Dovetails - Incra Jig Process Improvement

Had some trouble with getting the Incra Ultra to cut joints the way I wanted consistantly. Loose joints drive me crazy! Anyway, I set forth to tighten things up with a process approach towards improvement.

The system now cuts near flawless 1/2 blind and full dovetails about every time. I’m looking forward to progressing to some of the more advanced joinery thats possible with the Incra system.

Of particular note: I replaced the slightly chewed up runners on the base of the Horizontal fixture with custom made plywood/polyethylene replacements. Extended them another 2” out the back from the originals for added support. The polyetylene was cut from a large cutting board purchased from sams club. That stuff even joints nice! The fixture slides much better now.

http://img.photobucket.com/albums/v83/tprofera/Img_1291.jpg
http://img.photobucket.com/albums/v83/tprofera/Img_1290.jpg
http://img.photobucket.com/albums/v83/tprofera/Incra_Horiz_Fixture_Runner_Parts.jpg
http://img.photobucket.com/albums/v83/tprofera/Incra_Horiz_Fixture_Runners.jpg
http://img.photobucket.com/albums/v83/tprofera/Incra_Horiz_Fixture_Setup_for_Use.jpg
http://img.photobucket.com/albums/v83/tprofera/Incra_Horiz_Runners_Pre_Install.jpg

Below are the steps I took to make what I think are marked improvements!:
DONE – Tighten all Screws on Fence and jig
DONE – Verify Incra Jig Fence is 90 to router table top – shim if needed
DONE – Remove jig from table and blow out dust – blow out and brush incra jig teeth
DONE – Adjust router Table plate to be level with router tabletop height
DONE – Verify Router Base Plate is tightly secured to router table plate
DONE – Measure dovetail router bits with calipers to ensure correct sizing
Mark with Sharpie the size and bit type on bit shaft.
DONE – Clean dovetails bits of pitch and touch up with diamond stone.
Make dovetail rabbeting standup push jig.
DONE – Make new Horizontal jig jig runners from UHMW or Polyethylene Cutting Board.
DONE – Make spares runner part for future use (both 5” and 7”)
Add Aluminum or Wood Cross Member to runner extensions.
Add Lead Weight to top of base of Horizontal Fixture.
Add a handle to Horizontal fixture to push with.
Install UHMW on inside of horizontal fixture Al slide.
Test cuts with an MDF backer board on Horiz. fixture?
DONE – Test locking the router height. Note: not needed
FUTURE – Install in the table dust collection?
FUTURE – Install a tabletop dust collection catch.

Hope this is helpful to somebody. Let me know if you have any questions.
I very much appreciate all that I’ve learned from you good folks here.

TJ
Life is too short…this is not a rehearsal.