SETUP & OPERATION MANUAL FEATURES Male and female dovetail joints are cut simultaneously, to ensure perfectly matched dovetail joints. Side stops provided, allow repeated precise dovetail joint cutting with one initial setting. Comes with 1/2 half-blind template (#40-022). 24 DOVETAIL JIG SPECIFICATIONS Thickness capacity 1/2-1 1/4 (13 mm - 32 mm) Dimensions 30 1/8 x 11 x 6 3/4 (765 x 280 x 170 mm) Weight 29 LBS (13 kg) Version 2 / Revision 1 - June 2014 Copyright General International 2014 MODEL # 40-020
GENERAL INTERNATIONAL 8360 Champ-d Eau, Montreal (Quebec) Canada H1P 1Y3 Telephone (514) 326-1161 Fax (514) 326-5555 www.general.ca THANK YOU for choosing this General International item 40-020 (24 ) Dovetail jig. This dovetail jig has been carefully tested and inspected before shipment and if properly used and maintained, will provide you with years of reliable service. For your safety, as well as to ensure optimum performance and trouble-free operation, and to get the most from your investment, please take the time to read this manual before assembling, installing and operating the unit. The manual s purpose is to familiarize you with the safe operation, basic function, and features of this dovetail jig as well as the set-up, maintenance and identification of its parts and components. This manual is not intended as a substitute for formal woodworking instruction, nor to offer the user instruction in the craft of woodworking. If you are not sure about the safety of performing a certain operation or procedure, do not proceed until you can confirm, from knowledgeable and qualified sources, that it is safe to do so. Once you ve read through these instructions, keep this manual handy for future reference. DISCLAIMER: The information and specifications in this manual pertain to the unit as it was supplied from the factory at the time of printing. Because we are committed to making constant improvements, General International reserves the right to make changes to components, parts or features of this unit as deemed necessary, without prior notice and without obligation to install any such changes on previously delivered units. Reasonable care is taken at the factory to ensure that the specifications and information in this manual corresponds with that of the unit with which it was supplied. However, special orders and after factory modifications may render some or all information in this manual inapplicable to your unit. Further, as several generations of this model of dovetail jig and several versions of this manual may be in circulation, if you own an earlier or later version of this unit, this manual may not depict your unit exactly. If you have any doubts or questions contact your retailer or our support line with the model and serial number of your unit for clarification.
GENERAL INTERNATIONAL WARRANTY All component parts of General International and Excalibur by General International products are carefully inspected during all stages of production and each unit is thoroughly inspected upon completion of assembly. Limited Lifetime Warranty Because of our commitment to quality and customer satisfaction, General International agrees to repair or replace any part or component which upon examination, proves to be defective in either workmanship or material to the original purchaser for the life of the tool. However, the Limited Lifetime Warranty does not cover any product used for professional or commercial production purposes nor for industrial or educational applications. Such cases are covered by our Standard 2-year Limited Warranty only. The Limited Lifetime Warranty is also subject to the Conditions and Exceptions as listed below. Standard 2-Year Limited Warranty All products not covered by our lifetime warranty including products used in commercial, industrial and educational applications are warranted for a period of 2 years (24 months) from the date of purchase. General International agrees to repair or replace any part or component which upon examination, proves to be defective in either workmanship or material to the original purchaser during this 2-year warranty period, subject to the conditions and exceptions as listed below. To file a Claim To file a claim under our Standard 2-year Limited Warranty or under our Limited Lifetime Warranty, all defective parts, components or machinery must be returned freight or postage prepaid to General International, or to a nearby distributor, repair center or other location designated by General International. For further details call our service department at 1-888-949-1161 or your local distributor for assistance when filing your claim. Along with the return of the product being claimed for warranty, a copy of the original proof of purchase and a letter of claim must be included (a warranty claim form can also be used and can be obtained, upon request, from General International or an authorized distributor) clearly stating the model and serial number of the unit (if applicable) and including an explanation of the complaint or presumed defect in material or workmanship. CONDITIONS AND EXCEPTIONS: This coverage is extended to the original purchaser only. Prior warranty registration is not required but documented proof of purchase i.e. a copy of original sales invoice or receipt showing the date and location of the purchase as well as the purchase price paid, must be provided at the time of claim. Warranty does not include failures, breakage or defects deemed after inspection by General International to have been directly or indirectly caused by or resulting from; improper use, or lack of or improper maintenance, misuse or abuse, negligence, accidents, damage in handling or transport, or normal wear and tear of any generally considered consumable parts or components. Repairs made without the written consent of General International will void all warranty.
TABLE OF CONTENTS Rules for safe operation...5 Identification of main parts and components...6 Unpacking...7 Assembly instructions...7 Operating & set up... 7-8 Fitting & adjusting...8 Required tools based of template being used...9 Recommended optional accessories...9 Parts list & diagram...10 Contact information...12
RULES FOR SAFE OPERATION To help ensure safe operation, please take a moment to learn the machine s applications and limitations, as well as potential hazards. General International disclaims any real or implied warranty and hold itself harmless for any injury that may result from the improper use of it s equipment. 1. Learn the machine s applications and limitations, as well as the specific potential hazards particular to this machine. Follow available safety instructions and safety rules carefully. 2. Keep working area clean and be sure adequate lighting is available. 3. Do not wear loose clothing, gloves, bracelets, necklaces, or ornaments. Wear face, eye, ear, respiratory and body protection devices, as indicated for the operation or environment. 4. Keep hands well away from router bits and all moving parts. Do not clear chips and sawdust away with hands. Use a brush. 5. Make sure the router bit is moving at operation speed before cutting. 6. Do not push the router bit to hard. The router bit will perform better and be safer working at the rate for which it was designed. 7. Whenever possible use a dust collector with shaving hood to minimize health hazards. 8. Never leave the machine with the power on. 9. Keep children away. Make sure that visitors are kept at a safe distance from the work area. 10. Use recommended speed router bit, accessory, and workpiece material. 13. Do not force the machine. It will do the job better and be safer at a rate for which it was designed. 14. Keep guards in place and in working order. If a guard must be removed for maintenance or cleaning make sure it is properly attached before using the tool again. 15. Be sure that key and adjusting wrenches have been removed before turning power on. 16. Use only accessories designed for the machine. 17. Make sure tool is properly grounded. If tool is equipped with three-prong plug, it should be plugged into a three-pole electrical receptacle. Never remove the third prong. 18. Always disconnect tool before servicing and when changing accessories such as router bits. 19. Make sure that switch is in OFF position before plugging in cord. 20. Hold material firmly against the table. 21. Use ONLY recommended accessories. Use of accessories NOT recommended by General International may result in a risk of injury. 22. Do not use this dovetail jig for any purpose other than its intended use. If used for other purposes, General International disclaims any real or implied warranty and holds itself harmless for any injury, which may result from that use. 11. Never stand on tool. Serious injury could occur if the tool is tipped or if the cutting tool is unintentionally contacted. 12. Be sure the router bit is securely locked in the machine. 5
IDENTIFICATION OF MAIN PARTS AND COMPONENTS 40-020 B C B G D E D A F A A. VERTICAL CLAMPING KNOB B. HORIZONTAL CLAMPING KNOB C. TEMPLATE LOCK KNOB D. FENCE LOCK KNOB E. TEMPLATE F. VERTICAL STOP (2) G. HORIZONTAL STOP (2) 6
UNPACKING Carefully unpack and remove the unit and its components from its shipping container and check for missing or damaged items. NOTE: PLEASE REPORT ANY DAMAGED OR MISSING ITEMS TO YOUR GENERAL INTERNATIONAL DISTRIBUTOR IMMEDIATELY. LIST OF CONTENTS QTY A. 24 DOVETAIL JIG... 1 B. 1/2 ALUMINIUM TEMPLATE (INSTALLED ON JIG)... 1 A OPERATION & SET-UP You can mount the jig to a workbench through the two mounting holes found at the rear of the jig. You can also mount the jig to piece of plywood so that it can be clamped to your workbench when needed. TIP: ALWAYS SET-UP AND PRACTICE ON A TEST PIECE. The 24 dovetail jig comes with a 1/2 aluminum template. It should be used with a 1/2 dovetail router bit (1/4 shank, 14 ), and a 1/2 guide bushing. 1. Lay out the workpieces and mark according to the finished position as shown. 3 Left (INSIDE) Front (OUTSIDE) 4 2 Back (INSIDE) Right (OUTSIDE) 1 2. Slide the workpiece marked Front or Back B under the horizontal clamping assembly as shown B. The side marked inside should face up. B 3. Set the horizontal stop E so that the edge of the workpiece lines up in the centre of one of the template fingers as shown B. C D 4. Remove the template G by tightening the four screws F. 5. Remove the vertical clamping assembly by unscrewing the two knobs H. 6. Mark the workpiece 1/2 from the edge for template finger width G. Adjust the vertical stop against the square I. E G F CENTRE 7. Re-install the template and the vertical clamping assembly. H 8. Slide the workpiece marked Left or Right under the vertical clamping assembly. The side marked inside should face out. Match up the numbers you marked. 9. Adjust the clamping pressure knobs so that the bar is just over the workpiece. The workpiece should still move freely, hold the workpiece in place by pushing the lever. Excessive force should not be necessary to clamp the workpiece. 10. Set the template back from the front edge of the workpiece by approximately 1/8 as shown K. I J 7
11. Loosen the two knobs L to position the template. Measure from the two ends of the workpiece to the template to make sure the template is parallel to te front edge of the workpiece. 12. The fence N should be set from the template finger tip according to a simple equation found in Calculating distance from fence to template finger. Loosen the the two fence lock knobs M to position the fence. 13. Set the router bit so it is approximately 11/16 lower than the router base. 14. Rout off the front edge of the workpiece following along the template fingers. Rout out the rest of the material. 15. Remove the workpieces and verify for fit. L M N K CALCULATING DISTANCE FROM FENCE TO TEMPLATE FINGER EQUATION STOCK THICKNESS TIMES TWO, PLUS ROUTER BASE RADIUS*, MINUS BIT RADIUS, EQUALS DISTANCE FROM TEMPLATE FINGER TO FENCE. Stock thickness is 1/2 1/2 x 2 = 1 *Radius = Diameter 2 Router base radius is 3 1 + 3 = 4 Example Router base bit radius is 1/4 4 1/4 = 3 3/4 Then distance from fence to template finger is 3 3/4 FITTING & ADJUSTING If the dovetail fit is too tight; decrease the router bit distance from router base slightly. If the dovetail fit is too loose increase the router bit distance from the router base slightly. If the pins on the side piece fit too deeply in the tails of the front or the back piece; then the cut is too deep. Move the fence forward the same amount the pins are exposed. If the side piece sticks out from the front or the back piece; then the cut is too shallow. Move the fence back the same amount the sides stick out. If the edges on the front and side piece do not match adjust the stop. The front stop must be offset from the top stop the width of the template finger at 1/2. When you have the jig properly adjusted, you can dovetail the actual drawer parts. NOTES Joints for the left front corner and the right rear corner of a drawer or a box are cut on the left side of the jig. Joints for the right front corner and the left rear corner of a drawer or a box are cut on the right side of the jig. The drawer sides should be cut to the finished height. They can be left longer and cut to the finished length later. Once the desired router bit height is established make a simple gauge block out of a hardwood to quickly get the correct setting in the future. Once the stops are set properly and you have obtained the desired results use a scribe to mark the stop locations. 8
REQUIRED TOOLS BASED ON TEMPLATE BEING USED Dovetail template Router bit (1/4 shank) Guide bushing Depth of cut 1/4 (6 mm) 1/4 (6 mm) x 8 5/16 (8 mm) 5 mm 1/2 (13 mm) 1/2 (13 mm) x 14 3/8 (9.5 mm) 12.4 mm 1/2 (13 mm) 1/2 (13 mm) x 14 7/16 (11 mm) 6.4 mm 1/2 (13 mm) 5/8 (14 mm) x 14 15/16 (12 mm) 9.6 mm 1/2 (13 mm) 5/8 (14 mm) x 14 1/2 (13 mm) 12.4 mm Box joints Straight Bit (1/4 shank) Guide bushing Depth of cut 1/4 (6.35 mm) 1/4 5/16 (8 mm) 3/8 (9.5 mm) 3/8 1/2 (13 mm) 1/2 (13 mm) 1/2 5/8 (14 mm) Exact thickness of the workpiece RECOMMENDED OPTIONAL ACCESSORIES Here is a sampling of optional accessories available from your local General International dealer. For more information about our products, please visit our website at www.general.ca Item #40-026 - 1/4, #40-027 - 3/8, #40-028 - 1/2 (Box joint template). Item #40-021 - 1/4, #40-022 - 1/2 (Half-blind template). ALUMINUM DOVETAIL TEMPLATES 9
1 2 " DIAGRAM & PARTS LIST 4 8 16 6 12 3 5 5 9 10 14 15 11 7 2 9 4 3 13 1 10 IMPORTANT: When ordering replacement parts, always give the model number, serial number of the machine and part number. Also a brief description of each item and quantity desired. NO. PIECE DESCRIPTION SPECIFICATION QTY 40020-01 BASE 1 40020-02 THREADED BUSHING 4 40020-03 CLAMP BRACKET 2 40020-04 CLAMP KNOB 4 40020-05 KNOB 4 40020-06 FENCE 1 40020-07 BRACKET 2 40020-08 1/2 HALF BLIND DOVETAIL TEMPLATE (#40-022) 1 40020-09 STOPS (LONG) 2 40020-10 STOPS (SHORTS) 2 40020-11 FLAT WASHER 2 40020-12 SPRING 4 40020-13 THREADED BRACKET 4 40020-14 END CAP 4 40020-15 FLAT PHILLIPS MACHINE SCREW 10-24 X 5/8 8 40020-16 FLAT PHILLIPS MACHINE SCREW 1/4-20 X 3/8 4 10
NOTES 11
8360 Champ-d Eau, Montreal (Quebec) Canada H1P 1Y3 Tel.: (514) 326-1161 Fax: (514) 326-5565 - Parts & Service / (514) 326-5555 - Order Desk orderdesk@general.ca www.general.ca Follow us: 12