Woodhaven 7640: Keller Dovetail Kit - Manual (Page 2)

CUTTING PINS
Install the Keller Pin Template (7640T2) in place of the
Keller Dovetail Template. Install the straight bit (7543) in your
router. Set the depth of cut to 1/64" to 1/32" more than the
thickness of your stock, taking into account the 1/2" thickness
of the Pin Template.
Install a new piece of scrap in place of the scarp
used for the dovetails, following the same process.
Install the work in the front of the jig with the INSIDE
FACE of the part against the Ultra Track. Place the end of
the work against the underside of the template and the edge
of the work against the edge of the stop. The stops must
not be moved from the location they were at when you cut
the dovetails or the parts will not line up when assembled!!
Tighten the front clamps to hold the work in place. See fig. 3.
Make a test cut in some scrap. Cut from left to right,
following the fingers of the template. If you get chipping on
the face of your work you may need to clamp a scrap
of 1/4" plywood or hardboard to the face of the work.
Test the fit of the pins in the dovetailed part. The
parts should go together with light tapping at most. If the
pins are too loose, move the Pin Template forward. If the
pins are too tight, move the Pin Template back. A 1/16"
(.0625) adjustment (forward or back) of the Pin Template
makes a 1/64" (.015) difference in pin width. The template
brackets/pin template are adjusted in or out by loosening
the two 3/4" bolts holding the template brackets to the tem-
plate nuts. Make equal adjustments to both template brack-
ets. When satisfied, make all the pin cuts on all of your
parts. See fig. 4.
Any excess overhang of pins and dovetails can be
removed by sanding or routing after assembly.
©Copyright WOODHAVEN INC. 9/10/07
(800) 344-6657 or WWW.WOODHAVEN.COM
Template
Bracket
Template
Move template
brackets/pin template
forward to make
the pins larger and
tighten the joint..
Move template brackets/
pin template back to
make the pins smaller
and loosen the joint.
4
3