Leigh F1 User manual

LEIGH USER GUIDE

Joining Tradition with Today

Finger Joint Template

ii

Your New Leigh Fingerjoint Template

You now own a unique finger jointing system.

The Leigh F1 template and Variable Guidebush

System (VGS) will help you rout a variety of

square and rounded finger or box joints with

unique adjustment for precise tightness of fit.

“Finger” and “Box”: Both words are used uni-

versally to title this simple but strong joint.

As the first machine-made joint, it’s old enough

to be called antique, so we have been even-hand-

ed in using both terms thoughout this guide.

We recommend that you first mount the F1 on

your D Series Leigh Jig carefully following the

instructions in the first section of the manual.

Important: Inches and Millimetres

Leigh makes the F1 attachment in two models;

inch or metric. Text and illustrations in this

Leigh English-language user guide indicate

dimensions in both inches and millimetres.

Dimensions are indicated in text and illustra-

tions with “inches” first, followed by “mil-

limetres” in square parentheses.

Example:

3

⁄

4

" x 5

1

⁄

2

" x 8" or longer [20 x 140 x 200mm]

Do not be concerned if the inch/millimetre equiv-

alents are not always exact. Just use the dimen-

sions which apply to your jig.

Where finger assembly or template scales

overlay an illustration, the “inches” scale ➀

will be at the top, the “millimetres” scale ➁

will be at the bottom. Only the right “active”

half of the scales are illustrated. For clar-

ity, setting positions are indicated in the

manual with a red line. On the jig, the

lines are black.

General views of the template will show

inch markings ➂.

3

1

2

Then read the rest of the manual, following

along with the basic functions, before you try

to do any actual joinery routing. By all means,

cut a few practice joints in scrap boards before

you use the F1 to rout a precious hardwood

workpiece.

If you have any questions that are not answered

in the manual, please call the most convenient

Leigh customer support line *.

*See Appendix IV – Customer Support

iii

Glossary of Symbols............................................................................................................iv

CONTENTS

CHAPTER1- Assembly, Mounting and Template Alignment........................1

CHAPTER2-Using Your Template Safely..........................................................15

CHAPTER3-Operation Concepts and Basic Template Functions..........21

CHAPTER4-The Variable Guidebush System (VGS)..............................27

CHAPTER5-Board Width Selection....................................................................33

CHAPTER6-Box Joint Procedures ......................................................................39

CHAPTER7-Rounded Half-Blind Finger Joint Procedures....................49

CHAPTER8-Square Half-Blind Box Joint Procedures............................57

CHAPTER9-Rabbetted Half-Blind Finger Joints............................................63

CHAPTER10- Small Box Joints ................................................................................67

CHAPTER11- Wider Box Joints ......................................................................79

CHAPTER12- Hints and Tips............................................................................85

Appendix I - Variable Guidebush Selection......................................................91

Appendix II - Cutter Selection and Joint Specification..................................97

Appendix III - Template Parts List ......................................................101

Appendix IV - Customer Support......................................................................105

iv GLOSSARY OF SYMBOLS

Glossary of Symbols

The Leigh F1 template can be in one of only

two modes with either the 1⁄2"and 1⁄4" [12mm]

comb sizes to the front or the 3⁄8" and 5⁄16"

[10 and 8mm] comb sizes to the front.

Scale Icons

This icon on the green scale

background indicates the active

scale for square box joints.

This icon on the gray scale

background indicates the active

scale for rounded finger joints.

Template Icons

Indicates the two template positions

for square box joints

Indicates the two template positions

for rounded finger joints

How to Read the Symbols

To help you understand the instructions and

illustrations in this manual, we have used a

number of international symbols, plus a few

special ones of our own. They are all explained

below. You needn’t worry about memorizing

these symbols now, because they are repeated

quite frequently in the manual, and you will

soon get used to them.

v

The following symbols indicate:

lLeft side of item (drawer, box,

case, etc.)

rRight side of item

tTop of item

bBottom of item

eThis edge against side stop

fThis edge against side stop

As above, other side of board

Sawcut allowance

Caution: use special care for this

operation

Which Way Round Should the Board Go?

Most joinery done on the Leigh jig is for case-

work (i.e., boxes, cabinets, drawers, chests and

so on) so in nearly all the illustrations we have

indicated which side of the board shows

outwards when it is in the jig, eg. in this fig-

ure the inside face iof the tail board is

away from the jig.

oThis indicates the side of the board that

will face outward on the finished

project.

iThis indicates the side of the board that

will face inward on the finished project.

jThis indicates a side that can face

either inward or outward on the

finished project

Dotted line icons are on the other side of

the board.

➀➁➂ Reference in text

Diameter

Centreline of board or layout

Equals

Does not equal

Approximately

Less than or equal to

Greater than or equal to

GLOSSARY OF SYMBOLS

vi

Assembly, Mounting and

Template Alignment

CHAPTER 1

Chapter 1 F1 User Guide

Assembly and Mounting

Before you begin mounting the Leigh F1 finger

joint template to your D Series jig, make sure you

have received the model ordered (Inch or Metric),

and all the necessary parts.

1. 1 complete F1 template “inch” assembly

or

1 complete F1 template “metric” assembly

2. Variable Guidebush System consisting of:

1 storage box

1 pin wrench

1 hex key (Allen wrench)

1 700V holder with lock ring

1 701V holder

1 709V bush* with F1 “inch” only

1 711V bush

1 713V bush

1 716V bush

6 bush nylon plugs (on one tree)

3. 1 locator

1 screw

1 washer

1 nut (for D1258-24 jigs only)

1 dial knob

4. 1 user guide

If any of these items are missing, please notify your sup-

plier or Leigh Industries immediately.

Your Leigh F1 comes fully assembled and requires

only mounting and indexing to your Leigh jig.

This procedure is critical to the accuracy of the

finished joinery, so please follow the mounting

instructions carefully.

ASSEMBLY, MOUNTING AND TEMPLATE ALIGNMENT

2

1

2

3

4

Illustration shows F1 "Inch". See below for your template model.

Check that you have received one of the templates shown below:

“Inch”

“Millimetres”

3

1-1

Mount the 24"[610mm] D Series dovetail

jig firmly to a bench as per that jig

’

s instruc-

tions. Remove the dovetail finger assem-

bly, front clamp bar and springs.

1-2

D1258, D1258R and D3 jig owners:

If you already own the Leigh Mortise and

Tenon Attachment, fit the extended sup-

port brackets ➀of this attachment and use

for all finger jointing and dovetailing

procedures. If not, mark the tops of the

arrow pointers on the standard support

brackets ➁with a dark felt pen.

D4 Jig owners already have the extended

brackets.

1-3

Loosen the two scale bar set screws ➀, the

two fence bracket screws ➁, and two scale

thumb screws ➂at both ends of the tem-

plate.

21

3

1

2

ASSEMBLY, MOUNTING AND TEMPLATE ALIGNMENT

Chapter 1

4

Chapter 1 F1 User Guide

1-4

Slide the template assembly onto the jig

support brackets with the 3⁄8" and 5⁄16"

[10 and 8mm] combs toward you and lower

it gently onto a 3⁄4"[20mm] thick spacer

board ➃(A piece of 3⁄4"x 51⁄2"[20x150mm]

about 23"[580mm] long). Make sure the

scale reading is the same on both scales, say

on the 1"[25mm] mark, then tighten the

thumb screws ➂.

1-5

Loosen the fence knobs ➄and move the

fence on the template toward you as far for-

ward as possible and with the fence scale

reading the same at both ends ➅. Then

tighten the fence knobs ➄.

1-6

Tighten the scale bracket screws ➁, but do

not tighten the scale bar ➀screws yet.

34

5

6

2

1

5

1-7

To ensure that you produce the precise joints

the Leigh F1 template was designed to pro-

vide, the following procedures must be care-

fully followed:

First, the template bar and template must

be centred exactly between the two scale

assemblies ➀and…

1-8

…then, the side stops must be positioned

precisely 241⁄8"[613mm] apart ➁and equidis-

tant from the centreline ➂. Here's how to

do it.

1-9

On the logical assumption that you do not

have access to a 25"[650mm] dial calliper,

Leigh provides tools that fulfil the same

function.

The dial knob ➀has a tapered axle and a

cam shaped hub, and acts as a micrometer

to centre the template bar between the scales.

Each minor dial increment equals

0.0015"[0,04mm] of template movement.

The part ➁is the side stop locator.

====

1 1

Inch

Metric

3

2

3

1 2

ASSEMBLY, MOUNTING AND TEMPLATE ALIGNMENT

Chapter 1

6

Chapter 1 F1 User Guide

1-10

Align the template so that the template’s

centre hole ➀ lines up with the hole in the

bar (it will only align with one hole in the

bar) and insert the template pin ➁. Gently

twist and push the tapered pin into the hole

until it is fully seated. The template is now

perfectly centred on its bar, but now we

must centre the bar in the scales.

Note: Discard the shipping plug from the

centre hole.

1-11

Place the dial knob in the hole in the left-

hand end of the template bar next to the

scale. Align the No.2 mark on the dial with

the small pointer on the grey scale ➀.

1-12

Gently move the complete template and

bar assembly to the left until the (cam) hub

of the dial knob stops against the scale body.

2

1

3

4

1

2

1

4

5/16"

3/8"

4

2

0

2

4

1

3

4

1

2

1

4

3

4

1

2

1

4

1/4"

1/2"

5/16"

3/8"

4

2

0

2

4

7

1-13

Taking care not to turn the knob or move

the template/bar assembly, carefully pull

the dial knob directly out of the bar. Insert

the dial knob into the hole in the right-

hand end of the bar with the grey scale

pointer pointing to the zero mark on the

dial knob.

1-14

Slowly turn the dial knob (either way) until

you feel the cam surface of the hub light-

ly touch the scale casting. It should touch

before the “5” indicator mark passes the

scale pointer. Note the dial reading, e.g. 4

in this illustration. If the dial knob hub

does not touch the scale casting, repeat

steps 1-11 to 1-14 but start at a higher dial

number in step 1-11.

1-15

Turn the dial back to the average of the dial

settings at the left and right-hand ends. In

this example (2+4)÷2 =3.

4

2

0

2

4

2

0

2

4

2

0

2

4

ASSEMBLY, MOUNTING AND TEMPLATE ALIGNMENT

Chapter 1

8

Chapter 1 F1 User Guide

1-16

Push the template/bar assembly to the right

until it stops with the dial knob’s cam hub

against the scale.

1-17

The template/bar should now be centred

on the jig. Double check by pulling the dial

knob directly out of the right-hand gap,

inserting it back into the left-hand gap with

the “0” mark next to the grey scale point-

er. Turn the knob and verify that the hub

cam touches the scale casting at the same

reading as on the right-hand end (i.e., at

“3” in this example). Don’t fret over an odd

increment; remember, each is only

0.0015"[0,04mm] of template movement.

1-18

When the dial knob’s hub cam touches the

scale casting at the same dial reading at both

ends of the template, the template/bar

assembly is centred on the jig. With light

pressure from the template holding the dial

knob against the scale casting at the cor-

rect reading, tighten first one scale bar screw

➀, then the scale screw at the other end ➁.

4

2

0

2

4

3

4

1

2

1

4

3

4

1

2

1

4

1/4"

1/2"

5/16"

3/8"

4

2

0

2

4

3

4

1

2

1

4

3

4

1

2

1

4

1/4"

1/2"

5/16"

3/8"

4

2

0

2

4

2

0

2

4

1

2

9

1-19

D1258 jigs only: Loosen both front side

stop bolts. Remove the left-hand side stop

assembly and slide the small tab nut from

the centring kit into the front extrusion.

Replace the left-hand side stop assembly,

but leave it loose. The tab nut will remain

in the extrusion after assembly.

1-20

D1258R and D3 jigs: Loosen both front

side stop bolts and move both of the assem-

blies slightly out from their original posi-

tions.

1-21

D4 jig: Loosen the front side stop bumpers,

move them outward from the centre of the

jig, and leave them loose.

ASSEMBLY, MOUNTING AND TEMPLATE ALIGNMENT

Chapter 1

10

Chapter 1 F1 User Guide

1-22

Remove the template pin from the centre

hole, move the template slightly to the left

and align the left hand hole with its match-

ing bar hole. Insert the template pin, again

gently pushing and twisting until it is fully

seated.

1-23

With the screw and washer from the loca-

tor kit, lightly screw the side stop locator

to the front extrusion with the Leigh logo

below the screw and the upper tip of the

locator projecting up through the last open-

ing in the 3⁄8"[10mm] comb. Do not tight-

en yet: the locator must be movable. D1258

owners will use the tab nut, D1258R, D3

and D4 jig owners will use the angled side

stop square nuts already in the extrusion

slot to attach the screw.

1-24

With the projections on the rear of the loca-

tor resting on the bottom edge of the extru-

sion T slot to act as a try square, slide the

locator to the left until the outside edge of

the upper tip just touches the outside of

the 3⁄8"[10mm] comb’s leftmost opening ➀.

Holding the locator square, tighten the

screw snugly using your Leigh square drive

screwdriver. Note: Your Leigh square drive

screwdriver is one size too small for this

screw but it's okay for this one time use.

1

11

1-25

D4 Jig: Move the side stop bumpers against

the locator and tighten them firmly. Remove

the locator from the front extrusion.

1-26

D1258 Jig: Move the washer type side stop

to touch the locator, then tighten the nut.

Remove the locator from the front extru-

sion.

1-27

D1258R and D3 Jigs: Move the plastic

side stop to touch the locator and hold firm-

ly square while tightening the nut. Remove

the locator from the front extrusion.

ASSEMBLY, MOUNTING AND TEMPLATE ALIGNMENT

Chapter 1

12

Chapter 1 F1 User Guide

1-28

Remove the template pin, slide the tem-

plate a little to the right, and align the right-

hand alignment hole with the matching

hole in the bar. Place the template pin in

this hole, gently turning it until it is fully

seated.

1-29

Reverse the locator to the right-hand end

of the jig, with the Leigh logo below the

screw, facing toward the jig. Lightly screw

it onto the extrusion. The locator’s upper

tip projects up through the last opening in

the 5⁄16"[8mm] comb, with the outside edge

of the upper tip just touching the outside

of the comb’s opening➀. Repeat steps 1-

24 to 1-27 but mirrored for this right-hand

end of the jig. Store the dial knob and loca-

tor kit in the VGS box liner for future use.

1-30

Align the rear side stops to the front stops

using the method described in your dove-

tail jig body assembly instructions. Now

that this side stop indexing is complete,

your jig is set up for all Leigh attachments.

1

13

1-31

Replace the front clamp bar and knobs or

cam clamps. Your Leigh F1 Template is now

ready for use.

ASSEMBLY, MOUNTING AND TEMPLATE ALIGNMENT

14

Chapter 1 F1 User Guide

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