Clarke CDTJ12 Instruction Manual

WARNING: Read these instructions before using the machine

OPERATION & MAINTENANCE

INSTRUCTIONS

LS0111

DOVETAIL JIG

MODEL NO: CDTJ12 / CDTJ24

PART NO: 6462170, 6462175

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

INTRODUCTION

Thank you for purchasing this CLARKE Dovetail Jig.

Before attempting to operate the machine, it is essential that you read this

manual thoroughly and carefully follow all instructions given. In doing so you

will ensure the safety of yourself and that of others around you, and you can

also look forward to the dovetail jig giving you long and satisfactory service.

GUARANTEE

This CLARKE product is guaranteed against faulty manufacture for a period of

12 months from the date of purchase. Please keep your receipt as proof of

purchase.

This guarantee is invalid if the product is found to have been abused or

tampered with in any way, or not used for the purpose for which it was

intended.

Faulty goods should be returned to their place of purchase, no product can

be returned to us without prior permission.

This guarantee does not effect your statutory rights.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

CONTENTS

INTRODUCTION ............................................................... 2

GUARANTEE .................................................................... 2

CONTENTS ....................................................................... 3

OVERVIEW ....................................................................... 4

PREPARATION FOR USE .................................................. 5

Assembling the Jig................................................................ 5

Mounting the Jig................................................................... 5

Setting the End Stops............................................................ 6

Placing the Timber into the Jig............................................ 7

Setting the Template Position.............................................. 7

Setting the Backstop Position .............................................. 8

CUTTING A DOVETAIL ..................................................... 9

Preparation of Timber........................................................... 9

Setting the router Cutter depth .......................................... 9

Cutting the Joint ................................................................... 10

TROUBLESHOOTING ........................................................ 11

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

OVERVIEW

NO DESCRIPTION NO DESCRIPTION

1 Locking Clamp Handle 7 Backstop Locking Screw

2 Eccentric Cam 8 Horizontal Stop

3 Eccentric Bar 9 Vertical Stop

4Clamp 10Backstop

5 Clamp Adjusting Screw 11 Template

6 Template Securing Screw

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

PREPARATION FOR USE

ASSEMBLING THE JIG

Screw the front and top handles into

the eccentric bars.

• The workpieces will be locked

when the top locking clamp

handle is pushed away from

you and when the lower

locking clamp handle is pushed

downwards.

MOUNTING THE JIG

There are four holes provided in the base for mounting the jig.

1. Mount the jig to a bench as

shown and secure using suitable

screws (not suppled).

• The jig must be mounted flush

with the front edge of the

workbench.

• Make sure there is enough

space behind the jig to

accommodate the longest

length of timber you are likely

to work on.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

SETTING THE END STOPS

1. Use a set square to draw a pencil

line halfway across the first finger

of the template

• The line must be square to the

edges of the template.

2. Line up the inside edge of the left

horizontal stop with the line you

just drew on the template.

• Use a set square to ensure the

stop is square to the jig.

3. Offset the vertical stop 1/2” to the

right of the horizontal stop.

• Ensure the vertical stop is

square to the top of the jig.

4. Mirror these settings on the right

hand side of the jig.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

PLACING THE TIMBER INTO THE JIG

1. Align the timber so that the side of the workpiece is mounted in the front

vertical clamp.

• It should extend above the front edge of the jig by the thickness of

the piece to be mounted under the top clamp (front or back of the

drawer).

2. The piece of timber in the top

clamp is then butted up to this, so

that both pieces are flush under

the template.

3. The two pieces sit in the jig as

shown on the right.

• Make sure that both pieces are

butted up against the

horizontal / vertical stops.

4. Use the locking clamp handles to

secure the wood to the jig.

• You may need to adjust the top

and front clamp bars to suit the

thickness of the timber using

the clamp adjusting screws at

either end of each clamp bar

so that the wood is held firmly in

place

• When narrow pieces of wood

are being used, place another piece of wood (exactly the same

thickness) underneath the clamp bar at the opposite end to ensure

an even grip on the wood and to avoid distorting the bars.

SETTING THE TEMPLATE POSITION

1. Unlock the two template securing

screws and position the template

so that the tips of the fingers sit

3mm back from the edge of the

vertically mounted timber.

2. Lock the template into position

using the two template securing

screws.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

SETTING THE BACKSTOP POSITION

The distance the backstop needs to be positioned from the front of the

template fingers depends on the size of router base fitted to your router,

The formula to calculate this is:-

EXAMPLE

Using a router which has a base diameter of 160 mm, making a drawer that

has sides 18 mm thick and using the standard cutter supplied with a tip

diameter of 14.8 mm.

The distance from the tips of the template fingers to the vertical face of the

backstop should be set at 108.6 mm.

1. Set a micrometer or vernier

caliper to the calculated depth

and adjust the backstop as

shown.

2. Lock into place using the

backstop locking screws.

• It is not essential that this setting

is exact at this stage as final

adjustments can be made later

on.

• Ensure that the template and back stop stay parallel with the front

edge of the jig during this setting procedure.

cutter tip diameter

2 x width of the drawer sides )-( )

router base diameter

()+(

cutter tip diameter

2 x width of the drawer sides )-( )

router base diameter

()+(

14.8 mm

2 x 18 mm )-( )

160 mm

()+(

7.4 mm

)-( )

80 mm

()+(

Distance = 108.6 mm

36 mm

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

CUTTING A DOVETAIL

PREPARATION OF TIMBER

As with all detailed joinery the components must be sized, cut and squared

accurately.

• It is preferable that the width of the timber is in exact steps of 1/2" as

this will give a series of fully-formed dovetails.

The joints on the right of the project

(1 + 2) are cut on the left hand side of

the jig.

The joints on the left of the project

(3 + 4) are cut on the right hand side

of the jig.

• It is a good idea to identify the

drawer pieces as shown, so

that they are positioned

correctly in the jig.

The front and back pieces are mounted in the top of the jig with the inside

edges facing upwards and the top, butting up against the horizontal stop.

The left and right pieces are mounted vertically in the front of the jig with the

inside edges facing towards you and the top butting up against the vertical

stop.

SETTING THE ROUTER CUTTER DEPTH

1. Fit the bearing guided router bit securely into the router collet

2. Adjust the cutter depth, until the

bottom of the router bit protrudes

10-11 mm below the template

fingers.

• You may need to fit a packing

piece between the template

and the timber to ensure good

contact between the bearing

and the slots in the template.

• The cutting depth is critical to

the final fit of the joint, with as little as 0.5mm change in depth

making all the difference.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

CUTTING THE JOINT

You should carry out the initial cuts on two trial pieces of timber of the same

width and thickness as the final components. This will allow you to alter various

settings in order to get the joint to fit perfectly.

1. Position the router on the template with the cutter clear of the timber and

switch on your router.

2. Make the initial cut from the right, across the work, almost touching the end

of each finger.

• Avoid heavy-handed contact with the template, allow the router to

do the work.

3. Make the remainder of the cuts by following the template in and out of the

finger guides working from left to right.

4. When completed, switch the router off before lifting it from the jig.

5. Remove the pieces from the jig, make a trial fit and then, if necessary fine

tune the joint by making the following adjustments:

FINE TUNING THE JOINT

6. Having made the necessary adjustments we recommend that you make a

second trial cut.

7. Once the correct settings have been made then production runs of joints

can be undertaken,

• The settings will need to be checked periodically to maintain

accuracy.

CAUTION: DO NOT LIFT THE ROUTER FROM THE JIG WITH THE ROUTER STILL

RUNNING.

Problem Solution

Pins are too loose Increase the cutter depth by 0.5 mm.

Pins are too tight Decrease the cutter depth by 0.5 mm.

Pins stand proud of the joint Move the back stop further backwards.

Pins sit too deep in the joint Move the back stop further forward.

Pieces do not line up Adjust the horizontal/vertical stops

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