CRAFT$1VlAK

INDUSTRIAL
DOVETAIL
FIXTURE

Model No,
171.25450

Assembly
Operation

iMPORTANT;Thefollowingrouter bits are required

for usewith this fixture:#25414-1/4-in. Straight Router Bit and
#25415-9/16-in. Dovetail Router Bit which are used
for THROUGHor OPENJOINTS.
: #25505 or #26318-1/2-in. Dovetail RouterBit which
are used for a!l HALFBLINDJOINTS.

Readand follow
all instructions
carefully.
KEEPTHIS
MANUALFOR
' FUTURE
REFERENCE,
Sold by Sears, Roebuck and Co,, Hoffman Estates,IL 60179

83463

FAILURETO HEEDALLSAFETYAND OPERATINGINSTRUCTIONS

ANDWARNINGSREGARDINGUSEOF THIS PRODUCTCANRESULT
IN SERIOUSBODILYINJURY

1) KNOWYOURPOWERTOOL
Readtheowner'smanualcarefully.Learnitsapplicationsand
Iimitatlonsaswell asthe specificpotentialhazards
particularto
this tool.
2) GROUND
ALLTOOLS(UNLESSDOUBLE
INSULATED)
If tool is equippedwith anapproved3-conductorcordand a 3pronggroundingtypeplug,it shouldbepluggedinto a threehole
electricalreceptaute.
It adapteris usedto accommodate
a twoprongreceptacle,the adapterwire mustbeattachedto known
ground,(usuallythescrewsecuringreceptaclecoverplate).
Neverremovethird prong.Neverconnectgreengroundwireto a
terminal.
3) KEEPGUARDS
IN PLACE
--in workingorder,and in properadjustmentandalignment.
4) REMOVE
ADJUSTING
KEYSANDWRENCHES
Forma habitof checkingto seethat keysandadjustingwrenches
areremovedfrom tool beforeturningit on.
5) KEEPWORKAREACLEAN
Clutteredareasandbenchesinviteaccidents.Floormustnot be
slipperydoeto waxor sawdust.
6} AVOIDDANGEROUS
ENVIRONMENT
Donot usepowertools in dampor wet locations
or exposethornto
rain.Keepwork areawelI lighted.Provideadequatesurrounding
workspace.
7) KEEPCHILDREN
AWAY
All visitorsshooktbe keptata safedistancefrom work area.
B) MAKEWORKSHOP
CHILD-PROOF
--with padlocks,masterswitches,or by removingstarterkeys.
9) DONOTFORCETOOL
It will do thejob betterandsaferatthe ratefor which it was
designed.
10)USEAPPROPRIATE
TOOL
Donotforcetool or attachmentto doa job for which itwas not
designed.
11)WEARAPPROPRIATE
APPAREL
Donotwearlooseclothing,gloves,necktiesor jewelry(rings,
wristwatches)to getcaughtin movingparts.Nonslipfootwearis
recommended.
Wearprotectivehair coveringto containlong hair.
Rolllongsleevesel;Dyetheelbow.
12)USESAFETY
GOGGLES
(HeadProtection)
WearSafetyGoggles(mustcomptywith ANSIZ87.1) at all times.
Also,usefaceor dust maskif cuttingoperationis dusty,andear
protectors(plugsor muffs)duringextendedperiodsof operation.
13)SECURE
WORK
Useclampsor a viseto holdwork whenpractical,it's saferthan
usingyour handandfreesbothhandsto operatetool.

14) DONOTOVERREACH
Keepproperfootingand balanceat all times.
15) MAINTAIN
TOOLSWITHCARE
Keeptools sharpandc]eanfor bestand safestperformance.Follow
instructionsfor lubricatingand changingaccessories.
16) DISCONNECT
TOOLSBEFORE
SERVICING
-when changingaccessoriessuchas blades,bits,cutters,etc.
17)AVOIDACCIDENTAL
STARTING
Makesureswitchisin OFFpositionbeforeplugging
in.
18) USERECOMMENDED
ACCESSORIES
Consulttheowner'smanualfor recommended
accessories.Follow
the instructionsthat accompanytheaccessories.Theuseof
improperaccessoriesmay causehazards.
19) NEVERSTANDONTOOL
Seriousinjurycouldoccur ;f thetool Istipped orthecuttingtool is
accidentallycontacted.0o notstore materialsaboveor nearthe tool
that wouldmakeit necessaryto standon thetoolto reachthem.
20) CHECKDAMAGED
PARTS
Beforefurther useof thetooI, a guardor otherpart
thatis damaged
shouldbecarefullycheckedto ensurethat it will operateproperly
and performits intended
function.Checkfor alignmentof racy(rig
parts,bindingof movingparts,breakageof parts,mounting,andany
otherconditionsthat mayaffectits operation.A guardor otherpart
that isdamagedshouldbe properlyrepairedor replaced.
21) DIRECTION
OFFEED
Feedwork intoa bladeor cutteronly againstthedirectionof rotation
of the bladeor cutter.
22) NEVERLEAVETOOLRUNNINGUNA'n'ENDED
Turnpoweroff. Do notleavetool until it comesto a completestop.
23) KEEPHANDSAWAYFROMCUT(1NGAREA
24) STOREIDLETOOLS
Whennot in use,tools shouldbestored in dry, highor Iocked-up
place---outof reachof children.
25) O0 HOTABUSECORD
Keepcordawayfrom heat,oil, and sharpedges.
28) OUTDOOR
EXTENSION
CORDS
Whentoo! is usedoutdoors,useonlyextensioncords suitablefor
useoutdoors,and so marked.
27) NEVERUSEIN ANEXPLOSIVE
ATMOSPHERE
Normalsparkingof the motor couldignitefumes,flarnmab;eliquids,
or combustibleitems.
28) DRUGS,ALCOHOL,
MEDICATION
Do notoperatetool while underthe influenceof drags,alcohol,or
anymedication.

READANDUNDERSTAND
THISCOMPLETEINSTRUCTIONBOOK
BEFOREUSINGTHISPRODUCT

ADDITIONALSAFETYINSTRUCTIONS
FORYOUR
INDUSTRIALDOVETAIL
FIXTURE
1) Alwaysweareyeprotectionthat complieswith currentANSI
StandardZ78A.
2) Noiselevelsvarywidely.Toavoidpossiblehearingdamage,wear
earpIugsor muffswhenusingthe DovetailFixturefor hoursata
time.
3) Weara dust maskalongwith thesafetygoggles.
4) Donot usethis DovetailFixturewith routerbits or guide
bushingsotherthanthosespecifiedfor thecuts beingmade.
5) Followtheinstructionsin yourRouterOwnersManual.
6) Vibrationscausedbytherouterduring usecancausefasteners
to becomeloose.Beforeuseandperiodicallyduringusecheckall
fastenersto makesurethat theyareagtight andsecure.
7) Donot usethis productuntil all assemblyinstallationstepshave
beencompleted,andyouhavereadand understandnit safetyand
operationalinstructionsin this manual,andtheRouterOwners
ManuaL
8) Makesurethat therouterbit is properlypositionedin therouter
so that it doesnot contactthe guidebushingor thetemplatewhen
cutting.
9) TheDovetailFixturemustbe securelymountedto a workbench
or otherstablesurfacewhenin use.Thefront of the baseshould
overhangthe front of theworkbenchbyno merethan1/4" to provide
clearancewhenclampingworkpiecesto theDovetailFixture.
10) Donot usethe DovetailFixtureas a worksurface.Doingso may
causedamageto theDovetailFixture,whichcancauseit to be unsafe
to use.A workbenchshouldbeusedfor this purpose.

11)This productis designedto cut flatworkpieces.Donotcutor

attempttocutworkpieces
thatare notflat or thatareirregularly
shaped.
12)This productis to beusedfor cuttingwoodworkpiecesonly.Do
not usethisproducttocutmetalor anyothernon-woadmaterial.
13)This producthasbeendesignedto cut workpieceshaving
thicknessesof 3/8"to 1".Donot usefor workpiecesof anyother
thicknesses.
14) Donotclampanyworkpiecesto the DovetailFixtureor makeany
adjustmentsto theDovetailFixtureunlessthe routerhasbeenturned
off, the routerbit is notturning,andthe Routerhasbeen
disconnectedfrom theelectricaloutlet.
15)Whensetting"lhe-dopth-ot-cut"of the routerbit, makesurethat
theworkplaceis clampedto the DovetailFixturein sucha.manner
that therouterbit doesnotcutinto the Dovetailbasecausing
damageto it or passibleseriousinjurytoyou.
16)
ALWAYS
UNPLUG
THEROUTERFROMTHE
ELECTRICAL
OUTLET
BEFORE
INSTALLING
ORREMOVING
ROUTER
BITSFROMTHEROUTER
ANDWHENADJUSTING
THECUTTING
DEPTHOFTHEROUTER
BIT;ORWHENINSTALLING
ORCHANGING
GUIDEBUSHINGS,
17)NEVERLiFTTHEROUTER
UPWARDS
WHENTHEROUTER
iS
"ON",THEROUTER
BIT ISROTATING,
ANDTHEGUIDEBUSHINGiS
NEARORTOUCHING
THETEMPLATE,
BECAUSE
THISWILLCAUSE
THEROUTER
BITTOCUTINTOTHETEMPLATE
ANDDAMAGEIT.

INTRODUCTION
o

Your Sears/Craftsman industrial Dovetail Fixture is an accessory used with your Router to allow you to make drawers, 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 make 1" spaced flush and flush offset and 318"rabbeted haif-bfind dovetail joints, in addition you can
make 1" spaced (or open) dovetail joints.
Workplace widths up to 16" can be accommodated.
Workplace thicknesses between318"and 1" can be accommodated,
The Dovetail Basehas six pockets molded into its front which are gauges to 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 Fixture comes with two templates andtwo guide bushings for making bait-blind and through or open joints.
Sears/Craftsman router bits, #25414 and#25415, WHICH MUST BE PURCHASEDSEPARATELY,are required to make the THROUGHor
OPENjoints.
Sears/Craftsman router bit, #25505 or #26318, WHICH MUST BE PURCHASEDSEPARATELY,
is required for making the haIf-bIind joints.
Eachtemplate has a label, describing the joint that can be cut, 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, Universal Router Adapter,the DovetagFixture can be usedwith many nonCraftsman Routers, such as, Black & Decker,Makita, and SkiL

UNPACKING
ANDCHECKING
CONTENTS

in order to simplify handIing and to minimize any damagethat may occur during shipping, your Industrial Dovetail Fixtureis packaged
unassembled,
Separate all parts from the packing materials and check each onewith the igustrations and list of parts at the endof this manuaIto make
sure that ag parts are present before discarding any packaging material.
If any parts are missing or cannot be accounted for, do not attempt to assemble,install, or use the industrial Dovetail Fixture
until the missing parts havebeen obtained and the product has beenassembled correctly.
Contact your localSears Retail Outletfor a repIacement product or for the missing parts.

ASSEMBLYINSTRUCTIONS
Thefollowingtoolsare requiredfor assembly:
1) A mediumsizedPhillipsscrewdriver,
2) A smallor mediumsizedadjustablewrench.

ASSEMBLYOFTHERIGHTSIDETEMPLATESUPPORTTO THEDOVETAILBASE
1). Placethe dovetailbasetopsidedownon a flat surface.
2) insertoneof the5/16-18x 2" long roundheadsquareneckbolts into thes!ot in the rightsideof thebase.(NOTE:Therightsideof the
baseis identifiedbythewords RIGHTSIDEmoldedinto it.)
3) Placea 11/32"I.D_x 7/8"O.D.washerontothe bolt asshownin Figure1,
4) Threada 5/16-18hexnut ontothe bolt, asshown,until it bottomsout againstthe washer,
5) Backoff the nutfrom the washerbetween1/4 and 1/2turns. Nigh the nut sothat thecornersof the nutareverticallYlineduPasshown.
Notethe alignmentof the hexpocketinthetemplatesupport.Thebolt shouldbe freeto movesideto side; if it doesnot, loosenthenut 1/3
turn or untilthe cornersof thenut pointup anddown.
8) Assembletheright templatesupportto theright side of thedovetailbaseso thatthe hexoutlinesup andf ts into thehexpocketin the
right templatesupport,(NOTE:Therighttemplatesupporthasthewords RIGHTSIDEmoldedinto it for identification.)
7) Assemblea #10-32x 5/8tongpanheadmachinescrew,a 13/64"!.D.x 9/16"O.D.washer,anda #10"32hexnutt thebaseasshwn t
hold thetemplatesupportin place.Securelytightenthe nut and screw_
8) Thetemplatesupportshouldmovefreelyfront to backalongthe sideof the base,If it doesnot, it meansthat the 5/16-18hexnut is too
tight on thebolt andshouldbeloosened.Todo this, removethefastenersassembledin step T, andremovethetemplatesupport;repeatsteps
4 through7.
ASSEMBLE THE LEFT SIDE TEMPLATE SUPPORT TO THE DOVETAIL BASETHE SAME AS THE RIGHT SIDE
TEMPLATE SUPPORT WAS ASSEMBLED
"/8"longPANHEAD
MACHINE
SCREW

Fig. 1
11/32"LO.X T/8"O.D.WASHER

MUSTLINEUP

5/16-18X2"tongROUND
HEAD
SQUARE
NECK
BOLT

_.D.WASHER
?HEXNUT

DOVETAIL
BASE

BACKOFDOVETAIL
BASE

ASSEMBLYOF THETOP CLAMPINGBARTO THEDOVETAILBASE

1) Assemble
one of the boltsupportsto bothof the 5/16-18X 3-1/2"longroundheadsquareneck boltsas shown in Figure2.
2) Alignthe squareon the boltwiththe squareholein the boltsupport.Theboltsupportisto =bottom-out"againstthe bolt asshown in
Figure3.

FIG. 2

5/16-18X3-1/2"
FIG. 3
longROUND
HEAD
SQUARE

FIG. 3a

_-x

,o,,

3) Assembleone ofthespringsto eachof thenylonspring retainersby pushingthespringoverthe raisedcylindricalportionof the

springretaineras shownin Figure3a andFigure3b,
4) Positionthe dovetailbaseon a fiat smoothsurfaceso the backof the baserestson thesurface.
NOTE:ALTHOUGH
BOTHENDSOFTHEDOVETAIL
BASEARESHOWNASSEMBLED
IN THEFOLLOWING
FIGURES,
THEACTUAL
ASSEMBLYIS DONEONEENDATATIME.
5) Fromthe bottomof the base,inserta boltwithbolt supportthroughtheslot in the top of the basesothe raisedportionof the bolt
supportgoesinto theslot, asshownin Figure4,

Fig, 4

SLOT
IN
DOVETAIL

EASE

DOVETAIL
EASE

SLOTIN
DOVETAIL

BOLTAND
BOLT

BASE

BOLTAND
BOLT
SUPPORT

FRONTOFDOVETAIL
BASE
6) Placea 5/16" I.D.X 7/8"O.D.thick nylonwasheroverthe boltso that thecountersink
facesawayfromthe dovetailbaseas shownin
Figure6. It will be necessaryfor youto holdthe bolt in placewhenperformingthis andthe followingsteps.
HELPFUL
HINTS:Positionthe bolt andthe boltsupport underthe notchin the rib as shownin Figure5, to help hold thebolt in place,

Fig. 5

NOTCH
INRIB

SLOTIN DOVETAIL
BASE

BOLTAND
BOLT
SUPPORT

7) Placea springand springretainer,assembledin step3, overthe bolt sothespringfits intothe countersink

in thethick washerasshown
In Figure6.
8) Pressdownon thespringretaineruntiljust the endof the bolt sticksout pastthe endof the springretainer.
9) Slidethe clampingbaroverthe bolt sothatthe springretainerabutstheinsideof theclampingbar asshownin figure6. NOTE:THE
SPRINGRETAINER
MUSTPUSHAGAINST
THECLAMPNG
BAR.
10)Placean 11/32"I.D.X 7/8"O.D.thin nylonwasherandan 11/3Z I.D.X 7/8" O.D.washerover the bolt. It will be necessaryfor youto
pressdownonthe dampingbar whiledoingthis.
11) Takeone ofthe clamping
knobsandthreadit ontothe bolt asshown.DONOTTHREAD
the knobcompletelyontothe bolt--just enough
sothe knobholdsthe clampingbarin place.
CLAMPING

FIG. 6

Assembleclampingbar, knobs, end caps on bothends as shown

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

CLAMPINGBARDETAIL

11/32"LD.X T/8"O.D.
THINNYLONWASHER
CLAMPING
BAR

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

NYLON
SPRING
RETAINER
(RETAINER
ABUTSTHE

CLAMPING
BARENDCAP

WASHER LAMPING

SPRING
AND
NYLON
SPRING
RETAINER
FIT
INSIDE
THEOPEN
SIDEOFTHE
CLAMPING
BAR
(SEECLAMPING
BARDETAIL)

SAR)

OPEN
SIDEOFTHECLAMPING
BARPOINTS
TOWARD
THETOP
SURFACE
OFTHEDOVETAIL
BASE
11/32"LD.X 7/8"O,D.
\

THICKNYLON
WASHER

/
--

DOVETAIL
BASE
TOPSURFACE
OFTHE
RIGHTTEMPLATE
SUPPORT

SPRING
31/2"BOLT
BOLl
SUPPORT

CLAMPING
BAR(SHOWN
WITH
/
ENDCUTAWAYANDSECT!ONED
/
SONYLON
SPRING
RETAINER
/
PLACEMENT
CANBESEEN)
/
COMPRESSION
SPRING

12) Repeatabovesteps4 through11for theotherendof the clampingbar.

13) Assembletheendcapsto the endsof the clampingbar by pressingthem in; theyare designedto be "force-fit"intothe bar in oneway
only.It maybe necessaryto "tap" themin by gentlyhittingthem with a rubbermatletor a pieceof wood--since theyfit very tightly intothe
clamping
bar,
USECARE WHEN DOINGTHISSO AS NOT TO DAMAGE THEEND CAPS,
USECARETHATTHE CAPSAREPROPERLYALIGNEDAS SHOWN WHEN ASSEMBLINGTHEM TO THEBAR.

fig.7
CLAMPING
BARPARALLEL
TO
TOPOFBASE

J SPACING
TOBE
APPROXIMATELY
1-1/2"

14) Tightenthe clampingknobsontothe boltssothat thespacebetweenthebottomof theclampingbarand thetop of the baseis about
1 1/2".Theciampingbar shouldbe paralletto the top of the base.
15) After completingthe abovestepsyour DovetailFixtureshouldlooklikethe illustrationin Figure7.

ASSEMBLYOF THEFRONTCLAMPINGBARTO THEDOVETAILBASE

1) Assemblethe front clampingbarto the dovetailbasefollowingthesameprocedureusedto assemblethetop clampingbar tothe dovetail baseas shown in Figure8. The5/16-18X 4-1/2"long roundheadsquareneckboltsare used,

Fig. 8
CLAMPING
BAR
(SHOWN
WITH
ENDCUTAWAY
ANDSECTIONED
SONYLON
SPRING
RETAINER
PLACEMENTCANBE
SEEN)

4 I/2" BOLT

COMPRESSION
SPRING

""

11/32"1.D.
X 7/8"O.D,
THICK
NYLONWASHER

BOLT

COMPRESSION
SPRING
NYLON
SPRING
RETAINER
(RETAINER
ABUTSTHE
CLAMPING
BAR)

CLAMPING
BAR
ENDCAP
RETAINER

1!/32"LD.X 7/B"O.D,
THINNYLONWASHER
11/32"I.D.X 7/8"O.D.WASHER

ASSEMBLYOF THECAM HANDLESAND PIVOTSHAFTTO THEDOVETAILBASE

Afterthe cam handlesandpivot shafthavebeenassembledto thebase,it will be possible

to accuratelypositionthetemplatesfor close
fitting joints,
Notethat therearesomegraduationson bothtemplatesupports.
Rotatingthe cam handlesothat thepointerlinesup with one of thegraduationspermitsaccuratefront-to-backpositioningof the
template.
Camhandlesare designedto provideinfinitetemplateadjustment.
Onegraduationequals1/64"of movementof thetemplate.
Rotatingthe cam handlesothat thepointerlevermovestowardthe front of thebase.causesthetemplateto alsomovetowardsthefront
of the base.
Converselyrotatingthecamhandlesothat thepointerlevermovestowardthe backof the base,causesthetemplateto alsomove
towardsthe backof the basealso.

1) Assembleone of the camhandlesto the pivotshaftusinga #10-32x 5/8"long panheadmachinescrewanda 13/64"I.D.x 9/16" LD.
washer,asshown in Figure9,
2) Usecareso that the pivotshaftfits intothe hex-shapedholein thecam handle.Thepivotshaftmayfit tightly intothe camhandle;
this is normal.
3) Makesurethat thepivot shaftbottoms*outinsidethe cam handle.

Fig. 9

/
13/64"t.D.X 9/160.O,WASHER
--_,,,,_

CAMHANDLE
_

PIVOT
SHAFT

4) Securelytightenthe screw,
NOTE:THENEXTTWOSTEPSAREPRE-ASSEMBLY
STEPS.
5) Sgdetheretainerovertheendof thepivotshaftfor about2".Theretainermayfit tightly;thisis normal
6) Threadthe#1_`16x1/2"_ngpanheadtappingscrewint_theh_eintheretainerunti_itbott_ms-_tagain_tthepiv_tsha_.(Thescrew
will fit tightlyin the hole.)SeeFigure10.

Fig. 10

#!0-16X 1/2"LONG
PANHEAD
TAPPING
SCREW

7) Loosenthescrewaboutone turn. Removethe retainerfrom the shaftandsetit asidetemporarily.

8) Assemblethe pivot shaftwith camhandleto the basebyinsertingtheendof thepivot shaftthroughthe holestnthe righttemplate
support andthebase.
9) MAKESURETHEORIENTATION
OFTHECAMHANDLEISAS SHOWNIN FIGURE11.
10) Placethe retainerat thelocationshownin Figure12 end pushthe pivotshaftthrough.THEORIENTATION
OFTHERETAINER
RELAT]VE
TOTHECAMHANDLEWITHSCREWMUSTBEAS SHOWN.
NOTE:THERETAINER
MAYFITTIGHTLYONTHEPIVOTSHAFT;
THISIS NORMAL.

Fig. 11

DOVETAIL
BASE

11) Continuepushingthepivot shaftthroughthe holesand theretaineruntilthe endof the pivotshaftextendsout ofthe left templatesupport
asshowin Figure12.
12) Makesurethe endof thecam handlefits intothe holein thebaseasshown,

Fig. 12
PIVOT,
HOLE
INBASE,

PtVOT
SHAFT

SUPPORT
CAM
HANDLE

_"

13)With the camhandlepushedin againstthe base,positionthe retaineragainstthesidewallof the base,asshownin Figure13.Theretainer

shouldbarelytouchthesidewall ofthe base.Thepurposeof the retaineris to preventor minimizethe side-to-sideof thecam handleand
pivot shaft.

Fig. 13
RVOTSHAFT

-SIDEWALLOFBASE

14) Assemblethe othercam handleto theotherendof the pivot shaftusinga 13/64"I,D.x 9/16"O.D,washerand a#10-32X 5/8"long
penheadmachinescrew,asshownin Figure14.
15) Makesurethat thecamhandlelinesup with the camhandleat theotherend ofthe pivotshaftandthat theend ofthe camhandlefits into
the holein thebase.
16)Tightenthe screwsecurely,
LEFTTEMPLATE
SUPPORT

Fig. 14

/_

#10-32X5/8"LONG
PANHEAD
MACHINE
SCREW

_"

DAMHANDLE

17)Rotateone of thecamhandtes-ltshoutdrotatefreelyand movethetemplatesupports,

18) If this doesnot happen,loosenthescrewon the retainerand movetheretainerawayfrom thesidewall slightly,
19)Securelyretightenthescrew.
20) If thereis too muchside-to-sidemovement(play)of the cam handles;loosenthescrewin theretainerand movetheretainerc/oserto the
sidewaltof the base.
21) Securelyretightenthescrew,

ASSEMBLYOFTHEFRONTSTOPBLOCKSTOTHEDOVETAILBASE
1) Aseemblethe front stop blockstothefront 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) Makesurethat theopenrib portionfits intothe slot in the front of the base.Thestop blockwglfit intothe slot in onepositiononly,
3) Tightenthe screwsecurelyontothenut.
4) Assembletheotherfront stop blockto oppositeend o1the dovetagbasein the samemanner.

Fig. 15

FORREASONS
OFCLARITY,THEFRONT
CLAMPING
BAR,KNOBS,
BOLTS
AND
SPRINGS
ARENOTSHOWN

WASHER

DOVETAIL
BASE\

SLOT
_

SUPPORT

FRONT
OFDOVETAtL
BASE

#10-32HEX
13/64
_LD.X9/16O.D/
WASHER

5/8"LONGFLATHEAD
MACHINESCREW

FRONT
STOP
BLOCI_

10

#10_32XB/8OLONG
FLATHEADMACHINE
SCREW

ASSEMBLYOFTHETOPSTOPBLOCKSTO THEDOVETAILBASE

Thetop stop blocksareassembledto thetop of thedovetailbasein oneof two waysdependinguponwhich styleof dovetailjoint is
to becut:
a)
HALF-BLIND
FLUSHJOINTS--The"A" on thestop blockfacestowardthe "middleof the base".
b)
HALF-BUNDRABBET
JOINTS_The"B" on thestop blockfacestowardthe"middleof the base".
c)
THROUGH
JOINTS--The"A" on thestop blockfacestowardthe"middleof the base".
Sincetheflush joint is themorecommonlyusedjoint, thefollowinginstructionsapplyto theassemblyof the stop blocksfor this
stylejoint.

1) Positionthedovetailfixturerightsideup on a flat surface.

2) Assembleoneof thetop stop blocksto thetop surfaceof the baseusinga #10-32x 7/8"longflatheadmachinescrew,as shownin
Figure16.Thescrewthreadsintothe holein the bottomof thesIot.
3) Makesurethat the "A" facesthe "middleof the base".
4) Makesuretheopenrib portionof the stopblockfits intotheslot in thetop surfaceof thebase.

Fig.

RfB
ONSTOP
BLOCK_

16

#10_32
X 7/8_LONG
MACHINE
SCREW

#t0-32X 7/8"L'ONG
FLAT
HEADMACHINE
SCREW

TOPSTOPBLOCK

SLOTIN TOP
OFBASE
SLOTIN TOP
/
MIDDLEOFTHEBASE

OFBASE

5) Assembletheremainingtopstop blockto the oppositeend ofthe basein thesamemanner.

6) Againmakesurethat the "A" facesthe"middleof the base"
7) Tightenbothscrewssecurely.
8) Torepositionthestop blocksfor rabbetjoints,simplyloosenthescrewsjust enoughso thatthe ribson the stop blockscomeout of the
slot,Thestop block isthenrotated180 to thealternateposition,sothe "B"facesthe middleof thebase,and securelyretightenthe screws.

ASSEMBLYOF THECLAMPINGKNOBSTO THEDOVETAILBASE

1)
2)
3)
4)

Assemb_e1_/32"
_D.x 7/8"____was_ers_ntot_e_/1_-18b_its at b_thends_f t_ed__etai_
_aseassh__n in Figure17_
Assemblethe clampingknobsontothe boItsasshown.
Threadtheclampingknobsontothe boltsso that thespacingbetweenthewasherandthetemplatesupportsis approximately1/2".
Setthe dovetailbaseasidefor thetime beingand continueon withthe nextsection.

ASSEMBLYOFTHETEMPLATES
/ 5/16-18X2" longROUND

Fig. 17

/ HEAD
SQUARENECK
BOLT

5/t6- t8 X2 tongROUND
HEADSQUARE
NECKBOLT\

//

11/32"I.D.X T/8"
O.D,WASHER

KNOB

CLAMPING
/
!/2"SPACING
8ETWEFN
WASHER
AND
TEMPLATE
SUPPORT
(BOTH
ENOS)

KNOB
11

Placethetemplatestiffenerinto therectangularslot in the underneath

sideof thetemplate,asshownin Figure 18.
NOTE:THETEMPLATE
FORCUTTING
HALF-BLIND
JOINTSISBEINGUSEDASANILLUSTRATION
INTHEFOLLOWIHG
FIGURES.
1) Threada #8-36x 3/16"long panheadmachinescrewthrougheachof the fiveholesin thetemplateandinto thethreadedholesin the
templatesupport,asshownin Figure24 and securelytightenall of thescrews.
Fig. 18

_
\

TEMPLATE
STIFFENER

_J

jRECTANGULARSLOT

TEMPLATE

MACHINESCREwSLOTTED
BINDING
HEAD_

MA#&3gX3!!6"tngPANHEADcHINE
SCREW

NOTE:ONSOMEEARLY
VERSIONS
OFTHISPRODUCT,
A SLOTTED
BINDINGHEADMACHINESCREWHASBEENSUBSTITUTED
FORTHE
PANHEAD
SCREWSPECIFIED
FORASSEMBLING
THETEMPLATE
SUPPORTS
TOTHETEMPLATES.
(SEETHESCREWILLUSTRATION
IN
FIGURE18),
2) Assemblethetemplatebracketsto thetemplateusingfour #10-32x 3/8longpanheadmachinescrews_as shownin Figure19.
3) MAKESURETHATTHETEMPLATE
BRACKETS
AREASSEMBLED
TOTHEUNDERNEATH
SIDEOFTHETEMPLATE,
AS SHOWNIN
FIGURE19,ANDTHATTHEAL]GNMENT
OFTHEBRACKETS
IS ALSOASSHOWNIN THEFIGURE.
4) IT IS NOTNECESSARY
FORTHESCREWS
TOBETIGHTENED
ATTHISSTAGE;
THETEMPLATE
BRACKETS
SHOULD
BEFREETOMOVE
WITHRESPECT
TOTHETEMPLATE
ORELSEITWILL NOTBEPOSSIBLE
TOALIGNTHETEMPLATE
AS DESCRIBED
INTHENEXTSECTION.
5) Theassembledtemplateshouldlookliketheillustrationin Figure20.

Fig. 19

#10-32X 3/8"tongPANHEAD
MACHINE
SCREW

TEMPLATE

'\

_-

TEMPLATE
BRACKET
....

6) Assemblethetemplatestiffenerandthetemplatebracketsto the TEMPLATE

FORCUTTING
THROUGH
JOINTSusingthesamemethod
describedin the precedingsteps1 through5, Referto Figure20.

Fig. 20

lg

ALIGNMENTOFTHETEMPLATES
In orderfor the DovetailFixtureto functionproperly,it is necessaryfor thetemplatesto bealignedwith respectto dovetailbase.The
reasonfor this, isthat dovetailcutsareat both endsof the DovetailFixture.Whenproperlyaligned,the resultbeingall matingcorners
will alwaysbe linedup.
NOTE:THETEMPLATE
FORCUTTINGHALF-BLIND
JOINTSIS BEINGUSEDASANILLUSTRATION
IN THEFOLLOWING
FIGURES,
1) Withthe dovetailbasesti!l havingthe 1/2"spacingbetweenthewasherandthetemplatesupports(Referto Figure17),assemblethe
templateassemblyto thedovetailso that:
a) theslot in the templatebracketfits overthebolt,
b) theleg of the templatebracketis betweenthe washerand thetemplatesupport,and
c) thelegsfit intothe slotsin thetemplatesupports,asshownin Figure21.
d) NOTE:THISPROCEDURE
MUSTBE FOLLOWED
WHENEVER
THETEMPLATE
ISINSTALLED
ONTHEDOVETAIL
FIXTURE.
IT ISMOST
IMPORTANT
THATLEGOFTHETEMPLATE
BRACKET
ALWAYS
BEBETWEEN
THEWASHER
ANDTHETEMPLATE
SUPPORT
ORELSETHE
TEMPLATE
WILLNOTBEPROPERLY
POSITIONED
FORCUTTING
ACCURATE
DOVETAILS.
Forinitialsetup,Allowthelegsofthe template
bracketto "bottomout" in the slotsin the tempiatesupportsasshownin Figure21.

Fig. 21
_

RtGHTTEMPLATE
SUPPORT

WASHER
j

BOLT_

SLOTINTHETEMPLATESUPPORT

TEMPLATE
BRACKET

SLOTIN THETEMPLATE
BRACKET

"_TEMPLATE
BRACKET
"BOTTOMS-OUT"AGAINST
THIS
SURFACE
(BOTH
ENDSOFDOVETAIL
BASE)

TOREMOVE
THETEMPLATE
FROMTHEDOVETAIL
FIXTURE,LOOSEN
THECLAMPING
KNOBSSOTHATSPACING
BETWEEN
THE
TEMPLATEBRACKET
ANDTHEWASHERISABOUT1/2";GENTLYLiFTTHETEMPLATE
UPWARDFROMTHEDOVETAIL
BASESOTHATTHE
TEMPLATE
BRACKET
CLEARS
THESLOTSINTHETEMPLATESUPPORT
ANDSTOREIN A CONVENIENT
LOCATION,
2) LightIytighten theclampingknobsat bothendsof the baseso that thetemplatebracketsare heldin placeagainstthetemplatesupports
asshown in Figure21.
3) Movethetemplatefrom sideto sideonthe templatebracketsso that it is centeredwith respectto the templatebrackets,This meansthat
thetemplateand bracketsshouldlookIikeoneof the followingfigures:Figure22,Figure23,or Figure24,Movetemplatefront-to-backsothat
front edgeof templateis parallelwith thefront of the dovetailbase.In eachconditionthetemplateand thetemplatebracketsMUSTbe
symmetricalwith eachother.Thefiguresdo not showthe completedovetailfixture,butonlytheunderneathsideof thetemplatewith template
bracketscorrectlypositioned,in orderthat thecorrectpositionsof the partscanbeseenclearly.

]3

TEMPLATE

Fig. 22

_"DISTANCE
BETWEEN
THESE
SURFACES
MUSTBEEQUAL
ATBOTH
ENDS

I
TEMPLATE
BRACKET

CONDITIONONE."
TEMPLATE
BRACKETS
PROTRUDE
BEYONDTEMPLATES

Fig. 23

TEMPLATE

THESE
SURFACES
MUST
BEEQUAL
ATBOTH
ENDS

_0

TEMPLATE
BRACKET

CONDITION
TWO;TEMPLATE
PROTRUDES
BEYONDTEMPLATES
BRACKETS

.24
MUSTBEEQUAL
ATBOTH
ENDS

TEMPLATE
BRACKET

CONDITIONTHREE.TEMPLATE
EVENWITHTEMPLATE
BRACKETS

14

4) After thetemplatebracketshavebeencorrectlypositionedon thetemplatesecurelytightenthefourscrewsholdingthetemptatebrackets

to thetemplate.
5) Removethetemplateassemblyfrom the baseandset it asidefor now.
6) Align theothertemplateassemblyin thesamemanner,
IT SHOULDBENOTEDTHATYOUMAYFIND,THATAFTERMAKINGSOMESAMPLECUTS,SLIGHTADJUSTMENTS
MAYBEREQUIRED.
HOWTOMAKETHESEADJUSTMENTS
IS EXPLAINED
INTWOOFTHEFOLLOWINGSECTIONS:
"MAKINGADJUSTMENTS
FORHALFBLIND
JOINTS"or "MAKINGADJUSTMENTS
FOROPEN(THROUGH)
JOINTS".
7) Removethetemplateassemblyfrom the baseand set it asidefor now. (Figure25 below,is an exampleof INCORRECTLY
positioned
templatebrackets,)

CKET

THETEMPLATE
BRACKET
EXTENDS
tEMPLATE

BEYOND
THETEMPLATE
BRACKET
0

!o

CONDITION
FOUR:THISCONDITION
ISNOTCORRECT-TEMPLATE
BRACKET
EXTENDS
BEYOND
THETEMPLATE
AND
THETEMPLATE
EXTENDS
BEYOND
THETEMPLATE
BRACKET
StMPL
YMAKE
SURE
BRACKETS
AREPOSITIONED
THESAMEAT
EACHEND

ASSEMBLYOFA GUIDEBUSHINGTO THEROUTER

ALWAYSMAKESURETHATTHEROUTER
IS "TURNEDOFF"ANDTHATTHEELECTRICAL
CORDHASBEENUNPLUGGED
FROMTHEELECTRICAL
OUTLET
BEFORE
ASSEMBLING
A GUIDEBUSHING
TOTHEROUTER
ORMAKINGANYADJUSTMENTS
OR
CHANGING
ROUTERBITSIN THEROUTER.
REMOVE
ANYROUTERBITFROMTHEROUTER
BEFORE
PROCEEDING
WITHTHEASSEMBLY
OFA GUIDEBUSHING
TOTHEROUTER.
Assembly for Sears routers with three hole baseplates:
1) Placethe'router upsidedawnon a flat surfaceand removeanyguidebushingthat maycurrentlybein the router,
2) Placethe guidebushingrequiredfor thetypeof dovetagjoint to be cut undertherouterbaseplateasshownin Figure26.

Fig. 26

10-32X 3/8LONG
FLATHEAD
MACHINE
SCREW

NOTETHEORIENTATION
OF"
THEGUIDE
BUSHING

(1/2"DIAMETER
SHOWN)

3)
4)
5)
6)

MAKESURETHATTHEORIENTATION
OFTHEGUIDEBUSHINGIS ASSHOWN,
Positiontheguidebushingsothat thethreethreadedholesin the guidebushingline up with the countersunkholesin the baseplate.
Threada #10-32x 3/8"longflatheadmachinescrewinte eachon the holes.
SecureIytightenthescrews.

Assemblyfor Soars 1/2" Shank Industrial Routers Modal Nos. 27504, 27505 and 27506 or equivalent:
1)
2)
3)
4)
5)
B)

Placethe routerupsideon a flat surfaceand removeanyguidebushingthat maycurrentlybe inthe router.

Placethe guidebushingin the recessedportionof the routerbaseasshownin Figure27.
Alignthe cutoutsin theguidebushingwith the threadedhoIesin the base.
Threadthetwo roundheadscrews,that camewith the router,intothetwo threadedholesin the base.
Tightenthescrewssecurdy.
FORADDITIONAL
INFORMATION
CONCERNING
THISMATTER,
CONSULT
YOURROUTEROWNERSMANUAL.
MAKESURETHATTHEROUTER
BITISALIGNEDWITHORCENTERED
IN THEHOLE
IN THEGUIDEBUSHING.TODOTHIS,LOOSEN
SCREWS
HOLDING
BASEPLATEORADAPTER
PLATETOROUTER,
CENTER
GUIDEBUSHINGHOLE
WITHRESPECT
TOROUTER
BITANDRETIGHTEN
SCREWS
SECURELY

Fig, 27

_
I

- ROUTERBIT
i

TEMPLATE
GUIDE
--

',,@,
I

ROUTER
BA_

Assembly for other brands of routers:

IN ORDERTOUSETHEDOVETAIL
FIXTURE
WiTHOTHERBRANDS
OFROUTERS,
IT WILL BENECESSARY
FORYOUTOPURCHASE
A
CRAFTSMAN
UNIVERSAL
ROUTER
ADAPTER
PLATE,MODELNO.25326,FROMSEARS,ANDREPLACE
THEBASEPLATEONYOURROUTER
WITHTHEADAPTER
PLATE.
1) Placethe routerupsideon a flat surfaceand removeanyguidebushingthat maycurrentlybe in the router,
2) Placetheguidebushingrequiredfor thetypeof dovetailjointto be cut underthe routerbaseplateas shownin Figure2&
3) MAKESURETHATTHE
ORIENTATION
OFTHEGUIDEBUSHINGIS ASSHOWN,

Fig. 28

MACHINESCREW

NOTETHEORIENTATION
OF
THEGUIDE
BUSHING

(t/2" DIAMETER
SIlOWN)

MAKESURETHATTHEROUTER
BITtSALIGNEDWITHORCENTERED
IN THEHOLE
IN THEGUIDEBUSHING.TODO THIS,LOOSEN
SCREWS
HOLDINGBASEPLATEORADAPTER
PLATETOROUTER,
CENTER
GUIDEBUSHING
HOLEWITHRESPECT
TOROUTER
BITAND
RETIGHTEN
SCREWS
SECURELY

16

4) Positiontheguidebushingsothat thethreethreadedholesin theguidebushinglineup with the countersunkholesin the adapterplate.

5) Threada #10-32x 3/8"long flatheadmachinescrewinto eachon theholes,
6) Securelytightenthescrews.
_PLATE

Fig. 29

NOTETHEORIENTATION
OF
THEGUIDEBUSHING

INSTALLATION
INSTRUCTIONS
THEDOVETAIL
FIXTURE
MUSTALWAYS
BEFIRMLYANDSECURELY
MOUNTED
TOA SOLIDANDFIRMWORK
SURFACE,
SUCHASA WORKBENCH,
BEFORE
USE.FAILURE
TODOSOCOULDCAUSE
THEDOVETAIL
FIXTURE
TOTIPOVERORSLIDE
ALONGTHEWORKSURFACE,
RESULTING
IN PROPERTY
DAMAGE
ANDSERIOUS
PERSONAL
INJURY.
MOUNTING
THEDOVETAIL
FIXTURE
TOA WORKSURFACE
ORWORKBENCH
USINGCLAMPS
USINGTHISMOUNTING
METHOD
ALLOWSYOUTOMOUNTTHEDOVETAIL
FIXTURE
SOTHATIT CANBEEASILYINSTALLED,
FORUSE,
ANDREMOVED,
FORSTORAGE,
WITHOUTPERMANENTLY
TAKINGUPSPACEONYOURWORKBENCH
1) Makea solidwoodmountingboard,32"longx 6-1/4"widex 3t4"thick.
2) Remvethetemplateassemblyfrm thebaseif thereis no therecurrently'
3) Drill three1/8"diameterholes,3t4"deepinto themountingboardasshownin illustration.
4) PositiontheDovetailFixtureon the topof the mountingboardsothe holesin thebaseline up with thedrilledholesin the mountingboard.
5) Securethe DovetailFixtureto themountingboardusingthree13164"!.D.x 9/16"O.D. washersandthree#10-16x 1"long panheadself
tappingscrewsasshownin Figure30.

FIG. 30
/

FRONT
OFTHE
TOTHE

1/8"DIAMETER
DRILL
HOLE

TOTHE
FRONT
OFTHE_
DOVETAIL
BASE

17

9) Applying
a smallamountof soapto the screwthreadswill makeit easierto threadthescrewsintothe holes.
10) Line up thefront of themountingboardwith the front of a workbenchor othersturdysurface,
11) Usingtwo clamps,such asC-clamps,firmly clampthe DovetailFixture
to theworkbenchbyclampingon the mountingboardasshownIn
Figure31 and Figure31A.
12) Makesurethat the mountingboardlinesup with the front of the workbench.

Fig. 31

CLAMP
HERE
\

FRONT
SURFACE
OF
THEMOUNTtNG
BOARD

;URFACE
OF
THEWORKBENCH

FRONT
SURFACE
OFTHEBASE

Fig. 31,4

FRONT
SURFACE
OF
THEBASE

-]

FRONT
SURFACE
OFTHE
/
MOUNTING
BOARD
FRONT
SURFACE
OF/
THEWORKBENCH

USINGTHEDOVETAILFIXTURE
STYLES OF DOVETAIL JOINTS
Fourdifferentstylesof dovetadjointscanbe madewith the DovetailFixtureusingyour router.
Thesejoints aredescribedin thefollowingsections.
Half Blind Flush Joint:
TheHalfBlind FlushJointis usedwhentheheightof boththe drawerfront andthe drawerbackisthe sameheightasthedrawersides;
andthe lengthof boththedrawerfront andthedrawerbackis the sameasthewidth ofthe drawer.
SeeFigure32.

18

NOTE:THENORMALDEPTHOFCUTFORA HALFBLINDFLUSHJOINTIS3/8".

DRAWERFRONT(PtNPtECE
)

Fig. 32

DRAWER
SIDE(TAIL
PIECE)

SIDE(TAILPIECE)

DRAWER
BACK(PiNPIECE)
_
HALFBILHDFLUSH
JOINT

Half BlindFlushOffsetJoint:
TheHaftBlind FlushOffsetJoint is usedwhen:
Theheightof boththedrawerfront andthe drawerbackis the sameheightasthe drawersides;the tengthof thedrawerfront is 1/8"
longer(1/16"on a side)thanthewidth of thedrawer;andthe lengthof thedrawerbackis the sameasthewidth of thedrawer.
SeeFigure33.
Toobtainthe offset,cut a 1t16"deepby 3/8"widerabbeton theoppositeendson the insideof thedrawerfront.
NOTE:
THENORMALDEPTHOFCUTFORA HALFBLINDFLUSHOFFSET
JOINTIS 3/8",

DRAWER
FRONT
(PINPIECE)

Fig. 33

DRAWER
SIDE(TAILPIECE)

DRAWER
StDE(TAILPIECE)

TAILS

DRAWER
BACK(PINPIECE)
J_
HALFBILNDFLUSHOFFSET
JOINT

19

Half BlindRabbetedJoint:
TheHalfBlindRabbetedJoint is usedwhen:
thedrawerfront overlapsthe openingfor the draweron all four sides of theofthe draweropening(top bottom andtwo sides)that is;
thelengthof thedrawerfront is3/4 longer(3/8"on a side)thanthe width of thedrawer;the heightof the drawerfront is also3/4"higher
(3/8on side)thanthe heightof the drawer;the tengthof the drawerbackis thesameas thewidth of thedrawer;and theheightof the
drawerbackis thesameasthe heightof the drawer
SeeFigure34
Toobtainthis joint cut a 3/8"deepby3/8"wide rabbetaroundthe insideperipheryof thedrawerfront
NOTE:THENORMAL
DEPTHOFCUTFORAHALFBLINDRABBET
JOINTIS 3/8",
/DRAWERFRONT
(PiNPIECE)

Fig.34

"WIDERABBETAROUND
THE
PERIPHERY
OFTHEDRAWER
FRONT

DRAWER
SIDE(TAILPIECE)
\
\

DRAWER
SIDE(TAILPIECE)

TAILS
DRAWER
BACK(PINPIECE)
HALFBLINDRABBETED
JOINT

Openor ThroughJoint:

TheOpenor ThroughJoint is similar to theHalf B{indJoint exceptthat joint seamsarevisibieon the front, back,andsidesof the
workpiece;on theHalfBlindJoints,the seamsarevisible onlyon the sidesof theworkpiece,
Althoughthis styleof jointcanbealso usedfor drawers its mostpopularuseis for makingboxes,andsmall andfargochests
Theheightof boththefront andthe backof the draweror chestis the sameasthe heightasthesidesof thedraweror chest;
andthe lengthof boththefront and thebackof the draweror chestIs thesameasthe width of the draweror chest
SeeFigure35

NOTE:THEDEPTHOFCUTIS DETERMINED
BYTHETHICKNESSES
OFTHEFRONT,BACKANDSIDEPIECES,

Thefront and backpieces(sometimescalledpin pieces")arecut independently

from the sidepieces(sometimescalledtail pieces)
The'tail pieces arecut first usingoneedgeof thetemplateanda dovetailrouterbit Thedepthof cut is equalto thethicknessof the
pin pieces
The'pin pieces'arecut nextusingtheotheredgeof thetemplateanda straightrouterbit Thedepthof cut is equa{to the thicknessof the
taiI pieces Adjustmentsaremadeat this point to obtainjoint fit

Fig. 35

TAILS --____

TAILS

ii FRONT
(PtNPtECE)

\ RIDE(TAILPIECE)

OPEN(THROUGH)
JOINT

2O

_-_-_

BACK(PtNPIECE)

ADJUSTINGTHEDEPTH-OF-CUT
OFTHEROUTERBIT

Fig. 36

ALWAYS
MAKESURETHATTHEROUTERIS
"TURNEDOFF"ANDTHATTHEELECTRICAL
CORDHAS
BEENUNPLUGGED
FROMTHEELECTRICAL
OUTLET
BEFORE
ASSEMBLING
ORREMOVING
ROUTER
BITSTO
THEROUTER,
Youwill notethattherearesix pocketsalong thefront
surfaceof thedovetailbase,andthat theyare identified
bya dimensionssuchas3/8, I/2,-up to 1. These
pocketsare usedto setthe depth-of-cutof a routerbit.
Touseproceedasfollows:
DONOTUSEWITHA TEMPLATE
ASSEMBLED
TOTHEBASE.

DONOTINSTALL
ROUTERBITSTOTHE
ROUTER
UNLESSTHECORRECT
GUIDE
BUSHINGHASBEENASSEMBLED
TOTHE
BASEPLATE
FIRST.

ROUTER
BIT
GUIDEBUSHING

_
MAKESURE
THATTHEROUTER
BITISALIGNED
WITHORCENTERED
tN THEHOLE
IN THEGUIDE
BUSHING.
TODOTHIS,LOOSEN
SCREWS
HOLDING
BASEPLATE
ORADAPTER
PLATE
TOROUTER,
CENTER
GUIDE
BUSHING
HOLEWITH
flESPEC
T TOROUTER
BITANDRETIGHTEN
SCREWS
SECUREDf
1) InstaIIthe desiredrouterbitto therouterasexp{ainedin your RouterOwner'sManual SeeFigure3B.
A M{NIMUMROUTER
BITSHANKENGAGEMENT
OF3/4"IS REQUIRED
IN THECOLLETOFTHEROUTER,
2) TIGHTEN
THECOLLETNUTSECURELY.
3) Positionthe routeroverthepocketwith the requireddepth-of-cut,

Fig. 37

Fig.37A

POCKET

2]

4) Graduallymovethe routerbit outward,by usingthe depth-of-cutfeatureon the router,untilthetip of the routerbit touchesthe bottomot
the pocket,as shownin Figure37 andFigure37A.
5) Lockthe routerin position,

Fig. 38

?FOOT

6) Thedesireddepth-of-cuthasbeenset.
7) Toset a depth-of-cutNOTprovidedfor on the dovetailbase,simplypJacetheunusedtemplateen the routerbaseplate,
as shownin Figure38,Theheightfrom the templateto the end or tip of the routerbit will thenbe the requireddepthof cut,

WHEN
SETTING
THEDEPTH
OFcuT,MAKE
ABSOLUTELY
SURE
THATTHECOLLET
NUTDOES
NOTCONTACT
(TOUCH)
THEGUIDE
BUSHING.
THISCANCAUSE
THEGUIDE
BUSHING
TOHEATUPEXCESSIVELY
DURING
CUTTING
WHICH
CANCAUSE
DAMAGE
TOTHETEMPLATE.
TO
CORRECT
THISSITUATION
ORPREVENT
tTFROMOCCURRING,
REPOSITION
THEROUTER
BITIN THEROUTER.

CLAMPINGTHEWORKPIECES
TO THEDOVETAILBASE
(ORBACK)
FACES
UP

Fig. 39

TOTHETOPOFTHEBASE

TOP,

OFTHEWORKPIECB

FRONT
STOP
BLOCKr BECLEAR
OF
THEWORKPIECES
WORKPtECE
CLAMPED
TO
THEFRONT
OFTHEBASE

FACES
OUT

Fig, 40

WORKPIECE
CLAMPED
TOTHETOPOFTHEBASE--_-_-/

TOPC.MPINGB,

__i_-_-

INSIDE
SURFACE

TOPSTOP
RLOBK

ERO_T
OLAMPINGBAR__
WASHER,_,fUSTBE_ORKP_CES
_
\ __J_
"_TSTOPBLOCK
INStOESUREADE _'_-'--WORKPIEOECLAMPEO
TO
2,2,

THEFRONTOF THEBASE

Theclamping
barshavebeenspeciallydesignedto allowtheclamping
forcestobeappliednextto theworkpieces
for moreefficient
clamping.
This isaccomplishedbybeingableto positionthe clamping
knobsin closeproximityor nextto theworkpieces.
Figure39 illustratesthepositioningof theclamping
barsand theclampingknobswhentheworkpiecesare clamped
to the LEFTSIDEof
theDovetailFixture,
Figure40 illustrates
the positioningof theclampingbarsandtheclampingknobswhentheworkpiecesare clampedto the RIGHTSIDEof
the DovetailFixture.
Notethe closeness
ofthe clamping
knobsto the workpieces.Whennot in useclampingknobsandthe supportingboltsandspringsare
freeto be movedalongthe slots inthe base,
CAUTION:WHENCLAMPING,
MAKESURETHATTHECLAMPING
KNOBS
ARENOTPOSITIONED
SOCLOSETOTHEWORKPtECES
THAT
THEWASHERS
BECOME
TRAPPED
UNDERTHEWORKPIECES.
FORACCURATE
JOINTS,THEWORKPIECES
MUST"Bu]-r-uP" AGAINST
BOTHTHETOPANDTHEFRONTSTOPBLOCKS
TOENSURE
THEEXACTPOSITIONING
OFTHEWORKPIECES.
TOENSURE
ACCURATE
JOINTSANDSAFEOPERATION,
WOODSHAVINGS
ANDACCUMULATED
DUSTMUSTBEREMOVED
FROMTHE
DOVETAIL
FIXTURE
BEFORE
EACHSETUP,
EITHERBYUSINGA BRUSHOR BYVACUUMING.

MAKINGDRAWERSWITH HALFBLINDFLUSHJOINTS:

Thethicknessof boththe front andback(pin pieces)mustbeat least1/2".Thethicknessofthe sides(tail pieces)mustbe at least3/8".

A partialtail will becat for side(tail piece)thicknessesup to 9/16".Thisisnormalandwill notaffectthejointor its appearance.

Fig. 41
CORNER
#4
(CUTATTHERIGHT
SIDEOF
THEDOVETAIL
FIXTURE)

CORNER
#1
(CUTATTHELEFTSIDEOF
THEDOVETAIL
FIXTURE)

DRAWER
FRONT_

SURFACE
LINESUPWITH
FRONT
STOPBLOCKS

DRAWER
RIGHT
SIDE

SURFACE
LINESUPWITH
FRONT
STOPBLOCKS

PINS_

INSIDE
OFDRAWER

STOP
BLOCKS

OUTSIDE
OF
DRAWER

DRAWER
BACK

CORNER
#2

CORNER
#3

(CUTATTHERIGHT
SIDEOF
THEDOVETAIL
FIXTURE)

(CUTATTHELEFTSIDEOF
THEDOVETAtL
FIXTURE)

Figure41 showsa drawerandthe workpiecesthat makeit up. Thisfigureis similarto Figure33, exceptthat it showsthe workpieces
unassembled(or anexplodedview of thedrawer).

23

Inaddition,thefigure showswherethefour cornersof the drawerarecut on the DovetailFixture:

CORNERS
1AND3 arecot on theLEFTSIDEof the DovetailFixture,
CORNERS
2 AND4 areouton theRIGHTSiDEof the DovetailFixture.
Trialcutsare stronglyrecommended
usingscrapwoodto ensurethat thefinalworkpieceeare ofthe desiredquaIity,

GENERAL PREPARATIONS:
a) Theworkpieces
comprisingthedrawer,that is, front,back,left side,andrightsideshouldbe outto the properlength,width,and
thickness(es),
MARK"4"

Ei#. 42

MARKDRAWER
RIOHT
_

MARK"1"

/_

_",,

SIDETOPSURFACE"

MARK"DRAWER
LEFT
SIDEINSIDE
SURFACE"
(SHOWN
HIDDEN)

_ MARK"DRAWER
RACK
INSIDE
SURFACE"
_HOWN_DDEN)

b) Makesurethatall surfacesaresmoothandsquarewith eachofthe othersurfaces,

c) Lineup theworkpieceson a flat surface,standingon edge,asshownin Figure42.
d) With a softleadpencilmarkthefront, back,left side,andright side,asshownInFigure42. Thisis to aid you
workpiecesonthe DovetailFixture,priorto cuttingthedovetails

40"DIA.GUIDE
BUSHING
SEARS
CRAFTSMAN
DOVETAIL
ROUTER
BIT\

#25505OR#26318

24

positioningthe

e) Assemblethe.40"guidebushingto therouterbaseplate,asdescribedin a previoussection.Thisthesmallerof thetwo guidebushings

furnishedwith this product.
f) _nsta__Searsd_vetai_r_uterbit_#255_5_r#26318_t_ther_uterasdescribed_ny_urR__ter_wner_sManuaLShankengagement
shouldbe a minimumof 3/4%
_
MAKE
SURETHATTHEROUTER
BITtSALIGNED
WITHORCENTERED
IN THEHOLE
tN THEGUIDE
BUSHING.
TODOTHIS,
LOOSEN
SCREWS
HOLDtNG
BASEPLATE
ORADAPTER
PLATE
TOROUTER,
CENTER
GUIDE
BUSHING
HOLEWITH
RESPECT
TOROUTER
BtTANDRETtGHTEN
SCREWS
SECURELY.
_
WHEN
SETTING
THEDEPTH
OFCUT,MAKE
ABSOLUTELY
SURETHAT
THECOLLET
NUTDOES
NOTCONTACT
(TOUCH)
THEGUIDE
BUSHING.
THISCANCAUSE
THEGUIDE
BUSHING
TOHEAT
UPEXCESSIVELY
DURING
CUTTING
WHICH
CANCAUSE
DAMAGE
TOTHETEMPLATE,
TO
CORRECT
THIS
SITUATION
ORPREVENT
ITFROMOCCURRING,
REPOStTtON
THEROUTER
BITINTHEROUTER.

Fig. 43

' LEFTTOPSTOP
BLOCK

/"A" FACES
TOWARD
MIDDLE
OFBASE

RIGHTTOPSTOP
BLOCK
j

LEFTFRONT
STOP
BLOCK

POINTER
POINTS
TOCENTER
GRADUATION

STOPBLOCK

g) Adjust thedepthof cut to 3/8"usingthe depthgaugeonthe baseof the DovetailFixture,asdescribedin a previoussection.

Thissettingis approximateandsomeadjustmentmaybe required.
h) Positionboth of thetop stop bIocksso that the"A" facesthe "middleof the base"asshown in Figure43.
i) Positionthe camhandlesothat thepointerpointsto thecentergraduationasshownin Figure43.
THE FOLLOWING DESCRIBESTHE PROCEDURE TO BE FOLLOWED FOR CUTTING CORNERS 1 AND 3:
1) FORCORNER
#1, positionthe drawerfront on thetop of thebaseso that it linesup with thefront of thebaseandthetop surfaceabuts
the left top stop block.THEINSIDEOFTHEDRAWER
FRONTFACES
AWAYFROMTHETOPOFTHEBASE.Thewords"INSIDESURFACE"
markedin (d) in theSection,GENERAL
PREPARATIONS,
shouldbevisible.
2) Lightly clampthe drawerfront in place.

Fig. 44

DRAWER
FRONT

THEENDOFTHEDRAWER
SIDE
MUSTBELEVEL
ANDF
THEINSIDE
SURFACE
OFTHE
DRAWER
FRONT
(ORBACK)

"INSIDESURFACE"
SHOULDBE
VIStBLE
ON THISSURFACE
TOPOFTHEBASE

_MPLATE
SUPPORT
(ASNEEDED)

FRONTOF THEBASE

"INSIDESURFACE"
SHOULDBE VISIBLEONTHISSURFACE
NOTE:WORI(PIECESWILL BEPOSITIONEDON THE FIXTUREAS SHOWN.

25

3) PositionthedrawerRIGHTsideagainstthefront ofthe basesothat thetop surfaceabutstheleft front stop block.THEINSIDEOFTHE

DRAWER
SIDEFACES
AWAYFROMTHEFRONTOFTHEBASE.
Thewords "INSIDESURFACE"
markedin (d) Inthe Section,GENERAL
PREPARATIONS,
shouldbevisible.
4) Lineup the workpieeesso that theendof the drawersidelinesup with thedrawerfront asshownin Figure44.
5) Securelyclampthe drawersideto the base,
6) Securelyclampthe drawerfront to thebase.
7) Makesurethatthe parts remaingnedup.

Fig. 45
HALFBLIND
JOINT

SHORT
FINGERS
j

WASHER

8) AssembLe
the DOVETAIL
TEMPLATE
FORHALFBLINDJOINTSto the DovetagFixturesothat THETEMPLATE
BRACKETS
FITBETWEEN
THEWASHERS
ANDTHETEMPLATE
SUPPORTS
asshownFigure45.
NOTE:MAKESURETHETEMPLATE
CLAMPING
KNOBSARELOOSE
TOMAKETEMPLATE
ADJUSTMENT,
AFTERADJUSTMENT
ISMADE,
RETIGHTEN
TEMPLATE
CLAMPING
KNOBS.
9) Makesurethat theshort fingerson thetemplate,as shownin Figure45, facestowardthefront of the base.
10)Makesurethat thetemplateis flush andparallelwith the workpiecesclampedto base.Fornarrowdrawerfronts, the useof an auxifiary
supportfor thetemplateis recommended.Its purpose
is to aid in supportingtherouterwhilecutting.It canbemadefrom a pieceof scrap
wood; butits thicknessmustbethe sameasthe drawerfront. (Referto Figure44).
1!) Clampthe templatein placeby tighteningtheclampingknobs.
12) _
BEFDRE
MAKINGANYCUTSMAKESURETHATTHEBITWILLNOTCUTINTOTHEBASEORANYOTHERCOMPONENT
OF
THEDOVETAIL
FIXTURE.THISCANCAUSEDAMAGE
TOTHEDOVETAIL
FIXTURE;
ORLOSSOFCONTROL
OFTHEROUTER
WHICHCAN
RESULTIN SERIOUS
BODILY
INJURY.ATRIALRUNWITHTHEROUTER
TURNEDOFFANDUNPLUGGED
FROMTHEELECTRICAL
OUTLET
IS STRONGLY
RECOMMENDED,
13) TURNTHEROUTER
ON,

Fig. 46

DOVETAIL
CUTS

26

DRAWER
RIGHTSIDE

14) Cutthedovetailby movingthe routerfrom LEFTTORIGHT,with theguidehushingfollowingthetemplate,DONOTFORCE

ANYTHING;
MOVETHEROUTER
IN SLOWANDSMOOTH
FASHION.
15)Toensurea smoothand uniformjoint, retracethe previouscut by movingtherouterfrom RIGHTTOLEFTwith theguide bushingagain
followingthe template.
16) _
NEVERLIFTTHEROUTERUPWARDS
WHENTHEROUTER
IS ONANDTHEROUTERBITROTATING
ORWHENTHEGUIDE
BUSHING
IS NEARTOORTOUCHING
THETEMPLATE.
THISCANCAUSEDAMAGE
TOTHEDOVETAIL
FIXTURE;ORLOSSOFCONTROL
OF
THEROUTER
WHICHCANRESULT
IN SERIOUS
BODILYINJURY,
17)Afterthecut hasbeenmade,the workpiecesshouldlooklikethose Illustratedin Figure 46.

Fig. 47

/"INSIDE
SURFACE"
SHOULD
BEVISIBLE
_/(,_

/ONTHISSURFADE
TOPOFTHEBASE /

AUXILIARY
TEMPLATE
SUPPORT
(ASNEEDED)

DRAWER
BACK

"

SE

VISIBLE
ONTHISSURFACE

18) Removetheworkpiecesfrom the DovetailFixtureandcheckhowtheworkpiecesfit together.Someadjustmentsmaybe required,Referto

thesectionMAKINGADJUSTMENTS.

Fig. 48

DRAWER
LEFTSIDE

DOV_A__

19)FORCORNER
#3,positionthedrawerbackon the top ofthe baseso that it linesupwith the front of the baseandthetop edgesurface
abutstheleft topstop block.THEINSIDEOFTHEDRAWERBACKFACESUP.Thewords "iNSIDESURFACE"
markedin (d) in the Section,
GENERAL
PREPARATIONS,
shouldbevisible,SeeFigure47.
20) Lightlyclampthedrawerbackin place.

g?

21) Positionthe drawerLEFTsideagainstthefront of the baseso that thetop surfaceabutsthe left front stop block.THEINSIDEOFTHE
DRAWER
SIDEFACES
UP.Thewords "INSIDESURFACE"
markedin (d) in the Section,GENERAL
PREPARATIONS,
shouIdbevisible.
22) Lineup the workpiecesso that the endof the drawersidelinesup with thedrawerbackasshownin Figure47.
23)Continueas in Steps5 through16 above.
24)Afterthe cut hasbeenmade,the workpiecesshouldlooklike thoseillustratedin Figure48.
25) Removethe workpiecesfrom the DovetailFixtureand checkhowtheworkpiecesfit together.Someadjustmentsmay berequired.
Referto the sectionMAKINGADJUSTMENTS.
THE FOLLOWING DESCRIBES THE PROCEDURE TO 8E FOLLOWED FOR CUTTING CORNERS 2 AND 4:
CORNERS
2 AND4 arecut in thesameway as 1 and 3 exceptthey are positionedon the rightsideof the DovetailFixtureas shown Fig49.

Fig. 49

tN THIS
SURFACE
AUXtLIARY
TEMPLATE
SUPPORT
(ASNEEDED)

FRONT
OFTHEBASE
/
ORAWER
RtGHT
SIDE
"INSIDE
SURFACE"
SHOULD
BEVISIBLE
ONTHIS
SURFACE
NOTE:WORKPIECES
WILLBEPOSITIONED
ONTHEFIXTURE
ASSHOWN.

_BEFORE
MAKINGANYCUTSMAKESURETHATTHEBITWILLNOTCUTINTOTHEBASEORANYOTHERCOMPONENT
OFTHE
DOVETAIL
FIXTURE.THISCANCAUSEDAMAGE
TOTHEDOVETAIL
FIXTURE.
_NEVER
LIFTTHEROUTER
UPWARDS
WHENTHEROUTER
IS ONANDTHEROUTER
BITROTATING
ORWHENTHEGUIDE
BUSHINGISNEARTOORTOUCHING
THETEMPLATE.
THISCANCAUSEDAMAGE
TOTHEDOVETAIL
FIXTURE.
Afterthecut hasbeenmade,theworkpieeesshouldlooklikethoseillustratedin Figure45.
Thefinishedfront, back,andsidesshouldlooklikethose in Figure41.
Beforegluingthefront,back,andsidestogethez;
somepmvisienmustbe madefor installingthebottom,suchas dadoingor catting
e groovearoundtheinsideofthedrawerparts.
Yourdraweris nowreadyto begluedtogether,

MAKINGDRAWERSWITH HALFBLINDFLUSHOFFSETJOINTS:
GENERALPREPARATIONS:
a) Thelengthof thedrawerfront {s1/8_longerthanthe lengthof the drawerbeck.
b) Whencuttingcornersl and4;thecam handleis rotatedtwo graduationstowardthebackof the base,thus movingthe template1/32"
towardthebackof thebase.(Referto Figure50).
NOTE:MAKESURETHETEMPLATE
CLAMPING
KNOBS
ARELOOSE
TOMAKETEMPLATE
ADJUSTMENT.
AFTERADJUSTMENT
IS MADE,
RETIGHTEN
TEMPLATE
CLAMPING
KNOBS.

28

FIG. 50

A"FACES
MfDDLE
OFEASE

GRADUAtiON
TOWARD
THEBACK
OFTHEBASEFROMTHECENTER
GRADUAtiON

c) Whencuttingcorners2 and 3;the camhandleis positionedvertically,asshownin Figure4&

d) All otherGENERAL
PREPARATIONS
arethesameasthoseusedfor "MAKINGDRAWERS
WITHHALFBLINDFLUSHJOINTS",
THEPROCEDURE
FORCUTTING
THESE
JOINTSISTHESAMEASTHATUSEDFOR"MAKINGDRAWERS
WITHHALFBLINDFLUSHJOINTS".
After all dovetailcutshavebeenmade,cuta 1/16"deepby3/8"deeprabbeton oppositeendsof thedrawerfront.
Thefinishedfront, back,andsidesshouldlook likethose in Figure33.
Beforegluingthefront,back,andsidestogethez;
someprovision
mustbemadeforinstalling thebottom,suchas dadoingor cuttinga
groovearoundtheinsideofthedrawerpads.
Yourdraweris now readyto be gluedtogether.
Removethe pencilmarkingsby lightsandingor with a softeraserafterthedrawerpartshavebeengluedtogether.

MAKINGDRAWERSWITH HALFBLINDRABBETED
JOINTS:
GENERAL PREPARATIONS:
a) Thelengthof thedrawerfront is 3/4"longerthanthelengthof thedrawerback.

Fig. 51

LEFTTOPSTOP
BLOCK

/_"B"

FACES
TOWARD
MIDDLE
OFBASE
/ POINTER
POINTS
TO
CENTER
GRADUAtiON

29

b) Theheightof the drawerfrontis 3/4"higherthanthe heightof the drawerbackanddrawersides.

IT IS EXTREMELY
IMPORTANT
THATTHETEMPLATE
BEPROPERLY
ALIGNED
WHENMAKINGTHESEJOINTS,ORELSE,IN
ADDITIONTOTHEJOINTSPACING
NOTBEINGEQUAL,ASSHOWNIN FIGURE
55 BELOW,
THETOPSURFACES
OFTHESIDES,FRONT,
ANDBACKWILLNOT"LINE-UP"PROPERLY
EITHER.REFER
TOTHESECTION
"ALIGNMENT
OFTHETEMPLATES.
(FIGURE
55 ILLUSTRATES
A FLUSHDOVETAIL
JOINT.)
Ag otherGENERAL
PREPARATIONS,
exceptasnotedbelowin the procedure,
arethe sameasthoseusedfor "MAKINGDRAWERS
WITH
HALFBLINDFLUSHJOINTS".

Fi#. 52
/

DOVETAIL
TEMPLATE
FOR

LFBLIND
JOINTS

THEPROCEDURE
FORCUTTINGCORNERS1 AND4 IS THESAMEASTHATUSEDFOR"MAKING
DRAWERSWITH HALFBLINDFLUSHJOINTS"EXCEPT:
PositionBOTHtop stop blocksso thatthe "B" facesthe middieof thebaseasshownin Figure51,
Usethe sideof thetemplatethat hasthelongestfingers,
BeforegluingtheIront, back,andsidestogethez;
someprovision
mustbe madefor installing thebottom,suchasdadoingor cuttinga
groovearoundtheinsideofthedrawerparts.
Your draweris nowreadyto begluedtogether.
Removethe pencilmarkingsby light sandingor w!tha soft eraserafterthe drawerpartshavebeengluedtogether.
TROUBLESHOOTING:

If thejoint istooloose: iNCREASE

the depthof cut by INCREASING
theamountbywhichtherouterbit extendsbeyondthe basepiateby
1164"to 1/32"and makea trialcut.Continueadjustinguntil desiredjoint fit is attained,
If the jointis too tight: DECREASE
thedepthof cut by DECREASING
theamountby whichthe routerbit extendsbeyondthe baseplateby
1/64" to 1/32"andmakeatriaI cut.Continueadjustinguntildesiredjoint fit is attained.
If the joint is too shallow:Referto Figure53. Loosenthe clampingknobsholdingthetemplatebracketsandmovethetemplateINWARD
halfthe additionaldepthneededby turningthe camhandles.Retightenthe clampingknobs.
It the joint is too deep:Referto Figure54.Loosenthe clampingknobsholdingthetemplatebracketsand movethetemplateOUTWARD
by turningthecam handleshalfthedistanceneeded.Retightenthe dampingknobs.
If the jnint is notunilormly spacedtram top surfaceofdrawer:Referto Figure55. (Seethe Section"ALIGNMENT
OFTHETEMPLATES",)
With the templateclampedto the base,loosenthefour screwssecuringthetemplateto thetemplatebrackets,andmovethetemplate
slightlyto the Iuft.Tightenthe fourscrewsand makeatrial cut.If movingthetemplateto the left did notcorrectthe condition,butmadeit
worse,loosenthe screwsandmovethetemplateto the righta smallamount.Tightenthefour screwsand makeatriai cut.Continue
movingthetemplateto the rightuntilthe conditionis completeIycorrected,MAKESURETOSECURELY
TIGHTEN
THEFOURSCREWS.
it movingthe templateto theleft improvesthecondition,continuemovingthe templateto the left untiltheconditionis completeiy
corrected.Makesurethetemplateremainsparagelto thefront of thedovetailbase.MAKESURETOSECURELY
TIGHTEN
THEFOUR
SCREWS.AFTER
THETEMPLATES
HAVEBEENCORRECTLY
REALIGNED,
THEYSHOULDREQUIRE
NOFURTHER
ADJUSTMENTS
IF
THEYAREHANDLED
WITHCARE.

3O

Fig. 53

DRAWER
FRONT_

JOINTIS TOOSHALLOW
FRONT

DRAWER
LEF:

DRAWER
BA

\
Fig. 54
JOINTIS TOODEEP

BACKEXTENDS
OUTPASTSIDE

DRAWER
LEFT

DRAWER
RA

OUTPASTS_E

Fig.55
JOINTSPACINGIS
NOTUNIFORM

_,/

SPACING
LESSTHAN
DRAWER
BACK

DRAWER
BACKz-

L_I_

jJ

DRAWER
LEFTSIDEj_

31

Fig. 58
CORNER#4

CORNER#1

PROJECTFRONA_

SURFACE
LINES
UPWITHFRONT
STOPBLOCKS

PROJECT
RtGHTSIDE_._

OUTSIDE
OF
PROJECT
_

SURFACE
FRONT
STOPBLOCK

SIDE
PROJECT
TAtL_
CORNER
#2

"" PROJECT
BACK

CORNER#3

MAKINGPROJECTSWITH OPEN(THROUGH)FLUSHJOINTS:

Thethicknessof boththefront andtheback(pin pieces)must be between3/8" and1".

Thethicknessof the sides(tail pieces)mustalso be between3/8"and1".
Figure56 showsa projectandthe workpiecesthat makeit up.Thisfigureis similar to Figure35, exceptthat it showstheworkpieces
unassembled.
Trialcutsare stronglyrecommended
usingscrapwoodto ensurethat thefinalworkpiecesareof the desiredquality.

GENERAL
PREPARATIONS:
a) Theworkpiecescomprisingthe project,that is, front, back,Ieftsideandrightsideshouldbe cut to the properlength,width and thick
ness(es).
b) Makesurethat all surfacesare smoothand squarewith eachof the othersurfaces.
c) Line up the workpieceson a flat surface,standingon edge,asshownin Figure57,
d) WITHA SOFTLEADPENCILMARKTHEFRONT,BACK
ANDTWOSIDES,ASSHOWNIN FIGURE57, ALSO,THISISTOAIDYOUIN
POSITIONING
THEWORKPIECES
ONTHEDOVETAIL
FIXTURE,PRIORTOCUTTING
THEDOVETAILS,
e) Positionbothof thetop stop blocksso that the "A" facesthe "middleof the base"asshownin Figure43.
f) Positionthecam handlesothat the pointerpointsto the centergraduationasshownin Figure43.

32

MARK"4"

MARK"PROJECT
FRONTTOPSURFACE"\

Fig. 57

MARK"!"

TLEFT
SIDETOPSURFACE"

\,,\\

MARK"PROJECT
RIGHT_
SIDETOP
SURFACE

--_.

SURFACE"
(SHOWNHIDDEN)

SURFACE"
(SHOWNHIDDEN)
TOPSURFACE"

MARK
MARK"3"

MARK"PROJECT
LEFT
SIDEOUTSIDE
SURFACE"

MARK"PROJECT
BACK
OUTSIDE
SURFACE"

THEFOLLOWINGDESCRIBES
THEPROCEDURE
TO BEFOLLOWEDFORCUTTINGTHEPROJECT
RIGHTSIDEANDTHEPROJECTLEFTSIDE:
NOTE:THESEWORKPIECESMUST BECUTFIRST BECAUSE
ANYJOINTFIT ADJUSTMENTSTHATMAYBEREQUIREDCANONLYBE MADEWHEN
CUTTINGTHEPROJECTFRONTANDPROJECTSACK-THATIS, THEPROJECTFRONTANDTHEPROJECTBACKAREFIT TO THE PROJECTSIDES,

1) Assemblethe 1/2_guidebushingto therouterbaseplate,

as describedina previoussection,Thisis thelargerof thetwo guidebushings
furnishedwith this product.
2) InstallSearsdovetailrouterbit, #25414,to the routerasdescribedin your RouterOwnersManual.Shankengagementshouldbe a
minimumof 3/4".
MAKESURE
THATTHEROUTER
BITISALIGNED
WITHORCENTERED
INTHEHOLE
IN THEGUIDE
BUSHING.
TODOTHIS,LOOSEN
SCREWS
HOLDING
BASE
PLATE
ORADAPTER
PLATE
TOROUTER,
CENTER
GUIDE
BUSHING
HOLEWITH
RESPECT
TOROUTER
BITANDRETIGHTEN
SCREWS
SECURELY
WHENSETTINGTHEDEPTHOFCUT,MAKEABSOLUTELY
SURETHATTHECOLLET
NUTDOESNOTCONTAC
T (TOUCH)THEGUIDE
BUSHING.THISCANCAUSETHEGUIDEBUSHINGTOHEATUPEXCESSIVELY
DURINGCUTTINGWHICHCANCAUSEDAMAGETOTHETEMPLATE.
TO
CORRECT
THISSITUATION
ORPREVENT
IT FROMOCCURRING,
REPOStTION
THEROUTER
BITIN THEROUTER.

1/2 DIA.GUtDEBUSHtNG_

SEARSCRAFTSMAN
DOVETAtL
_
ROUTER
BIT#25414
3) Adjust the depth of cut. The depth of cut for an OPENDOVETAILJOINT is equal to the thickness of the mating part, That is:
FORCORNER#1 OF THE PROJECTRIGHTSIDE and FORCORNER#4 OF THE PROJECTLEFTSIDE,THE DEPTHOF CUT IS EQUALTO
THETHICKNESSOFTHE PROJECTFRONT.
FORCORNER#2 OF THE PROJECTRIGHTSIDE and FORCORNER#3 OFTHE PROJECTLEFT SIDE,THE DEPTHOF CUT IS EQUALTO
THE THICKNESSOFTHE PROJECTBACK.
Use the depth gaugeon the baseof the DovetaiIFixture, as described in a previous section, asa starting point
33

4) Atthis pointit will benecessaryforyou to makea top back-upboard.Thereasonsfor thetop back-upboardareto minimizesplintering
and to providesupportfor thetemplate.Thetop back-upboardis a scrappieceof woodhavingthefollowingdimensions:
LENGTH:6"to 8",sufficientlengthso that it canclampedbythe topclampingbarand beusedmorethanonce;
WIDTH;2"widerthanthe widthof the projectsides;
THICKNESS:
1/8"to 1/4"thickerthanthethicknessof theprojectsides;this to prevent"ACCIDENTALLY"
cuttinginto thedovetailbase,
This canalsobe accomplishedby usingmorethan onepieceof scrapas longasthe resultantlength,widthandthicknessareasdescribed.
5) TOCUTCORNER
#10F THEPROJECT
RIGHTSIDE,positionthetop back-upboardontopofthebasesothatitlinesopwiththe frontof
the baseandabutsto theright topstop blockasshownin figure58.
NOTE:BACKUPBOARDS
AREUSEDTOMINIMIZESPLINTERING
OFPROJECT
PIECES
ANDTOKEEPROUTER
BITFROMDAMAGING
THE
DOVETAIL
FIXTURE,

Fig, 58

TOP
BACK-UP
BOARD
\

AUXILIARY
TEMPLATE
\
SUPPORT(ASNEEDED)
\

TOP
OFTHEBASE\
_

//

_
_ _ _\_

'k
FRONTOFTHEBASE
_

.
/

_ "_','-._

....\

,.,

,J
((

_._

FRONT
IACK'UPBOARD
_

.- _ _,L

__

"OUTSIDE
SURFACE'
SHOULD
BEVtSIBLE
ONTHIS
SURFACE
IBEFORE
POSITIONING
THEFRONT
BACK-UP
BOARD
6) Lightly clampthe back-upboardin place,
7) Positionthe projectsideagainstthefront of thebasesothat thetop surfaceabutsthe rightfront stop block.Theuseof a front back'up
boardat this step is alsorecommended.
It is positionedbetweenthe projectsideandthe clampingbaras shownin Figure58.Thefront backup boardshouldhavethefollowingapproximatedimensions:
LENGTH:
6"to 8",sufficientlengthsothat it canbeclampedbythefront clampingbar andbe usedmorethanonce;
WIDTH:1"to 2"widerthanthewidth of thesides;
THICKNESS:
1/4"to 1/2".
THEOUTSIDE
OFTHEPROJECT
SIDEFACES
AWAYFROMTHEFRONTOFTHEBASE.
TEMPLATE
FOR
Fig. 59

TEMPLATE
BRACKET

CLAMPINGKNOBSI
j

CLAMPINGKNOB

\
WASHER

34

Thewords "OUTSIDESURFACE"
markedin (d) in the Section,GENERAL
PREPARATIONS,
shouldhavebeenvisiblebeforethefront back-up
boardwas put in place.
8) Lineup theworkpiecessothat the endof the projectsideandback-upboardsDineup asshownin Figure58.
9) Securelyclampthe projectsideandthe front back-upboardto the front of thebase.
10)Secureiydamp the topback-upboardto the top of the base.
11) Makesurethatthe partsremainlinedup.
12)Assemblethe DOVETAIL
TEMPLATE
FOROPEN(THROUGH)
JOINTSto theDovetaiIFixtureso thatTHETEMPLATE
BRACKETS
FIT
BETWEEN
THEWASHERS
ANDTHETEMPLATE
SUPPORTS
as shownFigure59; it will benecessaryto loosentheclampingknobsat theends
of the baseto do this
13)Makesurethat the templateis orientedasshown in Fig60.
14)Makesurethat thetemplateisflush and parailelwith the workpiecesclampedto base.Fornarrowprojectsides,the useof an auxiliary
supportfor the templateis recommended.Its purposeis to aid in supportingthe routerwhilecutting,It canbe madefrom a pieceof scrap
wood; butitsthicknessmustbethesameas thetopback-upboard.(Referto Figure58).

FIG. 60

TOPB,4CK-UP
BOARD
___

FRONT
BACK-UP
BOARD

<>
DOVETAIL
CU

RIGHT
SIDEOR
PROJECT
LEFTSIDE

15) Ciampthetemplatein placeby tighteningthe clampingknobs.

_
BEFORE
MAKINGANYCUTSMAKESURETHATTHEBITWILLNOTCUTINTOTHEBASEORANYOTHERCOMPONENT
OFTHE
DOVETAIL
FIXTURE.THISCANCAUSEDAMAGE
TOTHEDOVETAIL
FIXTURE;ORLOSSOFCONTROL
OFTHEROUTER
WHICHCANRESULT
IN SERIOUS
BODILYINJURY.
ATRIALRUNWITHTHEROUTER
TURNEDOFFANDUNPLUGGED
FROMTHEELECTRICAL
OUTLET
IS
STRONGLY
RECOMMENDED,
16) TURNTHEROUTER
ON.
17) Cutthe dovetaiIby movingthe routerfrom LEFTTORIGHT,with the guidebushingfoIIowiflgthetemplate.DONOTFORCE
ANYTHING;
MOVETHEROUTER
IN SLOWANDSMOOTHFASHION.
18) Toensurea smoothanduniformjoint, retracethe previouscut by movingtherouterfrom RIGHTTOLEFTwith theguidebushingagain
followingthetemplate.

35

NEVERLIFTTHEROUTERUPWARDS
WHENTHEROUTERIS ONANDTHEROUTERBITROTATING
ORWHENTHEGUIDE
BUSHINGIS NEARTOORTOUCHING
THETEMPLATE.
THISCANCAUSEDAMAGE
TOTHEDOVETAIL
FIXTURE;ORLOSSOFCONTROL
OF
THEROUTER
WHICHCANRESULT
IN SERIOUS
BODILYINJURY.
19)Afterthecut hasbeenmade,the workpiecesshouldlooklikethoseillustratedin Figure60.
20) Removetheworkpieceand back-upboardsfrom the DovetailFixture.
21) Theback-upboardscanbe reusedif thecut portionsof boardsare cut off.AFTERBEINGREUSED
UNTILTHEYNOLONGER
SERVE
THEIRINTENDED
FUNCTION,
NEWBACK-UPBOARDSMUSTBEMADE.
22) TOCUTCORNER
#3 OFTHEPROJECT
LEFTSIDE,positionthe top back-upboardon top of the basesothat it lineswith the front of the
baseand abutsthe righttop stop blockas shownin Figure58.
23) ContinueasSteps6 through20.
24) TOCUTCORNER
#2 OFTHEPROJECT
RIGHTSIDE,positionthe top back-upboardon top of the baseso that it linesup with thefront of
thebaseandabutsthe left top stop blockasshown in figure 61.

TOP
BACK-UPBOARD

Fig. 61

f
.....=.

TOP
OFTHE
BASE

/
,./

.,

AU,I ,AR TE PBR

, T SU,
V

,RO,
EDT ,ETSIDE
..... //.-. --.-./ 7/

--"t %

"OUTSIDE
SURFACE
_SHOULD
BEVISIBLE
/
ONTHtSSURFACE
BEFORE
POSITtONING
THEFRONT
BACK-UP
BOARD

TOPBACK-UP
BOARD,

Fig. 62

FRONT
BACK-UP
BOARD

DOVETAIL

36

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

26) Position the project side against the front of the base so that the top surface abuts the left front stop bIock, The use of a front back-up
board at this step is also recommended. It is positioned between the project side and the cIamping bar as shown in Figure 61. The front
back-up board is described in Step 7 above.
27) Continue as in Steps 8 through 19 above.
28) After the cuts have been made,the workpieces should look like those illustrated in Figure 62.
29) Remove the workpiece and the back-up boards from the Dovetail Fixture.NOTE:THE BACK-UP BOARDSARE REUSABLE.
30) TO CUT CORNER#4 OF THE PROJECTLEFTSIDE, position the top back-up board on top of the base so that it fines up with the front of
the baseand abuts the left top stop block as shown is Figure 6!.
31) Continue as Steps 27 through 32 above.
32) At this stage the project sides should look like those iIfustrated in Figure 56,

THEFOLLOWINGDESCRIBESTHEPROCEDURETO BEFOLLOWEDFORCUTTINGTHEPROJECT
FRONTAND BACK:
NOTE:Any joint fit adjustmentsthat may be required can only be made when cutting the project front and project back
pieces. That is, adjustmentsare made to project front end backpieces ONLY not to the side pieces,
.40"DIA,GUIDE
BUSHING

SEARS
CRAFTSMAN
STRAIGHT\
ROUTER
BIT#25415

1) Assemblethe .40"guidebushingto the routerbaseplate,asdescribedin a previoussection.This is thesmallerof thetwo guidebushings

furnishedwith this product,
2) InstallSearsstraightrouterbit, #25415,to therouterasdescribedin your RouterOwnersManualShankengagementshouldbe a
minimumof 3/4".
_i
MAKE
SURETHATTHEROUTER
BITfSALIGNED
WITHORCENTERED
tN THEHOLE
tN THEGUIDE
BUSHfNG.
TODOTHIS,
LOOSEN
SCREWS
HOLDING
BASE
PLATE
ORADAPTER
PLATE
TOROUTER,
CENTER
GUIDE
BUSHING
HOLEWITHRESPECT
TOROUTER
BfTANDRETIGHTEN
SCREWS
SECURELY
_
WHEN
SETTING
THEDEPTH
OFCUT,MAKEABSOL
UTELY
SURETHATTHECOLLET
NUTDOES
NOTCONTACT
(TOUCH)
THEGUIDE
BUSHING.
THISCANCAUSE
THEGUIDE
BUSHtNG
TOHEATUPEXCESSIVELY
DURING
CUTTING
WHICH
CANCAUSE
DAMAGE
TOTHETEMPLATE.
TO
CORRECT
THfS
SITUATION
ORPREVENT
ITFROMOCCURRING,
REPOSITtON
THEROUTER
BITtN THEROUTER.
3) Adjustthedepthof cut. Thedepthof cut for an OPENDOVETAIL
JOINTis equalto thethicknessof the matingpart, Thatis:
FORCORNER
#1 OFTHEPROJECT
FRONT,THEDEPTHOFCUTIS EQUALTOTHETHICKNESS
OFTHEPROJECT
RIGHTSIDE.
FORCORNER
#40FTHE PROJECT
FRONT,THEDEPTHOFCUTIS EQUALTOTHETHICKNESS
OFTHEPROJECT
LEFTSIDE.
FORCORNER
#2 OFTHEPROJECT
BACK,THEDEPTHOFCUTIS EQUALTOTHETHICKNESS
OFTHEPROJECT
RIGHTSIDE.
FORCORNER
#3 OFTHEPROJECT
BACK,THEDEPTHOFCUTIS EQUALTOTHETHICKNESS
OFTHEPROJECT
LEFTSIDE,
Usethedepthgaugeon thebaseof theDovetailFixture,as describedin a previoussection,asa startingpoint.
, 4) Atthisp_intitwi__benecess_ryf_ry_ut_makeat_pb_ck_upb_ard_Thereas_nsf_rthet_pback_upb_ard_ret_minimizesp_intering_
providesupportfor thetemplateandpreventdamageto the DovetailFixlure,Thetop back-upboardis a scrappieceof wood havingthe
following dimensions:
LENGTH:
6"to 8",sufficientlengthso that it canbe clampedbythe top clampingbarand be usedmorethan once;
WIDTH:2"widerthanthewidth of theprojectfront (or back);
THICKNESS:
1/8"to 1/# thickerthanthethicknessof the projectfront (or back);THISIS TOPREVENT
ACCIDENTALLY
CUTI'INGINTOTHE
DOVETAIL
FIXTURE.
This canalsobeaccomplishedby usingmorethanonepieceof scrapas longas the resultantlength,width, andthicknessareas described,

3?

5) TOCUTCORNER
#1 OFTHEPROJECT
FRONT,positionthe top back-upboardon top of thebasesothat it lines upwith the front of the
baseand abutsthe lefttop stop blockasshownin figure 63.

Fig.83

/ TOP
BACK
UP
BOARD
_

(
PROJECT
BACK

....

TOPOFTHEBASE

/'AUXILIARY TEMPLATE
SUPPORT

/CASNEEOEO,

__

<>

FRONTOFTNERA

BEFORE
POSITIONING
THEFRONT
BACK-UP
BOARD
6) Lightlyclampthe back-upboardin place.
7) Positiontheprojectfront (or back)againstthe front of the baseso thatthetop surfaceabutsthe left front stop bIock.Theuseof a front
back-upboardat this step isaIso recommended.
It is positionedbetweenthe projectfront (or back)and thedampingbaras shownin
Figure63.Thefront back-upboardshouldhavethefollowingapproximatedimensions:
LENGTH:
6"to 8",sufficientlengthso that it canclampedbythe front clampingbarandbe usedmorethanonce;
WIDTH:1"to 2"widerthanthe wJdthof thefront (or back);
THICKNESS:
1/4"to 1/2",
- THEOUTSIDE
OFTHEPROJECT
FRONT(ORBACK)FACES
AWAYFROMTHEFRONTOFTHEBASE,

Fig. 84

___ (

CLATEMPMTE
BRACKET
MPING
KNOB

_ WASHER

Thewords "OUTSIDESURFACE"
markedin (d) in theSection,GENERAL
PREPARATIONS,
shouldhavebeenvisible beforethefront back-up
boardwas put in place.
8) Line upthe workpiecessothat theend of theprojectfront(or back)andback-upboardsline up asshownin Figure63.
9) Securelyclamptheprojectfront(or back)andfront back-upboardto thefront of the base.
10)Securelyclampthetop back-upboardto the top of the base,
11) Makesurethat thepartsremainlinedup.
12)AssembletheDOVETAIL
TEMPLATE
FOROPEN(THROUGH)
JOINTSto theDovetailFixtureso that THETEMPLATE
BRACKETS
FIT
BETWEEN
THEWASHERS
ANDTHETEMPLATE
SUPPORTS
asshownFigure64;it will be necessaryto loosentheclampingknobsat theends
of the baseto do this.
13) Makesurethatthe templateis orientedasshownin Fig,64,

38

Fig.65

TOP
BACK-UP
BOARD
_

DOVETAIL
C

DRAWER
BACK

14) Makesurethat thetemplateis flush and parallelwith theworkptecesdampedto base,Fornarrowprojectfronts(orbacks),the useof an

auxiliarysupportfor the templateis recommended.
Its purposeis to aid in supportingthe routerwhilecutting,it canbe madefrom a pieceof
scrapwood; butits thicknessmustbethe sameasthetop back-upboard,(Referto Figure63).
15) Clampthetemplatein placebytighteningthe clampingknobs.
BEFORE
MAKINGANYCUTSMAKESURETHATTHEBITWILLNOTCUTINT0THEBASEORANYOTHERCOMPONENT
OFTHE
DOVETAIL
FIXTURE.THISCANCAUSEDAMAGE
TOTHEDOVETAIL
FIXTURE,
16)TURNTHEROUTERON.
17) Cutthe dovetailby movingtherouterfrom LEFFTORIGHT,
with the guidebushingfollowingthe template.DONOTFORCEANYTHING;
MOVETHEROUTER
IN SLOWANDSMOOTH
FASHION.
18)Toensure a smoothand uniformjoint, retracethe previouscut by movingtherouterfrom RIGHTTOLEFTwith the guidebushingagain
followingthetemplate.
19) MAKESURETHATALL OFTHEMATERIALISCUTAWAY;FREEROUTING
MAYBEREQUIRED
TOACCOMPLISH
THIS.EXTRACARE18
REQUIRED
IN CONTROLLING
THEROUTER
MOVEMENT
WHILEDOINGFREEROUTING,
(Referto Figure65).

Fig. 66

TOPOFTHEBAsE_PBACK-UPBOARD_/_._

A.XILIARY
T .PLATE
SU PORT,

:AS
NEEDED\

- i -:

FRONTOETHEBASE_

/
/ /

"OUTSIDE
SURFACE"
SHOULD
BEVISIBLE
ONTHISSURFACE
BEFORE
POSITIONING
THEFRONT
BACK-UP
BOARD

39

' \
v

-_ PROJECTFRONT
OR
PROJECT
BACK

NEVERLIFT THE ROUTERUPWARDSWHENTHE ROUTERIS ON AND THE ROUTERBIT ROTATINGOR WHEN THE GUIDEBUSHING iS NEARTO OR TOUCHINGTHE TEMPLATE.
20) After the cut bas been made, the workpiecesshould look like thoseillustrated in Figure 65,
21) Remove the workpiece and back-up boards from the Dovetail Fixture.
22) The back-up boards can be reused if the cut portions of boards are cut off. AFTERBEING REUSEDUNTIL THEY NO LONGERSERVE
THEIR INTENDEDFUNCTION,NEW BACK-UPBOARDSMUST BE MADE,
23) TO CUT CORNER#3 OFTHE PROJECTBACK, 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 as shown in Figure 63.
24) Continue as Steps 6 through 24.
25) TO CUT CORNER#4 OF THE PROJECTFRONT,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 as shown in figure 66.
26) Lightly clamp the back-up board in place,
27) Position the project front (or back) against the front of the baseso that the top surface abuts the right front stop block. The use of a fronl
back-up boardal this step is also recommended,It is positioned betweenthe drawer front (or back) and the clamping bar as shown in
Figure 66. The front back-up board is described in Step 7 above,
28) Continue as in Steps 8 through 20 above.
29) After the cuts have made,the workpieces should Iook like those illustrated in Figure65.
30) Remove the workpiece and the back-up boards from the Dovetail Fixture. NOTE:THE BACK-UPBOARDSARE REUSABLE.
31) TO CUT CORNER#2 OFTHE PROJECTBACK, position the top back-up board on top of the base so that it lines up with the front of the
base and abuts 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 Figure 56.
34) Check how the workpieces fit together_Some adjustments may be necessary. Referto the Section, MAKINGADJUSTMENTSFOROPEN
(THROUGH)FLUSHJOINTS
Your project is now ready to be gIued together,
Remove the pencil markings by light sanding or with a soft eraserafter the parts have been glued together.

TROUBLESHOOTING:
* If thejoint is too loose:This adjustmentcan onlybe madewhencuttingeitherthe front or theback(pin pieces).Loosentheclamping
knobsholdingthetemplatebracketsandmovethetemplateOUTWARD
byturningthe cam handles,Continueadjustinguntildesiredjoint
fit is attained.Retightenthe clampingknobs.
= tt the joint is too tight: This adjustmenttoo canonly bemadewhencuttingeitherthefront or the back(pin pieces).Loosenthe clamping
knobs holdingthetemplatebracketsandmovethetemplateINWARDbyturningthecam handles.Continueadjustingunti!desiredjoint fit
is attained.Retightenthe clampingknobs.
If the joint is too shallow:Referto Figure67,INCREASE
the depthof cut of therouterbit. This adjustmentcanbe madewhencuttingthe
front, theback,(pin pieces)and thesides(taiI pieces),
o If the joint is too deep:Referto Figure68. DECREASE
the depthof cut of the routerbit,This adjustmenttoo can be madewhencutting
the front, the back,(pin pieces)andthesides (tailpieces).
, If the jointis not uniformlyspacedfrom top surfaceof drawer:Referto Figure69.(Seethe Section"ALIGNMENT
OFTHETEMPLATES".)
With the templateclampedto the base,loosenthefour screwssecuringthe templateto the templatebrackets,and movethetemplate
slightlyto theleft. Tightenthe four screwsand makea trialcut. If movingthetemplateto the leftdid not correctthe condition,but madeit
worse,loosenthe screwsand movethetemplateto the right a emalIamount.Makesurethetemp[ateremainsparallelto the front of the
dovetailbase.Tightenthefour screwsandmakea trial cut, Continuemovingthetemplateto the right untgthe conditionis completely
corrected.PROPERALIGNMENT
OFTHETEMPLATES
TOTHETEMPLATE
BRACKETS
ISCRITICALFORJOINTUNIFORMITY.
ONCETHiS
iSACCOMPLISHED
CORRECTLY,
tT SHOULDNOTNEEDADJUSTMENTS
AGAIN.MAKESURETOSECURELY
TIGHTEN
THEFOUR
SCREWS.AFTERTHETEMPLATES
HAVEBEENCORRECTLY
REALIGNED,
THEYSHOULDREQUIRE
NOFURTHER
ADJUSTMENTS
IF
THEYAREHANDLED
WITHCARE.

4O

Fig. 67

FRONT
EXTENDS
OUTPAST
SIDE

JOINTIS TOO
SHALLOW

PROJECT
FRONT__

__.

PROJECT
LEFTSlOE
/

SIDEEXTENDS
OUTPAST
FRONT

/
PROJECT
BACI__

SIDEEXTENDS
OUTPAST
FRONT

Fi#.68
JOINTIS TOODEEP

FRONT
EXTENDS
OUTPAST
SIDE

SIDEEXTENDS
OUTPASTBACK

Fig. 69

FRONT
(PINPIECE)

SPACtNG
GREATER
THANBACK

JOINTSPACING
ISNOTEQUAL

SIDE(TAILPIECE)

SPACING
LESSTHANFRONT

BAOK(PINPIECE)

41

PARTS LIST
KEY OTY

for

#171.25450

INDUSTRIAL

PART NO.

DOVETAIL FIXTURE

DESCRIPTION

29LD-879

DOVETAIL BASE

29LD-880

DOVETAIL TEMPLATE

HALF BLIND

29LD-8BI

DOVETAIL TEMPLATE

OPEN (THROUGH) JOINT

29LD-882

TEMPLATE SUPPORT (RIGHT SIDE)

29LD-883

TEMPLATE SUPPORT (LEFT SIDE)

29LD-884

CAM HANDLE

29LD-885

FRONT STOP BLOCK

29LD-886

TOP STOP BLOCK

29LD-887

CLAMPING BAR END CAP

I0

29LD-888

RETAINER

I!

29LD-889

BOLT SUPPORT

12

29LD-890

ICLAMPING KNOB

13

29LD-891

CLAMPING BAR

14

29LD-892

PIVOT SHAFT

15

29LD-895

TEMPLATE BRACKET

16

29LD-896

TEMPLATE STIFFENER

JOINT

17

29LD-899

GUIDE BUSHING ASSEMBLY (.40"

DIAMETER)

!8

29LD-900

GUIDE BUSHING ASSEMBLY (I12"

DIAMETER)

I9

29LD-901

20

45A-350

COMPRESSION SPRING
PRODUCT LABEL (CLAMPING BAR)

21

45A-351

LABEL (TEMPLATE-BL IND)

22

45A-352

LABEL (TEMPLATE-OPEN

23

45A-353

WARNING LABEL (CLAMPING BAR)

49LD-50

INSTRUCTION MANUAL

NONE

24

29L-469-13

#10-32

X 518"

Ig.

PANHEAD MACHINE SCREW

25

29L-469-14

26

I0

29L-469-15

#I0-32
#8-36

X 318"
X 3/16"

Ig.
Ig.

PANHEAD MACHINE SCREW

PANHEAD MACHINE SCREW

27

29LD-841 -2

#I0-32

X 518"

Ig.

FLAT HEAD MACHINE SCREW

28

29LD-841 -3

#I0-32

X 7/8"

Ig.

FLAT HEAD MACHINE SCREW

29

29LD-841-4

_10-32

X 3/8"

Ig.

FLAT HEAD MACHINE SCREW

30

29L-684-6

#IO-16

X I12"

Ig.

PANHEAD TAPPING SCREW

31

29L-684-7

#I0-16

X I"

32

29A-310-15

5/16-18

X 4-1/2"

Ig.

ROUND HEAD SQUARE NECK BOLT

33

29A-310-16

5/16-18

X 3-I/2"

Ig.

ROUND HEAD SQUARE NECK BOLT

34

29A-310-17

35

29A-242-12

,5/16-18
#I0-32

36

29A-242-I3

5ll6-18

37

29A-306-37

3/64"1.D.

X 9/I6"0,D.

38

29A-306-40

1/32"I.D.

X 7/8"0,D.

X 1/I6"thick

39

29LD-930

1/32"I,D.

X 7/8"0,D.

THIN NYLON WASHER

40

29LD-969

4!

29LCN-IO05

BAGGED FASTENERS-CONSISTING OF :

5/16"I,D,

19. PANHEAD TAPPING SCREW

X 2" Ig. ROUND HEAD SQUARE NECK BOLT

HEX MACHINE SCREW NUT
HEX MACHINE SCREW NUT

X 7/8"0.D.

NYLON SPRING RETAINER

42

X 3/64"fhick

WASHER
WASHER

THICK NYLON WASHER

43

44

!
1
"/

/_

@
45

Notes

46

Notes

47

IIIII IIitII
49LD-60
MANUAL

Printed in U,S.A.
9/96
29LMD-50

When corresponding,always givethe following

informationas shownin the list.
1.
2.
3.
4.

The PARTNUMBER
The PARTDESCRIPTION
The MODEL#171.25450
The ITEM NAME-iNDUSTRIALDOVETAILFIXTURE