Leigh rtj400 User Manual
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Leigh rtj400 User Manual

Router table dovetail jig
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LEIGH RTJ400
Router Table Dovetail Jig
User Guide
Dedicated Customer Support
1-800-663-8932

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  • Page 1 LEIGH RTJ400 Router Table Dovetail Jig User Guide Dedicated Customer Support 1-800-663-8932...

  • Page 2: Table Of Contents

    Customer Support The RTJ400 is covered by the following patent: U.S. Patent No. 8,534,329 If you have any questions that are not answered in this user guide, Patents for all Leigh elliptical guide bushings: U.S. 8,256,475 UK GB2443974 please call Leigh Customer Support: 1-800-663-8932 in North America or email: help@leighjigs.com.
  • Page 3 Hex Key, 1/8" Ball End Note: See page 6 for instructions on Cam-Action Speed-Clamps, 4, for mounting workpieces to jig fitting the Leigh eBush to your router B lockers, 10, inserted in template guide openings to prevent routing table. Stop Rod, inserted in template holes to limit cutting depth Sidestops, 2, for mounting workpieces;...
  • Page 4 1-3/4" 3" collet 173-500C Solid Carbide 172-8 Bits 80-500, 160, 120-500 & 143-500 come with the RTJ400 1/2" to 8mm collet reducer Spiral upcut bits rout cleaner and faster, leaving a smoother finish 1 1/4" long. For 8mm shank bits...

  • Page 5: Introduction

    RTJ400 User Guide Introduction Accessory Kit for the RTJ400 (ACRTJ) This optional kit offers great savings over individual prices, and opens up a world of possibilities. Available from leighjigs.com The ACRTJ includes: Through Dovetail Bits Straight Bits for Box Joints High speed steel, for box joints Carbide tipped, 8º, 8mm shank, for through...

  • Page 6: Router Table Requirements

    Router Table Requirements Router tables are typically used with a bearing or fence, however, the Leigh RTJ400 is guided around a guide bushing mounted in the router table. Leigh eBushes (guide bushings) are designed around the decades-old Porter Cable/Black & Decker industry standard.

  • Page 7: Assembling The Rtj400

    RTJ400 OPERATION CHAPTER 1 Assembling the RTJ400 The following instructions will guide you through the assembly process for the Leigh RTJ400 Router Table Dovetail Jig.

  • Page 8: Chapter 1 Assembling The Rtj400

    Chapter 1 RTJ400 User Guide Assembling the RTJ400 Slide a latch into each end of the Insert the clamp T-bolt head into Template Clamps: Template Latches: template making sure the washer is in the T-slot. Use the hex the T-slot at each end of the template...
  • Page 9 RTJ400 User Guide Chapter 1 Assembling the RTJ400 The frame is located on the template by a pin on the frame Insert the stop rod in the 3/4" slot . The handles. Place the frame on the template by inserting the right...
  • Page 10 10 10 Chapter 1 RTJ400 User Guide Assembling the RTJ400...

  • Page 11: Glossary Of Symbols

    11 11 RTJ400 OPERATION CHAPTER 2 Glossary of Symbols Which Way Around Should the Board Go? The following symbols/icons are used throughout this user guide. They indicate which side of a board faces out when clamped in the jig, and which edge goes against the sidestop. They also indicate which faces are in or out when assembled.

  • Page 12: Chapter 2 Glossary Of Symbols

    Chapter 2 RTJ400 User Guide Glossary of Symbols...
  • Page 13 13 13 RTJ400 OPERATION CHAPTER 3 Using Your Jig Safely Safety is not optional. Read and follow the recommendations in this chapter. Read the owner’s user guide that came with your router Always wear: and router table. It is essential to understand all manufacturer’s •...

  • Page 14: Chapter 3 Using Your Jig Safely

    Do not tilt the jig. Keep the template flat on the router table Chips and sawdust are thrown out at high speed. Always at all times. stand and use the RTJ400 from behind the router bit, opposite to chip and sawdust ejection. ■...
  • Page 15 Backer Board IMPORTANT NOTE: Many of the images in this user guide show the “action” side of the jig, however the operator stands behind the RTJ400, away from the chips and sawdust thrown off by the router bit. Router Table Surface...

  • Page 16: Chapter 4 Basic Jig Functions

    16 16 Chapter 4 RTJ400 User Guide Basic Jig Functions Frame Pin Positioning  The frame is positioned on the template by inserting the Be sure to latch the frame securely each time the frame frame pins into the pin holes and slots .
  • Page 17 17 17 RTJ400 User Guide Chapter 4 Basic Jig Functions Backer Board  A short backer board is clamped horizontally behind the 4-12 4-11 Always ensure that the frame clamp levers do not tail board, to help prevent tearout, and to direct dust and chips project below the frame when engaged away when routing.
  • Page 18 18 18 Chapter 4 RTJ400 User Guide Basic Jig Functions...

  • Page 19: Chapter 5 Wood Preparation

    19 19 RTJ400 OPERATION CHAPTER 5 Wood Preparation Garbage In — Garbage Out This adage of the computer age stands equally true for dovetail joinery. Accurate and perfectly aligned joints require stock that is You will want to test the jig, so prepare boards of suitable straight, flat, even thickness and equal widths, with square ends size for the required joint type and size.
  • Page 20 20 20 Chapter 5 RTJ400 User Guide The Leigh eBush...
  • Page 21 CHAPTER 6 The Leigh eBush Note: Normal tolerances with bits, guide bushings and router runout will generally produce poor fitting joints. Leigh elliptical guide bushings (e7 and e10) solve this problem. Patents for all Leigh elliptical guide bushings: U.S. 8,256,475 UK GB2443974 Joint Fit Adjustment All routing starts with the eBush in the No.5 position...

  • Page 22: Chapter 6 The Leigh Ebush

    22 22 Chapter 6 RTJ400 User Guide The Leigh eBush Adjust the eBush with the pin wrench. Markings on All settings for the eBush will be aligned to the line the eBush indicate which way to turn it for a looser or tighter you’ve drawn on the router table.
  • Page 23 Through Dovetails on thinner boards are identical with the exception of depths of cut and template positions for frame pins. Optional Leigh bits can be used with these instructions. See Step 7-2 below and pages 3 to 6 for complete details of optional items, router table requirements and the RTJ400 Accessory Kit.

  • Page 24: Chapter 7 Through Dovetails

    When assembled with the thickness, in this case, the Leigh e10 Guide Bushing and the finished pieces properly oriented, any one of the pin ends will fit Leigh 80-500 bit.
  • Page 25 RTJ400 User Guide Chapter 7 25 25 Through Dovetail Joint Procedures With the router unplugged, install the Leigh 80-500 Insert the right frame pin in the hole ALL TD TAILS  dovetail bit. Make sure the bit spins freely within the bushing...
  • Page 26 Be sure the router bit has stopped moving before Rotate tail board 1 keeping the same 1/2" [12.7mm] Leigh 160 straight bit or equivalent spiral bit to unclamping the tail board. face of the board against the jig. Rout the tails. Repeat 7-15 and rout the full pitch through dovetail pins.
  • Page 27 RTJ400 User Guide Chapter 7 27 27 Through Dovetail Joint Procedures Clamp the pin board in the jig with its edge against Clamp the other end of the scrap backer board horizontally 7-20 7-21 test the sidestop with the marked outside face out and the bottom against the back of the pin board.
  • Page 28 28 28 Chapter 7 RTJ400 User Guide Through Dovetail Joint Procedures TOO LOOSE TIGHTEN 7-27 TOO TIGHT LOOSEN Re-tighten the eBush nut after each guide bushing adjust– If the joint is too loose, turn the eBush to a 7-26 Rout the other end of the test pin board. Once the fit is Test for Fit ment.

  • Page 29: Half Pitch Through Dovetails

    Half pitch through dovetail pins are routed with the optional e7 guide bushing and 140-8 or equivalent straight bit. The e7, all five bits and the 172-8 are available individually or in the RTJ400 Accessory Kit (ACRTJ) at leighjigs. e10 Guide bushing com.

  • Page 30: Chapter 8 Half Pitch Through Dovetails

    Leigh e10 guide bushing and the finished pieces properly oriented, any one of the pin ends will fit optional 3/8" Leigh 70-8 dovetail bit for tails and the optional e7 any one of the tail ends.
  • Page 31 RTJ400 User Guide Chapter 8 31 31 Half-Pitch Through Dovetail Joint Procedures With the router unplugged, install the Leigh 70-8 dovetail Insert the right frame pin in the hole ALL TD TAILS  bit. Make sure the bit spins freely within the guide bushing...
  • Page 32 Rotate tail board 1 and rout the other end. Repeat Leigh 140-8 straight bit. For cleaner routing, use the optional 5/ 1 6" routing for tail board 2. Remove the tail board and backer board.
  • Page 33 RTJ400 User Guide Chapter 8 33 33 Half-Pitch Through Dovetail Joint Procedures Position a backer board 1/2" [13mm] from the board edge Place the end of a tail board on the template and pencil a 8-20 8-21 . This prevents the backer board from interfering with the line on the pin board.
  • Page 34 34 34 Chapter 8 RTJ400 User Guide Half-Pitch Through Dovetail Joint Procedures TOO LOOSE TIGHTEN TOO TIGHT LOOSEN 8-27 Re-tighten the eBush nut after each guide bushing adjust– Rout a new pin board. Once the fit is correct, add the two...

  • Page 35: Half-Blind Dovetails

    RTJ400 Accessory Kit (ACRTJ) at leighjigs.com. See bit specs on page 4. Each bit is designed to cut to a specific cutting depth and is set using the Leigh cutter depth gauge. The stop rod is used for routing board thicknesses of 7/ 1 6"...

  • Page 36: Chapter 9 Half-Blind Dovetails

    When assembled with the thickness, in this case, the Leigh e10 Guide Bushing and the finished pieces properly oriented, any one of the pin ends will fit optional 1/2"...
  • Page 37 RTJ400 User Guide Chapter 9 37 37 Half-Blind Dovetail Joint Procedures Unplug the router and install the Leigh 120-500 dovetail Insert the right frame pin in the HALF-BLIND ½" SIDES  bit. Make sure the bit spins freely before reconnecting the power.
  • Page 38 38 38 Chapter 9 RTJ400 User Guide Half-Blind Dovetail Joint Procedures When making a box, it is important to label the corners 9-14 Center a tail board over the template so that the side 9-15 test of each board . When routing the corners of the...
  • Page 39 RTJ400 User Guide Chapter 9 39 39 Half-Blind Dovetail Joint Procedures TOO LOOSE TIGHTEN TOO TIGHT LOOSEN 9-20 If the joint is too loose, turn the eBush to a 9-21 Each increment on the eBush changes the joint glue line...

  • Page 40: Rabbeted Half-Blind Dovetails

    40 40 Chapter 9 RTJ400 User Guide Half-Blind Dovetail Joint Procedures Left: Rotate tail board 2 (corner C). Remove pin board 1 and Left: Remove tail board 1. Insert tail board 2 (corner 9-27 9-26 insert pin board 2 (corner C). Rout in all openings.
  • Page 41 RTJ400 User Guide Chapter 9 41 41 Half-Blind Dovetail Joint Procedures Rabbeted Half-Blind Dovetails cont. 9-30 Note: The pin board and tail board are routed separately Center and clamp a tail board for rabbeted half-blind joints. test in the jig. Adjust the sidestop to touch the right edge of the board...
  • Page 42 42 42 Chapter 9 RTJ400 User Guide Half-Blind Dovetail Joint Procedures Rabbeted Half-Blind Dovetails cont.  Clamp a pin board in the jig against the sidestop Rout in each template opening. The eBush must touch 9-36 9-37 test bringing it forward until it rests against the shop made limit one side of the opening as you enter and the other side as you exit.

  • Page 43: 3/8" Box (Finger) Joints

    3/8" box joints are routed with the included 3/8" straight bit 143-500, or optional 173-500 or 173-500C bits, the e10 guide bushing (eBush), and the stop rod (for positioning the sidestop only). They can be routed in board thicknesses up to the maximum capacity of the RTJ400 Template and the cutting depth of the bit, in this case, 1" [25.4mm]. "...
  • Page 44 44 44 Chapter 10 RTJ400 User Guide Box Joint Procedures - 3/8" 10-3 Board Width Selection Board widths are determined by the total number of pins and sockets in the joint design and whether the joint is symmetrical or asymmetrical. Use this chart to determine board widths up to 16" [406mm].
  • Page 45 Insert the right frame pin in the hole 10-9 No.1 BOX JOINTS 143-500 bit. For cleaner routing use the optional 3/8" Leigh and the left frame pin in the slot. Latch the HALF-BLIND & BJ 173-500 (HSS) or 173-500C (solid carbide) spiral upcut bit, frame.
  • Page 46 46 46 Chapter 10 RTJ400 User Guide Box Joint Procedures - 3/8" TOO LOOSE TIGHTEN TOO TIGHT LOOSEN To save time and wood, clamp two 1/2" 10-14 Quick Fit Test  thick scrap boards in the jig, back to back...
  • Page 47 RTJ400 User Guide Chapter 10 47 47 Box Joint Procedures - 3/8" OVER FLUSH UNDER FLUSH Rout the sockets making sure to contact both sides of If the joint is over flush, lower the bit to suit. 10-20 10-21 Flushness each opening with the guide bushing.
  • Page 48 48 48 Chapter 10 RTJ400 User Guide Box Joint Procedures - 3/8" 3/8" Half-Blind Box Joints PIN BOARD 10-22 Getting Started Review the drawing opposite, to get a clear understanding of how the boards fit together and to learn the joinery terms.

  • Page 49: Half-Blind Box Joints

    10-28 If you have already determined the correct fit in the 3/8" box joint Leigh 143-500 bit. For cleaner routing use the optional 3/8" Leigh chapter, use that setting, or alternatively use the Quick Fit Test, 173-500 (HSS) or 173-500C (solid carbide) spiral upcut bit, ...
  • Page 50 50 50 Chapter 10 RTJ400 User Guide Box Joint Procedures - 3/8" 3/8" Half-Blind Box Joints cont. ⁄ " ⁄ " ⁄ " ⁄ " ⁄ " ⁄ " or more ⁄ " ⁄ " When the frame pin and stop rod are in the 1/2" positions, 10-31 For tail boards from 3/8"...
  • Page 51 RTJ400 User Guide Chapter 10 51 51 Box Joint Procedures - 3/8" Half-Blind Box Joints cont. To save time and wood, clamp the two 10-38 Quick Fit Test Adjust the bit to the center of the line 10-37 1/2" thick scrap boards in the jig, back to back .
  • Page 52 52 52 Chapter 10 RTJ400 User Guide Box Joint Procedures - 3/8" 3/8" Half-Blind Box Joints cont. OVER FLUSH Do not adjust flushness 10-44 Flushness IMPORTANT NOTE: until correct joint tightness in previous steps is achieved. For over flush tails , move the frame pin to a minus (“–”) tail position ...

  • Page 53: 3/4" Box (Finger) Joints

    RTJ400 OPERATION CHAPTER 11 3/4" Box (Finger) Joints IMPORTANT SAFETY NOTE Before using your Leigh RTJ400 you must have completed the preparatory steps listed in the previous pages, including reading the jig safety recommendations in Chapter 3. 11-1 Getting Started Review the drawing below.
  • Page 54 54 54 Chapter 11 RTJ400 User Guide Box Joint Procedures - 3/4" 11-3 Board Width Selection Board widths are determined by the total number of pins and sockets in the joint design and whether the joint is symmetrical or asymmetrical. Use this chart to determine board widths up to 15 5/8" [397mm].
  • Page 55 11-9 No.1 BOX JOINTS 143-500 bit. For cleaner routing use the optional 3/8" Leigh and the left frame pin in the matching slot, then latch the frame. 173-500 (HSS) or 173-500C (solid carbide) spiral upcut bit, Put the short end of the stop rod into the hole.
  • Page 56 56 56 Chapter 11 RTJ400 User Guide Box Joint Procedures - 3/4" To save time and wood, clamp the two 11-15 Quick Fit Test  1/2" thick boards in the jig, back to back test Review the This procedure requires routing into alternating template...
  • Page 57 RTJ400 User Guide Chapter 11 57 57 Box Joint Procedures - 3/4" Rout into the first opening and every other template Loosen the latches and move the frame pin to the 11-20 11-21 No.2  opening i.e. 1, 3, 5 and 7.
  • Page 58 58 58 Chapter 11 RTJ400 User Guide Box Joint Procedures - 3/4" OVER FLUSH UNDER FLUSH Theoretically, there will be nothing left in the sockets, f the joint is over flush, lower the bit to suit. If the joint 11-26 11-27 I where the bit has passed by twice.

  • Page 59: 3/16" Box (Finger) Joints

    Bits, Guide Bushing and Stop Rod 3/ 1 6" box joints are routed with the optional 3/ 1 6" Leigh straight bit 166 or 166C, the e10 guide bushing (eBush), and the stop rod (for positioning the sidestop only). They can be routed in board thicknesses up to the maximum cutting depth of the bit, in this case, 5/8"...
  • Page 60 60 60 Chapter 12 RTJ400 User Guide Box Joint Procedures - 3/16" Symmetrical Joints have a full pin at Asymmetrical Joints have a pin at one edge and each board edge. The total number of pins and a socket at the other. The total number of pins and sockets will always be an odd number.
  • Page 61 Insert the right frame pin in the hole and No.1 BOX JOINTS optional 3/ 1 6" Leigh 166 (HSS) or 166C (solid carbide) bit. Make the left frame pin in the slot. Latch the frame. Put TD TAILS & BJ...
  • Page 62 62 62 Chapter 12 RTJ400 User Guide Box Joint Procedures - 3/16" TOO LOOSE TIGHTEN To save time and wood, clamp the two 12-14 Quick Fit Test TOO TIGHT LOOSEN  1/4" thick scrap boards in the jig, back to back...
  • Page 63 RTJ400 User Guide Chapter 12 63 63 Box Joint Procedures - 3/16" Unlatch and move the right frame pin to the Remove pin board 2. Unlatch and move the frame pin 12-20 12-21 No.2 BOX hole, latch the frame. Rout into every opening. Unclamp to the hole and latch the frame.
  • Page 64 64 64 Chapter 12 RTJ400 User Guide Box Joint Procedures - 3/16"...

  • Page 65: 3/32" Box (Finger) Joints

    RTJ400 OPERATION CHAPTER 13 3/32" Box (Finger) Joints IMPORTANT SAFETY NOTE Before using your Leigh RTJ400 you must have completed the preparatory steps listed in the previous pages, including reading the jig safety recommendations in Chapter 3. 13-1 Getting Started Review the drawing below.
  • Page 66 66 66 Chapter 13 RTJ400 User Guide Box Joint Procedures - 3/32" Symmetrical Joints have full a pin at Asymmetrical Joints have a pin at one edge and each board edge. The total number of pins and a socket at the other. The total number of pins and sockets will always be an odd number.
  • Page 67 TD TAILS & BJ optional 3/ 3 2" Leigh 163 bit. Make sure the bit spins freely within the bushing before reconnecting the power. Raise the bit above the template and move the template, 13-10 Set pin board 1 on the template, touching the 3/ 3 2"...
  • Page 68 68 68 Chapter 13 RTJ400 User Guide Box Joint Procedures - 3/32" To save time and wood, clamp the two 13-15 Quick Fit Test approx. 3/ 1 6" thick scrap boards in the jig, back to back test  Adjust the bit until the tip is level with the center of...
  • Page 69 RTJ400 User Guide Chapter 13 69 69 Box Joint Procedures - 3/32" . Unlatch the frame and 13-21 Leave the board in place . Unlatch the frame and 13-20 Leave the board in place move the right frame pin to position 2. Rout in all openings.
  • Page 70 70 70 Chapter 13 RTJ400 User Guide Box Joint Procedures - 3/32" Rout in and out of each template opening. . Unlatch the frame and 13-26 13-27 Leave the board in place move the right frame pin to position 3. Rout in every template opening.
  • Page 71 71 71 RTJ400 OPERATION CHAPTER 14 Jig Parts When ordering parts, please quote the jig model, serial number, part number, part description and quantity required. PART DESCRIPTION PART NO. QUANTITY Template Extrusion, Machined 2500 Frame Extrusion, Machined 2505 Left Hand Handle...

  • Page 72: Chapter 14 Jig Parts

    72 72 Chapter 14 RTJ400 User Guide Jig Parts 2580 2581 2565 2582 2583 2520 2584 2530 2525 2515 6410 2570 2535 2575 9140 2550 2505 2510 2065 260R 2595 2540 2545 2500 9130 2560 8618 730V 2555 143-500 120-500...

  • Page 73: Chapter 15 Customer Support

    Web: www.leighjigs.ua (Ukraine) © 2014 Leigh Industries Ltd. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in Printed in Canada any form or by any means, electronic, mechanical, recording, or otherwise, without the prior written permission of Leigh Industries Ltd. 02/2015...
  • Page 74 74 74 Chapter 16 RTJ400 Dovetail Jig Quick Reference RTJ400 OPERATION CHAPTER 16 Quick Reference Board Width Selection for Dovetails Through Dovetails (Full Pitch) Board widths are based on the number of full tails in your design. Board edges should always end in a half-pin Board Width Selection for Through Dovetails No.

  • Page 75: Chapter 16 Quick Reference

    75 75 RTJ400 Dovetail Jig Chapter 16 Quick Reference Board Width Selection for Box Joints 3/8" Box Joints Board widths are determined by the total number of pins and sockets in the joint design and whether the joint is symmetrical or asymmetrical.
  • Page 76 76 76 Chapter 16 RTJ400 Dovetail Jig Quick Reference Board Width Selection for Box Joints cont. 3/16" Box Joints Board widths are determined by the total number of pins and sockets in the joint design and whether the joint is symmetrical or asymmetrical.

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