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CUTTING THE SECOND BOARD (B2)
1.
Flip template over so the "B TAILS" label (P) Fig. I14 is on
the left as you face the jig.
2.
Remove the first board B1 and mount the second board
B2, noting that the "outside surface" of second board B2
should now be facing away from the jig.(See Fig. I14) The
horizontal scrap pieces (X) do not need to be moved and
can remain in place to help reduce tearout when cutting the
second board (B2).
NOTE: The second board can be cut in a single pass for any
wood thickness since the changes required for wood
greater than 3/4" thick with the first board B1 are not
applicable. In addition, the spacers on the template stops
that are an integral part of cutting the first board B1 do not
apply here.
3.
Set router bit depth to thickness of first board B1. Use
previous instructions as a guide.
4.
To cut second board (B2), use router bit (S3) with template
guide G3.
Before making any cuts, be sure you read your
router owner's manual for safe operating instructions.
5.
To reduce tearout, the first pass (Fig. I15) of each area
to be cut should be from right to left. Only a light cut is
required, no deeper than a 1/4" for example. For other cuts
(Fig. I16), the router should enter from the left and exit from
the right. Continue until cutting is complete and the final cut
should resemble Fig. I17.
NOTE: Cut only between angled corners - do not cut between
straight edges as shown in Fig. I18.
6.
Remove B2 and fit boards B1 and B2 together. (See
"ADJUSTING FOR TIGHTNESS OF FIT" in this chapter if
your joint is too loose.)
MINIATURE TEMPLATE (77246 or 55166)
The procedure is the same as the variable finger template, with
these exceptions:
board, or B1.
board, or B2.
top of this piece is flush with the horizontal scrap board.
This will need to be checked manually with a straight edge.
(FIg. I19)
"MAXIMUM BOARD WIDTH" section from earlier
in chapter for direction on the fingers that should be used
on mini template in order to cut a box joint.
X
X
B2
Other cuts:
In on left, out
1st Pass - 1/4" deep
on right
right to left
Fig. I15
Flush
Fig. I19
P
Outside surface facing
away from the jig
Fig. I14
N O
Fig. I16
Fig. I17
Cut in here
Do not cut here
Fig. I18
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