Had trouble with getting the Incra Ultra to cut joints the way I wanted consistantly. Loose joints drive me crazy! Anyway I set to tighten things up with a process approach towards improvement. My system now cuts flawless 1/2 blind and full dovetails about every time now. I'm now looking forward to progressing some of the more advanced joinery thats possible with the Incra system.
Of particular note: 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.
Here are the steps I took to get it RIGHT!
INCRA JIG Improvements for cutting Dovetails:
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 good handle to Horizontal fixture to push with.
Install UHMW on inside of horizontal fixture Al slide.
Install 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.
Let me know if any of this is of help.
Life is too short...this is not a rehearsal.