Instruction/ maintenance manual of the product 4210 Porter-Cable
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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.
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 .
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.
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.
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.
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” .
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.
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.
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.
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.
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).
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.
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.
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".
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.
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.
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.
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.
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.
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.
22 SA W KERF ALLOWANCE 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.
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.
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).
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.
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.
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.
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.
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 ° .
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.
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.
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°.
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).
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.
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.
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.
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.
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).
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" .
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 V AILABLE ROUTER BIT SIZES" .
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 .
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.
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.
The following are trademarks of POR TER-CABLE • DEL T A (Las siguientes son marcas registradas de PORTER-CABLE • DEL T A S.A.) (Les marques suivantes sont des marques de fabriquant de la POR TER-CABLE • DEL T A): Auto-Set ® , BAMMER ® , B.O.S.
An important point after buying a device Porter-Cable 4210 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Porter-Cable 4210 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Porter-Cable 4210 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Porter-Cable 4210 you will learn all the available features of the product, as well as information on its operation. The information that you get Porter-Cable 4210 will certainly help you make a decision on the purchase.
If you already are a holder of Porter-Cable 4210, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Porter-Cable 4210.
However, one of the most important roles played by the user manual is to help in solving problems with Porter-Cable 4210. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Porter-Cable 4210 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
