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Leigh D4R Pro User Manual

Dovetail jig
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Dedicated Customer Support
1-800-663-8932
For the Leigh D4R Pro Dovetail Jig
Leigh Router Joinery Jigs
Joining Tradition with Today

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Summary of Contents for Leigh D4R Pro

  • Page 1 For the Leigh D4R Pro Dovetail Jig Leigh Router Joinery Jigs Dedicated Customer Support 1-800-663-8932 Joining Tradition with Today...

  • Page 2: Table Of Contents

    Chapter 15 Box Joints ................53 Chapter 16 Sliding Dovetails ..............59 Chapter 17 Hints & Tips ................65 Appendix I Attaching the Leigh e-Bush to the Router ......69 Appendix II Bit Selection .................71 Appendix III Jig Parts ................79 Appendix IV Customer Support ...............83...

  • Page 3: Contents And Standards

    Your New Leigh D4R Pro Dovetail Jig Congratulations! You now own the world’s most useful and versatile dovetailing tool. The Leigh D4R Pro Dovetail Jig will help you rout an infinite variety of joints, and all of its major functions are described in detail in this guide.
  • Page 4 The Leigh jig’s guidefinger assembly can be in any one of four joint modes, depending on what type of joint and which part of the joint you are routing.
  • Page 5 D4R Pro User Guide Contents and standards Which Way Round Should the Board Go? As virtually all dovetail joinery is used to make boxes, drawers and chests etc., we devised these simple (and hopefully intuitive) icons to indicate which side of a board faces inwards or outwards on the finished “box”,...
  • Page 6 Combine the VRS with a Bit Set for Exceptional Savings! Leigh Brand Bit Sets Offer Great The D4R Pro Accessory Kit is the best deal going. Savings...and the Box Is Free! Enjoy great savings on the 12-piece Bit Set and even greater savings when you combine it with Save over individual bit prices.
  • Page 7 They employ proven cam-action technology developed for the award-winning Leigh jigs, the D4R Pro and FMT. Bench clamps can be used in any size hole and surface clamps can be mounted on any flat surface, both on any angle. You can never...
  • Page 8 D4R Pro User Guide Contents and standards Mortise & tenon Joints have never been easier! Leigh Super FMT Leigh FMT Pro Mortise & Tenon Jig Mortise & Tenon Jig Item SFMT Item FMT Pro Rout mortises and tenons in 60 seconds!

  • Page 9: Jig Assembly, Mounting, And Using The Clamps

    Using the Clamps Make Sure You Have All the Parts. Before you start to assemble your Leigh D4R Pro, check to make sure you have received all the required parts. The small carton you removed from the end of the main carton contains: 1.
  • Page 10 Position so that the washers seat into the round for possible future attachment of accessories. See Chapter 9. milled recesses. Tighten the four clamp bolt nuts with the Leigh wrench. Place four springs and two clamp bars on the T-bolts.
  • Page 11 D4R Pro User Guide Chapter 1 Jig asseMbLy, MoUnting, and Using the CLaMps Insert the right and left support brackets. Attach the Place the finger assembly on your bench with the guidefinger knobs, raise to full height and tighten. Note: For clarity, the set screws ...
  • Page 12 Chapter 1 D4R Pro User Guide Jig asseMbLy, MoUnting, and Using the CLaMps 1-13 1-14 A smooth, firm action is enough to engage the clamp. Do Not use the lever as a torque arm. Adjust the clamp tension only with the clamp disengaged.
  • Page 13 2 lengths of bridge piece extrusion 1 cross cut fence 1 instructional DVD, and this user guide. Please keep all these items for ready use. 1 warranty card. *Please register your warranty. You will automati- cally be entered in Leigh’s Warranty Registration Contest.
  • Page 14 Chapter 1 D4R Pro User Guide Jig asseMbLy, MoUnting, and Using the CLaMps...

  • Page 15: Adjusting The Finger Assembly

    D4R Pro - CHAPTER 2 adjusting the Finger assembly THE FINGER ASSEMBLY IS THE HEART OF THE LEIGH JIG. Spend a few minutes now to familiarize yourself with these simple adjustments. NOTE: The first few times you use your jig, some fingers may "stick". This is normal. To "unstick", loosen the finger screw approximately 3/4 of a turn, and with the screwdriver still in the screw, press down firmly (on the screwdriver).
  • Page 16 2-5 Do not over-tighten the guidefinger locking screws. The 2-6 Always tighten unused guidefingers before routing, as router Leigh screwdriver provided will give ample torque for easy lock-up vibration will cause loose screws and wedge nuts to fall out and without strain.

  • Page 17: The Leigh E-Bush And Optional Guidebushes

    The guidebush is the vital link between router and jig. All joints created on the D4R Pro are routed with the unique e7* elliptical guidebush, a Leigh innovation that provides precise joint fit adjustment for box joints and sliding dovetails.

  • Page 18: Chapter 3 The Leigh E-Bush And Optional Guidebushes

    This setting is used for all through and variably spaced half- orientation. Make a small scratch line or permanent ink mark on blind dovetails on the D4R Pro. Settings for single pass half-blinds, the router base or e-Bush adaptor at the 12 o’clock position  .

  • Page 19: Basic Jig Functions And Scale Modes

    D4R Pro CHAPTER 4 basic Jig Functions and scale Modes Here are the very basics for understanding the different D4R Pro dovetail modes and settings. THE FOUR SCALE MODES This index line is used when setting the finger assembly The Finger Assembly attaches to the support brackets in four scales.
  • Page 20 Chapter 4 D4R Pro User Guide basiC Jig FUnCtions and sCaLe Modes 4-1 The two clamp bars hold workpieces horizontally or verti- 4-2 The guidefinger assembly slides on to the support brackets cally. The side stops align the boards in the correct position each above the workpiece.

  • Page 21: Using Your Jig Safely

    Always operate variable speed routers at the fastest Protect yourself from harmful dust with a face mask. For complete dust and waste collection, add a Leigh VRS (Vacuum possible speed. & Router Support) to your jig. See page vi.
  • Page 22 See page vi. of the jig. With the Leigh VRS fitted to your jig you can simply park your router to one side. 5-7 Do not rout at face level.

  • Page 23: Wood Preparation

    6-2 You will want to test the jig, so prepare some ⁄ " x Leigh jig must be prepared straight, flat, of even thickness and equal ⁄ "[20x140mm] boards. Cut them to length as you need them widths, with square ends and edges. Note that plywood is generally for the jig tests you want to perform.
  • Page 24 Chapter 6 D4R Pro User Guide Wood preparation...

  • Page 25: Router Preparation

    D4R Pro - CHAPTER 7 router preparation Fit the e7-Bush  . One is included with your D4R Pro. When fitting a bit to the router  , fit the shank as far into the collet  as possible. Always rout with the collet as close to the If the e-Bush is incompatible with your router, any ~ "[11,1mm]...

  • Page 26: Through Dovetails

    If you don’t have this type, it might pay to stick to a single router for through dovetails. 7-9 Shank Selection/Collet Reducer All Leigh Dovetail jigs are shipped with superior strength 8mm shank dovetail bits and a ⁄...

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