Porter-Cable 4210 & 4212 manual

Part No. A06477 - 02-23-05 DOVET AIL JIG SUPPLEMENT AR Y INSTRUCTION MANUAL The Model and Serial No. plate is located on the main housing of the tool. Record these numbers in the spaces below and retain for futur e refer ence. Model No. _____________________________________ T ype __________________________________________ Serial No.________________[...]

SAFETY GUIDELINES IMPORT ANT SAFETY INSTRUCTIONS ADDITIONAL SPECIFIC SAFETY RULES BACKGROUND INFORMA TION OPERA TION MISCELLANEOUS TECHNIQUES THROUGH-DOVET AILS WITH CLAMPING BOARDS THROUGH-DOVET AILS WITH UNLIMITED BOARD WIDTH AL TERNA TIVE METHOD - THROUGH-DOVET AILS WITH UNLIMITED BOARD WIDTH HALF-BLIND DOVET AILS WITH CLAMPING BOARDS USING A RO[...]

3 Indicates an imminently hazardous situation which, if not avoided, will r esult in death or serious injury . Indicates a potentially hazardous situation which, if not avoided, could r esult in death or serious injury . Indicates a potentially hazardous situation which, if not avoided, may r esult in minor or moderate injury . Used without the saf[...]

4 The details for basic joints are found in the instruction manual for the 4212 Dovetail Jig, along with information regar ding the use of various router bits and/or templet guides, and will not be r epeated in this supplemental manual. The purpose of this document is to provide you with an advanced knowledge of the jig and to pr omote that knowled[...]

5 OPERA TION MISCELLANEOUS TECHNIQUES Using these techniques can simplify your dovetailing projects. USE A DEAD-BLOW HAMMER Use a plastic dead-blow hammer to join your workpieces together to help prevent the marring of wood (Fig. 1A). CHAMFER THE T AIL EDGES Chamfering the inner tail edges can make the joints go together easier and may prevent dama[...]

6 THROUGH-DOVET AILS WITH CLAMPING BOARDS Y ou can use both the normal through-dovetail template (included with the 4212 Jig and the 4213 Accessory Kit), and the miniature thr ough-dovetail template (included with the 4215 Accessory Kit) with a clamping board. NOTE: Y ou can modify these clamping board methods to make box joints. SETUP Step 1 - Ste[...]

7 Fig. 6B Fig. 6C Fig. 6D CUTTING THE T AILS Step 3 - Step 1 - Step 2 - Clamp the tail board with the outside surface facing away fr om the clamping board (Fig. 7A). Align the tail board, using the instructions in your basic manual in the section “OPERA TION” . Look under “POSITIONING THE WOOD” , STEP 4 . This step is optional. Clamp stop b[...]

8 THROUGH-DOVET AILS WITH UNLIMITED BOARD WIDTH Y ou can cut dovetails in boards wider than the templates mounted on clamping boar ds by cutting the first part of the joint, sliding the templet down the workpiece, and cutting the rest of the joint. NOTE: Become familiar with the procedur e for cutting through-dovetails with a template on a clamping[...]

9 Step 3 - Step 1 - Step 2 - CUTTING THE T AILS Fig. 10B Fig.10A Step 5 - Step 4 - Fig. 10C Step 6 - Step 7 - Step 8 - Fig. 10D Clamp the tail board with the outside surface facing away fr om the clamping board (Fig. 10A). If the board is a width in 1" incr ements, (12", 13", etc.), center the edge of the board exactly between the tw[...]

10 AL TERNA TE METHOD THROUGH-DOVET AILS WITH UNLIMITED BOARD WIDTH This alternate method may be more accurate for correctly cutting the tail and pin boar ds. Step 3 - Step 1 - Step 2 - Clamp the tail and pin boards together with a 2" wide block (Fig. 13A). Use a square to align an edge of the tail and pin boar ds (Fig. 13B). Cut the pins and [...]

11 HALF-BLIND DOVET AILS WITH CLAMPING BOARDS Y ou can mount your half-blind template that comes with the 4210 and 4212 jigs and the 4211 accessory kit to a board. This method, however , limits your workpiece width capacity to 8". SETUP Items needed to setup for the half-blind dovetails: 1. W ood to make the clamping boar d parts 2. Clamps 3. [...]

12 CUTTING THE JOINT Step 3 - Step 1 - Step 2 - Clamp the tail board (drawer side) to the main clamping boar d with the outside surface facing the board (Fig. 16A). Move the offset clamping block to the right until it touches the tail boar d (Fig. 16B). Tighten the 1/4-20 x 4" bolt that holds the offset clamping block. Insert the pin board (dr[...]

13 Step 5 - Step 4 - Step 6 - Step 7 - Step 8 - Fig. 16E Fig. 16F Fig. 16D NOTE: Y ou can cut the pin and tail board separately , if you prefer . Slide the straight clamping block to the left so that it contacts the pin board (Fig. 16D). Hook the straight clamping block over the front and back of the main clamping boar d. Secure the pin boar d by c[...]

14 HALF-BLIND DOVET AIL BITS The differ ence in using alternate bits and standard bits in making half-blind dovetails is in the depth-of- cut. DOVETAIL BIT WOOD FOR HALF-BLIND JOINT HALF-BLIND TEMPLET TEMPLET GUIDE ROUTER SUB BASE DEPTH OF CUT FOR A HALF-BLIND JOINT Fig. 19A ROUTER SUB BAS E TEMPLET GUIDE DOVETAIL BIT DOVETAIL BIT DIAMETER WHEN THE[...]

15 Some items to consider when purchasing alternate bits for half-blind dovetails are: 1. A shallow angle of the bit requir es a deeper cut. A steeper angle requir es a shallower cut. 2. The diameter of the bit should be slightly greater than 1/2". The gr eater the diameter , the deeper the cut. 3. The bit should have a cutting length at least[...]

16 DOVET AIL DADO BITS Any dovetail bit can be used to make dovetail dados (sliding dovetails) as long as the bit does not cut into the template guide or the base of the jig. The process is identical to that of the standar d dovetail dado. Also, you can use template guides smaller than 3/4" OD which will have the effect of making the dado slot[...]

17 ROUTER SUB BAS E TEMPLET GUIDE DOVETAIL BIT DOVETAIL BIT DIAMETER WHEN THE DIAMETER OF THE ROUTER BIT IS GREATER THAN THE INSIDE DIAMETER OF THE TEMPLET GUIDE THERE IS A MINIMUM DEPTH OF CUT I.D. OF TEMPLET GUIDE Fig. 22A Cutting a dado with a templet guide that has an OD smaller than 3/4" requir es two passes. 1. Start on the left side. Ke[...]

18 MITERING THE PINS On the inside surface, use a square and pencil to draw a line fr om the base of the pins to the edge where the miter will be cut (Fig. 28A). Use a table saw with the miter gauge set to 45 ° to miter the squared-of f half pin (Figs. 28B and 28C). Step 1 - Step 2 - Remove the template, turn it horizontally so that the straight f[...]

19 Fig. 28B Fig. 28A Fig. 28C MITERING THE T AILS On the inside surface, use a square and pencil to draw a line fr om the base of the tails to the edge where the miter will be cut (Fig. 29A). Set the table saw blade so that the height of cut of the saw blade is the same as the thickness of the mitered half-pin. Use a table saw with the miter gauge [...]

20 HALF-BLIND DOVET AIL, SKIPPED PIN METHOD This method is similar to making standard half-blind dovetails, except that the tails and pins are cut separately . Cut the tails first. Use a scrap workpiece (thick enough to prevent contact with the base of the jig) to support the template. Fig. 33A Hold the pin board against the tail boar d and mark th[...]

21 Make a climb cut from right to left. Cut only between the fingers where you want the pins to be (Fig. 34A). Use the router to r ound over the ends of the cuts (Fig. 34B). The joint will hide any accidental excess material cut (A) Fig. 34C. Use a pencil to mark the location of the ends of the templet fingers on the wood (Fig. 34D). Remove the tem[...]

22 SA W KERF ALLOW ANCE METHOD An effective way to match the grain in a decorative box is to make the box fr om one piece of wood and then cut the lid with a table saw . However , if the dovetails are evenly spaced, they may be unattractive because the saw kerf removed needed material. NOTE: For this method, you will need a spacer block equal to th[...]

23 Center and clamp the tailboard as normal, but use the spacer on the left side of the boar d (A) Fig. 38A. (The spacer will cause the board to move slightly of f center to the right). Mark between the two fingers on the template where you want the kerf to be (B) Fig. 38B. Cut the tails from the far left to the right. Stop at the mark (Fig. 38C). [...]

24 END-TO-END JOINTS Y ou can use the 4200 series dovetail jigs to join boards end-to-end to incr ease length and to make visually interesting lar ger panels. BOX END-TO-END JOINTS Fig. 42A Remove the spacer and slide the pin board to the left (Fig. 39D). Start with the pin to the right of the mark and cut the rest of the pins to the right (Fig. 39[...]

25 The standard joint is shown is Fig. 42B and the end-to-end joint is shown in Fig. 42C. Fig. 42B Fig. 42C DOVET AIL END-TO-END JOINTS Fig. 43A Fig. 43B Fig. 43C A dovetail end-to-end joint is a combination of a box joint and a half-blind dovetail joint. the workpieces are mounted to the jig in the same way as for a box joint. However , the router[...]

26 Fig. 45C Fig. 45D Fig. 45E Fig. 45F Fig. 45G Fig. 45H Round over the ends of the two workpieces (Fig. 45C). Use a drill press to drill a hole in the center of each boar d for the hinge pin (Fig. 45D). Make an end-to-end box cut. (Make the depth-of-cut slightly deeper than the thickness of the boards (Fig. 45E). Make the length of the hinge pin n[...]

27 270 ° HINGES WITH A DRILLED HOLE Follow the previous dir ections for 180 ° Hinge and use the following photos to help you make a hinge that will have 270 ° or more range of motion. Cut the boar ds as shown in Fig. 46A. Fig. 46A Fig. 46B Fig. 46C 180 ° HINGES WITH ROUTER-MADE GROOVES When the width of the workpieces are too wide for a drill b[...]

28 Fig. 49B Fig. 49C Fig. 49D Fig. 49E Use a router to make a half-r ound dado near the end of a board. Make the diameter of the gr oove equal to the diameter of the hinge pin, and the depth of cut half the diameter of the hinge pin(Fig. 49B). Round over the ends of the boards (Fig. 49C). Cut off the ends of the boar ds. The length of the cut-off s[...]

29 ANGLED JOINTS OBTUSE ANGLED JOINTS Y ou can join boards at angles other than 90 ° . Four dif ferent methods ar e shown below by using the through dovetail procedur e. The simplest of these angled joints is the obtuse-angled dovetail. In this joint, two boards ar e joined together at an angle greater than 90 ° . Fig. 50A This joint can be made [...]

30 Fig. 53C Cut the end of the tail board accor ding to the instructions in the drawing (Fig. 53A). Y ou can make these cuts on a table saw with the blade beveled (Fig. 53B). Set the miter gauge at 90 ° for the first cut, then use a tenoning jig for the second cut (Fig. 53C). If you use the template mounted to the base of the jig, mount the board [...]

31 Fig. 53D Fig. 53E Fig. 53F CUTTING THE PINS Cut the end of the pin board accor ding to the drawing (54A). If you use the template mounted to the base of the jig and a 12" angled insert, remove the small fr ont knobs, clamping rod and clamping U channel. Then r emove the angled insert and reinstall the har dware. Hold the boards together and[...]

32 CUTTING THE PINS Cut the end of the pin board accor ding to the instructions on the drawing (Fig. 57A). Steep angles or thin wood will make for a weak joint. Make this cut on a table saw with the blade beveled, and with the miter gauge set at 90°. Clamp the workpiece as you did for the obtuse-angled joint. Hold the boards together and mark the [...]

33 SLANTED-SIDE JOINTS T wo boards joined at 90 °, with one boar d slanted to the side is known as a slanted-side joint. This method is used to make a box with the ends at right angles to the table, but with the sides tilted outward (cradles, planters, magazine racks). Fig. 58A Fig. 58B NOTE: Usually , the tails are cut into the ends and the pins [...]

34 COMPOUND-ANGLE JOINTS T wo boards joined at 90 °, with both boar ds slanted to the side is known as a compound-angle joint. This method is used to make serving trays or planters. Fig. 62C Fig. 62A Fig. 62B Side Angle Side Angle FITTING THE JOINT Fitting the joint is the same as fitting the standard dovetail. HINT : Use pieces of scrap wood the [...]

35 NOTE: The instructions given here ar e for templates mounted to the base of the jig. However , this joint can also be made with templates mounted to angled clamping boards. Y ou must use the angled clamping board for steeper angles. Use the following table for setting up your table saw for these cuts: DESIRED SIDE ANGLE 85° 80° 75° 70° 65° [...]

36 CUTTING THE PINS Cut the end of the tail board accor ding to the drawing (Fig. 65A). Set the miter gauge and tilt the blade to the values in the previous table. Remember that the miter gauge for the tailboar d must be tilted opposite for the pin board. If you are using the 12" long angled insert, r emove it from the jig. Hold the outside su[...]

37 FITTING THE JOINT Fitting the joint is the same as fitting the standard dovetail. HINT : Use pieces of scrap wood the same thickness and species of wood to make test pin boards until the template is adjusted for a perfect fit. INLA YED JOINTS The 4200 series dovetail jigs will allow you to make joints with inlays of differ ent colored wood for a[...]

38 If desired, you can cut of f the small area shown fr om the remainder of the inlay wood (Fig. 68C). If left on, the completed joint will have an extra amount of material on the inside. another alternative is to bevel this extra material (Fig. 68D). MAKE THE SECOND JOINT Make the second joint the same way as you would a standard thr ough dovetail[...]

39 SETUP Select one set of dovetail bits from the table for Combinations for Half-blind dovetails with the pins and the tails cut separately in the section "T ABLES OF COMMONL Y A V AILABLE ROUTER BIT SIZES" . Use the following table to determine the thickness of the inlay line: Dovetail Bit Set H1 H2 H3 H4 H5 Thickness of Inlay Line in D[...]

40 INLA YED BOX JOINT This joint is made by cutting two box joints on top of each other . SETUP Select one set of dovetail bits from the table for “Box Joint Bit Combinations" in the section "T ABLES OF COMMONL Y A VAILABLE ROUTER BIT SIZES" . Use the following table to determine the thickness of the inlay line: Straight Bit Set B2[...]

41 THROUGH DOVET AIL ROUTER BIT COMBINA TIONS T ABLES OF COMMONL Y A V AILABLE ROUTER BIT SIZES Combination Number T1 T2 T3 T4 7° Dovetail Bit 3/4" 5/8" 9/16" 17/32" Straight Bit 3/16" 5/16" 3/8" 13/32" HALF-BLIND DOVET AIL BITS Bit (Diameter and Angle) Approximate* Depth of Cut Combination Number H1 H2 H3 H[...]

42 REPLACEMENT P ARTS When servicing use only identical replacement parts. SERVICE AND REP AIRS All quality tools will eventually requir e servicing or replacement of parts due to wear fr om normal use. These operations, including brush inspection and replacement, should ONL Y be performed by either an AUTHORIZED PORTER-CABLE SER VICE ST A TION or [...]

43 PORTER-CABLE LIMITED ONE YEAR WARRANTY Porter -Cable warrants its Professional Power T ools for a period of one year from the date of original purchase. W e will repair or replace at our option, any part or parts of the product and accessories covered under this warranty which, after examination, pr oves to be defective in workmanshi p or materi[...]

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