Porter-Cable OMNIJIG 55160 Instruction Manual page 65

NOTES ON CUTTING THE BOX JOINT
Before we get into the steps for cutting box joints, here are a
few key points about using the box joint accessory kits with the
appropriate templates:
For other applications such as through and half-blind dovetails,
the position of the template or the router bit depth is used to
control the tightness of the joint. For the box joint method,
a series of template guides with slightly different outside
diameters control the tightness of joint.
The box joint accessory kits include a Box Joint Setup Guide
(Fig. I4). This card provides guidance for both making cuts
and adjustments. The instructional labels on either end of the
variable finger template and mini-template should therefore be
ignored when cutting box joints.
Use stops (E) Fig. I6 labeled "BOX LEFT" and "BOX RIGHT"
for the variable finger template. Use stops labeled "MINI-BOX
LEFT" and "MINI-BOX RIGHT" for the mini finger template.
Both boards for box joints are cut in the vertical position. Be
sure to mount scrap wood horizontally under the template on
both left and right sides. These pieces should be the same
thickness to ensure template flatness, but do not need to be the
same thickness as the vertical board being cut.
The boards for your box joint will be referred to in this chapter
as the "first board" cut (B1) (Fig. I5) and "second board" cut
(B2) (Fig. I5). As shown in Fig. I5, B1 and B2 do not have to be
the same thickness.
CUTTING THE JOINT
Fig. I4
The instructions in this chapter for cutting a box joint using the
accessory kit assume you have read the "BASIC OPERATIONS"
chapter of this manual, as well as any chapter addressing
usage of the variable finger templates.
Cutting instructions for the variable finger template are given
below, while the differences in the steps when using the mini
B1
template follow.
B2
B1
B2
Fig. I5