On 12/17/2020 5:15 PM, StevenWoodward wrote:
I struggled with the Porter Cable Dovetail Jig model 4212, because it
would not give me consistent results in tightness of joint and alignment
of pieces. With a few modifications to eliminate variation, I was able
to get consistent results. I keep a dedicated router with the bit
installed so that I can set up quickly and make a perfect fitting drawer
on first try without any adjustments to the jig or router. Saves a lot
of time.
Modifications are explained in this YouTube Video
https://youtu.be/hTRCSAM-YTk
I am interested in any other ideas to improve the Porter Cable Dovetail Jig


As with 90% of all jigs that use templates there are numerous steps that
have to be taken to insure a proper fit.
I have had 2 different DT jigs and they were about equal in delivering
results. A Craftsman and a Leigh D4 jig.

You have made tweaks and extra parts to over come the jigs deficiencies.
And you have dedicated a router, guide bushing and DT bit to eliminate
set up tweaking, of your router, every time.

Unfortunately that bit will have to be replaced at some point and test
fitting with different depths will have to be done over again.

Your set up looks to be working out pretty good for small jobs. But
with larger and multiple projects you will probably do more adjustments.

I have pretty much given up on template jigs altogether at this point.

Several days ago I built boxes with box joints with a relatively new
approach. While box joints are somewhat simpler than DT's, the accuracy
of my new tool should make repeatable accuracy a breeze. Set up and a
test cut took me approximately 2 minutes and I was on my way to cutting
728 slots and pins for these 14 boxes, for the very first time ever with
this new tool.

My new tool, the Shaper Origin and Workstation are absolutely not for
every one but if you do sell your work it pays for itself in time
savings in short order. The Shaper Workstation incorporates a
shockingly simple indexing set up that is absolutely spot on and never
ever needs adjustment. I cannot help but wonder why no one has thought
of this before now.

The Origin is basically a hand held CNC machine with repeatable accuracy
down to .001". With the replacement of any bit, even mid cut into a
series of pins and tails or pins and slots, setting the correct depth is
a 5 second step. The Origin remembers the proper depth of cut and
calibrates during that 5 second step.

If you ever tire of the typical template guided DT jig, take a look at
Shaper Origin and its Workstation. Pricey but it does much much more
than cut finger or DT joints.