriate personal protective equipment, including eye protection and hearing protection, when operating power tools.
• Ensure your workpiece is securely clamped before routing.
• Disconnect power to your router before making any adjustments or changing bits.

Preparing the Workpiece

Ensure your wood pieces are cut squarely and to the desired dimensions. The jig accommodates various board widths. Mark the face and edge of your boards to ensure correct orientation during routing.

Cutting Pins (Hand-Router Application)

1. Attach the jig to the workpiece securely using the integrated clamps. The side marked 'CUT PINS THIS SIDE' should be facing up.
2. Insert the 14-degree, 1/2-inch dovetail router bit into your hand-held router. Adjust the router bit depth according to the thickness of your wood and desired joint tightness. It is highly recommended to test on scrap wood first to fine-tune the depth.
3. Carefully guide the router along the template slots to cut the pins. Maintain consistent pressure and movement for clean cuts.

Cutting Tails (Hand-Router Application)

1. Re-position the jig on the workpiece, ensuring the side marked 'CUT TAILS THIS SIDE' is facing up.
2. Adjust the router bit depth as needed for the tails. Always test on scrap material to verify the fit.
3. Guide the router along the template slots to cut the tails.

Cutting Pins (Table-Router Application)

1. Mount the jig securely to your router table, ensuring it is stable and level.
2. Insert the 14-degree, 1/2-inch dovetail router bit into your router table. Adjust the bit height for the pins, testing on scrap wood for optimal fit.
3. Feed the workpiece through the jig, guiding it along the template to cut the pins.

Cutting Tails (Table-Router Application)

1. Adjust the jig or workpiece setup for cutting tails on the router table.
2. Feed the workpiece through the jig to cut the tails, ensuring proper alignment and consistent feed rate.

Assembling the Joint

1. After cutting both pins and tails, carefully align the two pieces. They should fit together snugly.
2. Apply wood glue to the joint surfaces if desired for permanent assembly.
3. Use a mallet or clamps to gently tap the pieces together until the joint is fully seated.

Maintenance

• After each use, clean the jig to remove sawdust and debris. A brush or compressed air can be used.
• Inspect the router bit for wear or damage. Replace dull bits promptly to ensure clean cuts and prevent tear-out.
• Store the jig in a dry, clean environment to prevent corrosion and damage.

Troubleshooting

Loose Joints

Cause: Router bit depth too shallow, or template not properly aligned.

Solution: Increase router bit depth slightly. Ensure the jig is securely clamped and aligned. Test on scrap material to achieve the desired fit.

Tight Joints

Cause: Router bit depth too deep, or template not properly aligned.

Solution: Decrease router bit depth slightly. Ensure the jig is securely clamped and aligned. Test on scrap material to achieve the desired fit.

Tear-out

Cause: Dull router bit, incorrect feed rate, or lack of a backer board.

Solution: Replace dull bits. Use a slower, consistent feed rate. Consider using a sacrificial backer board to minimize tear-out on the exit side of the cut.

Jig Movement During Operation

Cause: Insufficient clamping pressure.

Solution: Ensure all clamps are tightened securely to the workpiece and workbench.

Specifications

Warranty and Support

Warranty Information: This product comes with a manufacturer's warranty. Please refer to the warranty card included in your original packaging for specific terms and conditions.

For technical support, replacement parts, or further assistance, please visit the official General Tools website or contact their customer service department.

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