Woodhaven 4556: Portable Box Joint Jig User Manual

Page 2

Install Clamps:

The Clamps get installed on the rear upper T-slot of the 12" Ultra

Track. The two Clamps (4556B2) have a hex bolt and pin that fits

into the T-slot of the track. Loosen the knob and slide the bolt head into
the T-slot first, followed by the pin. When the pin is inside the T-slot a
1/2" or so from the end of the track, tighten the knob on the hex bolt.
Reposition the Clamps if necessary to avoid interference with your router.

Clamp Plate:

Rear View

Install Router Supports & Router Stops:

Slightly loosen the Stops and Sub-Fences installed before so they don't interfere with the installation and tightening of the Router

Supports. The Router Supports a Router Stops get installed on the top T-slot of the 12" Ultra Track. The two Router Supports (4556B1)

and Router Stops (4556C) are identical and are ribbed to fit into the T-slot of the track. Slide one of the Router Supports in from the left end of
the Ultra Track, position it 2-3/4" in from the left end of the track and firmly tighten the two screws. This Left Router Support should NEVER
be adjusted from this position.

Determine what size joint you'll be cutting. For 1/2" to 1" joints, you'll use one

Router Stop (4556C) between the Router Supports. For joints larger than 1", place
both Router Stops between them. Place the Router Stops so their long end over
hangs the sub-fences. Attach one or both Router Stops to the track.

Slide the Right Router Support on the track, position it about 1" from Left

Router Support and loosely tighten it. The Right Router Support is what you will
adjust to set the joint size. If you have one Router Stop left, install it near
the Right Router Support.

The Stops and Sub-Fences should

be flush against the underside
of the Router Supports, then
retightened.

Left Router Support

4556B1

Right Router Support

4556B1

4556C

4556B2

4556C

2-3/4"

Adjust Clamps for work thickness:

Place the work between the Clamp Pad and the Sub-

Fence. Position the Clamp Pad so it's flat against the work

by adjusting the 3/4" knob at the back of the Clamp. Make sure
the end of the bolt on the 3/4" knob remains bottomed out in the
recessed hole at the back of the Clamp Pad. Next turn the 3/4"
knob approximately 1/4 turn more, pushing the top of the Clamp
Pad slightly away from the work. When tightened, the Clamp Pad
should sit flat on the work. Tighten the 2" T-Knob at the front of the
Clamp Pad until the Jig is snug on the work. Do not over tighten!
You'll also need to provide a 6" bar clamp (for the first
and last few cuts on the work) to clamp the opposite side
of the work from the Clamp Pad when it's only possible
for one of the Clamp Pads to engage on the work.

Bar

Clamp