DJ300 Dovetail Jig - Wood · PDF fileDJ300 Standard 1/2” (12.7mm) Template The DJ 300...

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Transcript of DJ300 Dovetail Jig - Wood · PDF fileDJ300 Standard 1/2” (12.7mm) Template The DJ 300...


  • DJ300


    1 x 1/2 (12.7mm) Dovetail template

    4 x Template bracket screwscountersunk socket head

    1 x Hex key - 1/8 (3.2mm) A/F

    2 x Template bracket complete withintegral nuts

    No.1 Edge guidesFor 1/2 (12.7mm) lapped dovetailtemplate

    No.2 Edge guidesFor 1/2 (12.7mm) rebated dovetail &comb jointing template

    2 x Template spring pin stops

    2 x Edge guide pan head screws

    2 x Edge guide screw washer

    1 x Template guide bush 15.7mmdiameter

    2 x Countersunk machine screw M5x 10mm for guide bush

    1 x Spanner 7/16 (11.1mm) A/F foradjusting template lock nut

    1 x Manual

    1 x Guarantee Card






    1 x Jig body

    1 x Front clamping bar(short) with abrasivestrip

    1 x Top clamping bar (long)with abrasive strip

    4 x Nylon spacer

    4 x Clamp knob female

    4 x Clamp bar set boltUNC1/4 - 20 x 13/4(long)

    6 x Set bolt half nutUNC1/4 - 20

    2 x Template set boltUNC1/4 - 20 x 11/2(short)

    4 x Spring

    2 x Template lock nut UNC1/4 - 20

    2 x Knurled brass thumbscrew

    1 x Dovetail cutter 12.7mm dia x 104

    4 x Self tapping screw No.10 x 1/2

  • DJ300


    Always switch off the power and unplug therouter when changing cutters or when makingadjustments.

    Always wear protective goggles when routing.

    Wear sound protective ear muffs when routingfor long periods of time.

    Always wear a dust mask or respirator. Usedust extraction equipment whenever possible.

    Do not wear loose clothing. Make sure baggysleeves are rolled up and ties are removed.

    Always remove spanners and hex keys fromthe workpiece before switching router on.

    Keep hands well clear of the router cutterwhen routing.

    Avoid accidental starting of the router. Makesure the power switch is in the Off positionbefore plugging in and connecting to theelectrical supply.

    Never leave the router unattended whenrunning. Always wait until the router comes toa complete stop before making anyadjustments.

    Do not switch the router on with the cuttertouching the workpiece.

    Mount the Dovetail Jig securely to a workbench or to a workboard fitted to a suitablesurface.

    Periodically check all nuts and bolts to makesure they are tight and secure.

    Use dust extraction equipment.

    Cutter Care Do not drop cutters or knock them against

    hard objects.

    Cutters should be kept clean. Resin build-upshould be removed at regular intervals withResin Cleaner. The use of a dry lubricantwill act as a preventative such as TrendicotePTFE spray.

    Cutter shanks should be inserted into thecollet at least 3/4 of shank length to prevent

    distortion. A distorted collet should bediscarded, as it can cause vibration anddamage the shank.

    Do not overtighten collet as this will score theshank and create a weakness.

    It is also advisable to periodically check therouter collet nut for wear.

    Useful Advice Judge your feed rate by the sound of the

    motor. In time, the operator will acquire afeel for the router and a feed speed relativeto the work will come naturally. Too slow afeed will result in burning.

    Apply the normal precautions as with anyelectric power tool.

    The main cause of routing machine failure isthe inclination for operators to overload them.The motto is Keep the revs up. The drop inrevolutions should not exceed, if possible,more than 20% of full running speed.

    The motor of a router is susceptible to theaccumulation of sawdust and wood chips andshould be blown out, or vacuumed,frequently to prevent interference with normalmotor ventilation.

    Refer to the Instruction Manual supplied withyour router for full details of its features andsafety information.

    The use of a fine height adjuster is highlyrecommended (if available for your router) foraccurately adjusting the height of the cutterwhen dovetailing.

    Trial cuts should be made on waste materialbefore starting any project.


  • DJ300

    1. Clamp knob female2. Nylon spacer3. Clamping bar - short4. Clamping bar - long5. Spring6. Template spring pin stop7. 1/2 (12.7mm) dovetail template8. Template bracket screws9. Template bracket10. Dovetail edge guide11. Edge guide pan head screws


    Using the drawing below as a guide to assemblethe jig.

    12. Edge guide washer13. Clamp bar set bolt UNC1/4 - 20 x 13/4 (long)14. Knurled brass thumb screw15. Edge guide fastening slot16. Jig body17. Lock nut UNC1/4 - 2018. Embossed slot for bar set bolt (front slots

    hidden from view on diagram above) 19. Template set bolt UNC1/4 - 20 x 11/2 (short)20. Half nut UNC1/4 - 2021. Embossed slot for template set bolt










    351421 18 1715 2 1


















  • DJ300

    Assembly Instructions To fit the four clamp bar set bolts (13), firstly

    insert the half nut (20) into the embossedslot(18) in the jig body (16). For the clampbar set bolts the two back top embossedholes and the two front inner embossed slotsare used. Assembling one assembly at a timefit the clamp bar set bolt (13) into the half nut(20) from inside the jig body (16). Tightenusing the spanner enclosed. Repeat for theremaining three bolt assemblies.

    To fit the two template set bolts (19), firstlyinsert the half nut (20) into the two outer frontembossed slots (21) in the jig body (16).Screw the template set bolt (19) into the halfnut (20) from inside the jig body (16). Tightenusing the spanner enclosed. Repeat for theother bolt assembly.

    Fit the edge guides marked 1L (left-hand) &1R (right-hand) to the dovetail body (16),securing them with the edge guide washer(12) and pan head screws (11) through thefastening slots (15) and into the tapped holesin the top of the body of the jig.

    Screw the lock-nut (17) onto each of thetemplate bolts (19) on the front of the dovetailbody, followed by the knurled brass thumbscrew (14), keeping the knurled side to thefront. Adjust the lock-nuts so that they areboth 8mm from the jig body using the spannerprovided.


    To install the clamping bars, identify frontclamping bar - short (3) and top clamping bar- long (4).

    Fit spring (5) onto the clamp bar set bolt (13)and the fit clamp bar (3) or (4) on the set bolt(13). Fit the nylon spacer (2) onto the set bolt(13). (When using material, with a thicknessgreater than 23mm, the nylon spacer must beremoved).

    Thread the female clamp knob (1) onto theset bolt (13). Fit both front and top clampbars in the same way.

    Using a hammer, gently tap the two templatespring pin stops (19) into the holes in theedge of the template (7). (This procedure isalso required for the 1/4 (6.35mm) templateaccessory ref. DJ300/01).

    Attach the aluminium template (7) to thetemplate brackets (9) with the four sockethead countersunk screws (8).

    Slide the template by engaging the slots ofthe template brackets (9) over the bolt (13).Lightly tighten the knurled brass thumbscrews (14).

    The jig will need to be mounted onto theworkbench or false work surface as shown onpage 8.


    18 or 21


    13 or 19

    IMPORTANT!Periodically check tightness ofall nuts and bolts.

  • DJ300

    Standard 1/2 (12.7mm)TemplateThe DJ 300 Dovetail Jig is supplied with astandard 1/2 (12.7mm) dovetail templateand will produce lapped dovetail andlapped rebated dovetail joints. The15.7mm template guide bush and the12.7mm (1/2) diameter x 104 Dovetailrouter cutter should be used and aresupplied with the jig.

    SpecificationMin material thickness is 12mm.Max material recommended is 20mm.Pitch width is 25.4mm.

    SpecificationMin material thickness is 8mm.(A 6mm plywood or MDF packing piece behindfront bar is required.)Max material recommended is 12mm. Pitch width is 11.3mm.

    SpecificationMin material thickness is 11mm.Max material thickness is 25mm.Pitch width is 21.5mm.

    Optional 1/2 (12.7mm) CombJoint Template Ref. DJ300/02The comb joint is ideal for strong cornerjoints for boxes. The finger size are 1/2(12.7mm) in diameter. The template usesthe 15.7mm guide bush (ref. GB157) assupplied with the standard dovetail jig. The cutter is not supplied as standar d.The principle for setting-up and routingthe comb is different to that for thedovetail, each piece is routed separatelyunder the front clamp bar.Also included with the optional 1/2(12.7mm) comb are edge guides No. 3.

    Optional 1/4 (6.35mm) LappedDovetail Template Ref. DJ300/01The size of dovetail is 1/4 (6.35mm) andis ideal for small boxes and small drawers.The template includes a 7.74mm guidebush (ref. GB774).

    The cutter is not supplied as standar d.

    The principle for setting-up and routingthe dovetail is the same as for thestandard 1/2 (12.7mm) dovetail template.

    The edge guides No. 3 and No. 4 aresupplied with the optional 1/4 template(6.35mm).


    Template Specification

    12.7mm (1/2) dovetailcutter ref. L120 (UK &Eire), C041 (Europe)

    6.0mm dovetail cutterref. S31/11 (UK &

    Eire), C154 (Europe)

    Comb Joint

    1/4 (6.35mm)Lapped Do vetail

    1/4 (6.35mm) Lappedrebated do vetail

    1/2 (12.7mm) Lapped Do vetail

    1/2 (12.7mm) Lappedrebated do vetail

    12.55mm x 25mmstraight cutter ref.3/76 (UK & Eire)C021A (Europe)

    Pin Pin Depth9.5mm ( 3/8)

    Pin With12.7mm ( 1/2)

    Pin Width6.3mm ( 1/4)

    Pin Depth20mm Max

    Pin Width12.7mm ( 1/2)

    Pin Depth4.8mm (