[reuelt]

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

 

[reuelt]

You should only need one,

MORE THAN 2
ITEMS NEEDED FOR just Through Dovetail and Box Joint
Template 17/32",
7° Dovetail Bit 43776PC 13/32"
Straight Bit, 43743PC 3/4" O.D.
Template Guide, 42040 (with dovetail bit) 5/8" O.D.
Template Guide, 42046 (with straight bit)
Template Guide Lock Nut, 42239

 

[reuelt]

If he’s doing a variety. But if he’s doing standard 1/2 blind dovetails he only need one

Half-blind Dovetail Template
17/32", 7° Dovetail Bit 43776PC 3/4" O.D.
Template Guide, 42040
Template Guide Lock Nut, 42239

The ONE template guide is 42040 and NOT the 42046 (you suggested)

 

[reuelt]

Take a 42024 and trim off 18/32” – 7/32” = 11/32” (8.73 mm)
and you will get a 42040 sized template guide.
(easily done on metal lathe)

 

[reuelt]

one pre-owned 42040 is available at ebay

PORTER-CABLE 42040 3/4-inch Router Template Guide for sale online | eBay

Find many great new & used options and get the best deals for PORTER-CABLE 42040 3/4-inch Router Template Guide at the best online prices at eBay! Free shipping for many products!

www.ebay.com

 

[reuelt]

I tried the hack saw method of shortening the barrel of my PC aluminum guide bushing but the result was too ugly for my taste. Instead, I purchased the Wood River (Woodcraft) set of brass guide bushings. The Wood River set will work with template stock as thin as 1/4". I have been satisfied with my set. At the time I purchased the Wood River set, you could buy individual replacement guide bushings. If you drop a brass guide bushing, it may no longer be round. Don't ask how I know this.

Identical set available in many different brands too - All Made in China.
e.g.
DTC
O'SKOOL
Taylor Toolworks
Powertec
Rubyliutools