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Discussion Starter · #1 ·
I have a Porter Cable Dovetail Jig model 4210 that I have not used for sometime. Recently I tried to set it upgh. and ran in an issue with the guide bushing. It pertrudes below the template. I am using a Dewalt Router, I am suspious that the router base is not thick enough. Any help would be appreciated.
 

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I have a Porter Cable Dovetail Jig model 4210 that I have not used for sometime. Recently I tried to set it upgh. and ran in an issue with the guide bushing. It pertrudes below the template. I am using a Dewalt Router, I am suspious that the router base is not thick enough. Any help would be appreciated.
What model is your Dewalt router?
You may need to get the
DEWALT 32912001 Guide Bushing Adapter
and
then use
Porter Cable branded Guide bushings with your router

Bicycle part Rim Auto part Circle Nickel
 

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G'day Fibber, welcome to the forum.

How thick is the template?

Easiest way would be to trim the guide bushing so that it protudes only 1/4".

I had to do that with one of my guide bushing sets.
 
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Welcome. I gave up on mine. Watched an experienced woodworker use one and she couldn't get the pins and tails to fit after an hour. I don't recall that you use a bushing with that jig, don't you just use a top bearing bit? I switched to a Sommerfeld Katy Jig (like the Leigh), where you move the jig on a fixed router. Much easier to set up and use.

Here's a video that may help...https://www.youtube.com/watch?v=37wzUGaYqDw
 

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Your dovetail jig should have come with a bushing that was just a little thinner than the templates. Mine did. I don't use the dovetail jig much as I can cut dovetails using my CNC, but I do use the thin bushing with other templates I made for other jobs. 5/8" outside diameter. Should look like this:
 

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Discussion Starter · #14 ·
The orignal guide bushing was P/N 42040. Unfortunately PC has discontinued the item. Per their Service personnal they reccommended the p/n 42024, which I purchased only to find that the guide sleve was approx 5/8" long, which extends approx 1/4" below the template. Somebody at PC does not know what they are doing. That said another forum member found and alternative on Amazon, which I am about to order. Thank you for your efforts.
 

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OK, so we find that you were not using the correct guide bushing!!!
Not you fault...

I would trim back the one you have with a hack saw, and tidy up with high grit sandpaper.

I did see a Youtube video showing how, but cannot find it....
 
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Discussion Starter · #17 ·
My Dewalt accepts PC Guide bushings as long as they are compatable with the template. I have inquirery with PC Service. Depending on their response, I going to give them a piece of my mind the incorrect information. I ordered the alternative bushing from Amazon, I expect it to arrive next Friday
 
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