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CUTTING THE DADO BOARD
You will use the same stops, bit, template guide and depth of cut
for the dado that was used for the tenon.
1.
The dado board (vertical side panel, as shown at A1 or A2,
Fig H3) will be mounted on the jig horizontally with the out-
side surface facing down and the rear edge aligned to the
right of the jig base. With the board in this orientation, draw
a straight line (U) Fig. H15 to mark the center of the dado.
From this line, measure up the board 1-5/8" and draw an-
other line (V) parallel to this first line.
2.
Mount dado board (W) Fig H16 horizontally with the outside
surface facing down and the rear edge to the right. Line up
the rear edge of the dado board with the right edge of the
textured surface of the jig base. Line up the pencil line mark
(V) with the scribed line (Y) in the fixed fingers and line up
making multiple cuts, it is recommended that you slide the
right edge guide over until it is flush with the right side of the
of the dado board and tighten it down. The edge guide can
then be used as a reference for the proceeding dado board
cuts. Remove the stabilizer bar from the jig if it interferes
with the dado board.
If your board extends more than two feet beyond
the front of the jig, be sure to use auxilliary supports to
support the end of the workpiece.
3.
REMINDER: Make sure there is a board of similar thickness
clamped on the left side of the jig for stability. Also, be sure
the template is flat on both boards and that the template lock
knobs are tight.
Before making any cuts, be sure you read your
router owner's manual for safe operating instructions.
4.
To reduce wear on the dovetail bit and avoid excessive
vibration, the bulk of the material must first be cut using
a straight bit. The bit should be set to a slightly shallower
depth than the dovetail bit, and stepped passes with the
straight bit may be required for deeper depths of cut. Failure
to follow this step may cause an ill fitting joint. (Router bit S1
combined with either template guide G1 or G2 will work for
this. When using router bit S1, do not take off more than 1/4"
of material in each pass.)
5.
As you make the cut, guide the router from left to right
along the back side (AA) Fig. H17 of the slot. Then, guide it
along the front side (BB) of the slot from right to left. After
removing the bulk of the material with a straight bit in this
manner, make the final cut with the dovetail bit the same
way.
6.
Mark the left side of the dado with an "X" as shown in Fig
H18. This will identify the entry point for the tenon board
during assembly.
W
V
1-5/8"
OUTSIDE
SURFACE
U
Fig. H15
AA
BB
Fig. H17
W
Y
V
Z
REAR
EDGE
U
Fig. H16
Fig. H18
X
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