Note: Rockler may not carry all products and/or sizes listed in this vendor's publication SUPPLEMENTARY INSTRUCTION MANUAL To learn more about Porter-Cable visit our website at: http://www.porter-cable.com Copyright © 2005 Porter-Cable Corporation DOVETAIL JIG MODELS 4210 & 4212 (39887) IMPORTANT...
USING A ROUTER TABLE ALTERNATE ROUTER BITS HALF-BLIND DOVETAIL TAILBOARDS THICKER THAN 7/8" MITERED THROUGH-DOVETAILS THROUGH-DOVETAIL, SKIPPED PIN METHOD HALF-BLIND DOVETAIL, SKIPPED PIN METHOD SAW KERF ALLOWANCE METHOD MULTIPLE SPACER METHOD END-TO-END JOINTS DRAWERS WITH DOVETAIL DADOS WOODEN HINGES ANGLED JOINTS...
NOT be modified and/or used for any application other than for which it was designed. If you have any questions relative to its application DO NOT use the tool until you have written Porter-Cable and we have advised you.
16. AVOID UNINTENTIONAL STARTING. Do not carry a plugged-in tool with finger on switch. Be sure switch is off when plugging in. Keep hands, body and clothing clear of blades, bits, cutters, etc. when plugging in the tool. 17. OUTDOOR USE EXTENSION CORDS. When tool is used outdoors, use only extension cords marked “Suitable for use with outdoor appliances –...
MISCELLANEOUS TECHNIQUES Using these techniques can simplify your dovetailing projects. USE A DEAD-BLOW HAMMER Use a plastic dead-blow hammer to join your workpieces together to help prevent the marring of wood (Fig. 1A). CHAMFER THE TAIL EDGES Chamfering the inner tail edges can make the joints go together easier and may prevent damage to the pins (Fig. 1B).
TEMPLATES MOUNTED TO CLAMPING BOARDS You can mount the jig templates to clamping boards and take the templates to the workpiece to make the joint. The benefits of this operation are: 1. You can maneuver a mounted template onto a large workpiece easier than clamping a large workpiece to the jig.
Fig. 6B CUTTING THE TAILS Step 1 - Clamp the tail board with the outside surface facing away from the clamping board (Fig. 7A). Align the tail board, using the instructions in your basic manual in the section “OPERATION”. Look under “POSITIONING THE WOOD”, STEP 4.
FITTING THE JOINT Step 1 - Orient the template so that the “PINS” side is facing you (Fig. 9A). Step 2 - Loosen the two #10 screws. Step 3 - If the joint is too loose, move the template toward you slightly. Step 4 - If the joint is too tight, move the template away from you slightly.
CUTTING THE TAILS Step 1 - Clamp the tail board with the outside surface facing away from the clamping board (Fig. 10A). Step 2 - If the board is a width in 1" increments, (12", 13", etc.), center the edge of the board exactly between the two fingers of the template farthest to the left (Fig.
Step 7 - Unclamp the templet, slide it down, and center the last cut between the two angled fingers and reclamp (Fig. 11D). Step 8 - Repeat STEPS 6 and 7 until the pins are cut across the entire board. Step 9 - Remove the pin board and check the fit with the tailboard.
HALF-BLIND DOVETAILS WITH CLAMPING BOARDS You can mount your half-blind template that comes with the 4210 and 4212 jigs and the 4211 accessory kit to a board. This method, however, limits your workpiece width capacity to 8". SETUP Items needed to setup for the half-blind dovetails:...
Step 4 - Make the straight clamping block. If the workpiece is thinner than 3/4", you will need to modify the dimension (Fig. 15D). Make two thickness blocks the same Step 5 - thickness as the pin board. Drill a hole big enough for the wood screw to go through (Fig.
Slide the straight clamping block to the left so that it contacts the pin board (Fig. 16D). Hook the straight Step 4 - clamping block over the front and back of the main clamping board. Step 5 - Secure the pin board by clamping it between the offset and straight clamping blocks (Fig. 16E). Step 6 - Loosen the #10 wood screws, align the template lines with the line where the pin board and tail board meet, and retighten the #10 wood screws (Fig.
Since 1/2" shank bits are stronger and are much less prone to deflection than the 1/4" shank bits, we recommend that you use the 1/2" shank bits with the 4210 and 4212 dovetail jigs, and with the 4211 and 4213 accessory kits.
If you have two routers, you will not have to go through the process of changing the bit each time you make a different cut. This method requires, however, two 3/4" OD template guides and two template guide locknuts, available from Porter-Cable. DOVETAIL BIT APP. DEPTH OF CUT 17/32", 7°...
Two routers will make this job easier. However, this two-router method will require two 3/4" OD template guides and two template guide lock nuts, available from Porter-Cable. In selecting straight bits for these modified box joints, keep in mind the following: The sum of the diameters of the two straight bits must equal 1".
Cutting a dado with a templet guide that has an OD smaller than 3/4" requires two passes. Start on the left side. Keep the router toward the back edge of the dado slot, and cut to the right until you have completed the cut.
On the inside surface, use a square and pencil to draw a line from the base of the pins to the edge Step 1 - where the miter will be cut (Fig. 28A). Step 2 - Use a table saw with the miter gauge set to 45° to miter the squared-off half pin (Figs. 28B and 28C). Fig. 27B Fig. 25A Fig.
On the inside surface, use a square and pencil to draw a line from the base of the tails to the edge where the miter will be cut (Fig. 29A). Step 2 - Set the table saw blade so that the height of cut of the saw blade is the same as the thickness of the mitered half-pin. Step 3 - Use a table saw with the miter gauge set to 45°...
CUTTING THE PINS Step 1 - Hold the pin board against the tail board and mark the edges of the tails on the end of the pin board (Fig. 32A). Step 2 - Shade in the areas on the end of the pin board where the tails will be (Fig. 32B). Step 3 - Cut all the pins (Fig.
Step 1 - Make a climb cut from right to left. Step 2 - Cut only between the fingers where you want the pins to be (Fig. 34A). Step 3 - Use the router to round over the ends of the cuts (Fig. 34B). Step 4 - The joint will hide any accidental excess material cut (A) Fig.
NOTE: For this method, you will need a spacer block equal to the thickness of the saw kerf, typically 1/8" on a standard saw blade. Also, make the boards wider than the final size of the box by the same thickness.
CUTTING THE PINS Step 1 - Clamp the pin board with the spacer on the left (Fig. 39A). Mark the pin the saw kerf will go through (Fig. 39B). (Use the tail board for comparison.) Step 2 - Step 3 - Cut the tails from left to right.
Once the box is glued and dried, separate the box lid and bottom with a table saw. MULTIPLE SPACER METHOD The saw kerf allowance method can be modified by using multiple spacers on the same joint to create more varied spacing of the pins and tails.
The standard joint is shown is Fig. 42B and the end-to-end joint is shown in Fig. 42C. DOVETAIL END-TO-END JOINTS A dovetail end-to-end joint is a combination of a box joint and a half-blind dovetail joint. the workpieces are mounted to the jig in the same way as for a box joint. However, the router bit and bit depth are set-up for a half- blind dovetail.
WOODEN HINGES A wooden hinge can be used to make hinged table leafs or hinged legs for a collapsible table. The hinge pins are normally are made of stainless steel, but you can use other materials, including wood for that purpose. 180°...
270° HINGES WITH A DRILLED HOLE Follow the previous directions for 180 ° or more range of motion. Cut the boards as shown in Fig. 46A. Fig. 46A 180° HINGES WITH ROUTER-MADE GROOVES When the width of the workpieces are too wide for a drill bit to make the hole, use this method.Two boards compose each hinge half.
270° HINGES WITH ROUTER-MADE GROOVES This method uses two pieces of wood glued together for each hinge-half. One of the pieces is very short. Step 1 - Use a router to make a half-round dado near the end of a board. Make the diameter of the groove equal to the diameter of the hinge pin, and the depth of cut half the diameter of the hinge pin(Fig.
ANGLED JOINTS You can join boards at angles other than 90 procedure. OBTUSE ANGLED JOINTS The simplest of these angled joints is the obtuse-angled dovetail. In this joint, two boards are joined together at an ° angle greater than 90 This joint can be made with either the template mounted to the base of the jig or to a clamping board.
Cut the end of the tail board according to the instructions in the drawing (Fig. 53A). You can make these cuts on a table saw with the blade beveled (Fig. 53B). Set the miter gauge at 90° for the first cut, then use a tenoning jig for the second cut (Fig.
Fig. 53D CUTTING THE PINS Step 1 - Cut the end of the pin board according to the drawing (54A). Step 2 - If you use the template mounted to the base of the jig and a 12" angled insert, remove the small front knobs, clamping rod and clamping U channel.
Cut the end of the tail board according to the instructions on the drawing (Fig. 56A). Steep angles or thin wood will make for a weak joint. Make this cut on a table saw with the blade beveled. Set the miter gauge at 90°...
SLANTED-SIDE JOINTS Two boards joined at 90°, with one board slanted to the side is known as a slanted-side joint. This method is used to make a box with the ends at right angles to the table, but with the sides tilted outward (cradles, planters, magazine racks).
CUTTING THE PINS Step 1 - Cut the pin board according to Fig. 60A. Step 2 - Hold the boards together and mark the pin board at the edges of the tails (Fig. 60B). Step 3 - Rotate the template so that the tapered fingers for cutting the pins is facing you. Step 4 - Mount the pin board with the outside surface facing away from the base of the jig.
NOTE: The instructions given here are for templates mounted to the base of the jig. However, this joint can also be made with templates mounted to angled clamping boards. You must use the angled clamping board for steeper angles. Use the following table for setting up your table saw for these cuts: DESIRED SIDE ANGLE 85°...
CUTTING THE TAILS Step 2 - With the angled insert attached to the base of the jig, mount the tail board with the outside surface of the board facing the jig and with the board centered between the fingers of the template (Fig. 64D). Step 3 - Align the template using the “Tails”...
FITTING THE JOINT Fitting the joint is the same as fitting the standard dovetail. HINT: Use pieces of scrap wood the same thickness and species of wood to make test pin boards until the template is adjusted for a perfect fit. INLAYED JOINTS The 4200 series dovetail jigs will allow you to make joints with inlays of different colored wood for a very unique look.
CUT OFF THE INLAY BOARD After the joint has dried, cut the inlay board to an amount equal to the thickness of the inlay (Fig. 68B). If desired, you can cut off the small area shown from the remainder of the inlay wood (Fig. 68C). If left on, the completed joint will have an extra amount of material on the inside.
SETUP Select one set of dovetail bits from the table for Combinations for Half-blind dovetails with the pins and the tails cut separately in the section"TABLES OF COMMONLY AVAILABLE ROUTER BIT SIZES". Use the following table to determine the thickness of the inlay line: Dovetail Bit Set NOTE: If the thickness of the inlay line is very thin, you may have difficulty cutting the inlay correctly.
MAKE THE SECOND JOINT The second joint is also identical to that described in the section on Half-Blind Dovetail Bits with the Pins and Tails Cut Separately under the chapter “ALTERNATE ROUTER BITS”. Use the board from the previous section as the tail board.
TABLES OF COMMONLY AVAILABLE ROUTER BIT SIZES THROUGH DOVETAIL ROUTER BIT COMBINATIONS Combination Number Bit (Diameter and Angle) 17/32" 17/32" 9/16" 5/8" COMBINATIONS FOR HALF-BLIND DOVETAILS WITH THE PINS AND THE TAILS CUT SEPARATELY. Combination Large Dovetail Bit Number (Diameter and Angle) The actual depth-of-cut may be a little deeper or shallower than what appears on this table.
For assistance with your tool, visit our website at www.porter-cable.com for a list of service centers or call the Porter-Cable help line at 1-800-487-8665. KEEP TOOL CLEAN Periodically blow out all air passages with dry compressed air. Clean all plastic parts with a soft damp cloth. NEVER use solvents to clean plastic parts.
ONE YEAR WARRANTY Porter-Cable warrants its Professional Power Tools for a period of one year from the date of original purchase. We will repair or replace at our option, any part or parts of the product and accessories covered under this warranty which, after examination, proves to be defective in workmanship or material during the warranty period.
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