MILESCRAFT PocketJig400 Pocket Hole Jig Instruction Manual

PocketJig400 Pocket Hole Jig
Instruction Manual

Pocket Jig400™

1 — Main Body
2 — Clamp Base Screw (2)
3 — Clamp Base
4 — Fence
5 — Dust Port
6 — 3mm Hex Key
7 — 3/8″ Stop Collar
8 — 3/8″ Pocket Hole Drill Bit
9 — 6″ T20 Hex Shaft Driver Bit| 10 — 1˝ T20 Screws, Coarse (10)
11 — 1-1/4″ T20 Screws, Fine (10)
12 — 1-1/4″ T20 Screws, Coarse (10)
13 — 1-1/2″ T20 Screws, Coarse (10)
14 — 2″ T20 Screws, Coarse (10)
15 — 2-1/2″ T20 Screws, Coarse (10)
16 — Pocket Plugs (10)
17 — Mounting Screw (4)
18 — Storage Drawer
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APPLICATIONS FOR THE POCKETJIG400™

PACKAGE CONTENTS:

Unpack all items and check with Figure 1 and “Replacement Parts table” (see page 16). Make sure all items are accounted for before discarding any of the packing material.  For any missing parts, contact Customer Service at info@milescraft.com or 1-224-227-6930 in U.S. and Canada.
Outside of the U.S. and Canada dial
001-224-227-6930.

SAFETY WARNING:
Read, understand, and follow your power tool manufacturer’s instructions for safety. Always wear safety glasses or eye shields before commencing power tool operation.  Always keep hands, face, hair, loose clothing, and body at a safe distance from spindles and cutting tools. Always keep a firm grip on tool handles when in operation. Always  disconnect from power source before adjusting power tools.

Screw Length & PocketJig400™ Setting Based on Material Thickness

Board| Jig Setting
| Depth Setting
| Screw

---|---|---|---
Imperial| Metric| Imperial| Metric| Imperial| Metric| Imperial| Metric
1/2″| 12mm| 1/2″| 12mm| 1/2″| 12mm| 1″| 25mm
3/4″| 13-19mm| 3/4″| 19mm| 3/4″| 19mm| 1-1/4″| 30mm
1″| 20-27mm| 1″| 27mm| 1″| 27mm| 1-1/2″| 40mm
1-1/2″| 28-38mm| 1-1/2″| 38mm| 1-1/2″| 38mm| 2-1/2″| 60mm

T20 Self-Tapping Pan Head/Washer Head Screws

• Provides more positive connection between the bit and the screw head.

Self-Tapping Coarse Thread Screws
Used for softwoods & composite materials: Pine, Cedar, Basswood, Poplar, Plywood, MDF, and Particle Board

Self-Tapping Fine Thread Screws
Used for hardwoods: Ash, Oak, Maple, Walnut, Hickory, Cherry, Mahogany, and Birch

HINTS

1. The included drill bit, driver, Stop Collar, Fence, and Hex Key can be stored in the Storage Drawer (see FIG. 1).
2. The Stop Collar helps to prevent the drill bit from rolling off your work surface.
3. Use the removable Dust Port to minimize the amount of dust. The Dust Port fits 1-3/8″ OD, 1-5/16″ ID and 2-1/2″ OD, 2-1/4″ ID vacuum hoses (see FIG. 2).
4. The jig base has a height of 3/4″. For longer work pieces, use 3/4″ scrap material as an extended platform (see FIG. 3).
   See page 14 for a plan to make a Mounting Base.
   5We recommend using Milescraft ® Pocket Hole screws, items #5200-5206 & 5209. You may use standard flathead screws. Tapered screws should be avoided as they can split the wood (see FIG. 4).

SETTING YOUR POCKETJIG400™

1. Measure the board thickness. If measurements differ, be sure to use the measurement of the thinnest board. Using the measurement from the thinnest piece, set the Drill Block height, bit depth, and choose screw length.

2. Turn the red knob on the Drill Block counter-clockwise to loosen. Using measurement from step 1, raise or lower the Drill Block until the indicator line on the block  aligns with one of the 4 setting options. For example, setting for a 3/4″ (19mm) thick board, (see FIG. 1a). For a 1-1/2″ (38mm)thick board, (see FIG. 1b). Slightly  tighten the Drill Blocks.

3. With the toggle clamp handle in the downward, clamped position, place the work piece between the clamp pad and Drill Blocks. Adjust the clamp pad and hex nut until the work piece just fits (see FIG. 2, Page 7).

4. Release the clamp handle. Give the clamp pad one fullturn outward, while adjusting the hex nut. Tighten the hex nut by hand to avoid over tighten (see FIG. 3).

5. Determine the spacing of the Pocket Holes based on the width of the work piece. There’s a scale on top of the L-Base, loosen the Drill Block knob and align the center  marks of the Drill Blocks to the desired setting (see FIG. 4a). Tighten the knob to lock the Drill Blocks in place (see FIG. 4b).
   Be sure the Pocket Holes are not too close to the edges of the work piece.

6. Press the handle down to clamp the board in place (see FIG. 5). Make sure the clamping pressure is enough to secure the work piece without being too tight. Adjust if necessary.

7. There are mounting holes to screw (screws are included) the jig down (see FIG. 6a) and a Clamp Base (see FIG. 6b) to secure the jig to your work surface. Use a Milescraft® #4001 FaceClamp™ or similar (a larger clamp may be necessary).

GETTING READY TO DRILL

1. Using the included Stop Collar and drill bit, you are now ready to set your drilling depth. The Storage Drawer has four built-in depth settings for the drill bit. Rest the drill bit into the built-in depth setting slot and align the step of the drill bit with the matching board thickness you are planning to drill. (See FIG. 1)
   Assure the step of the bit is aligned to the recess and not the pilot tip.
   The inside of the drawer is marked with both Imperial and Metric measurements.

2. Slide the Stop Collar onto the shank side of the bit and rest it in the Stop Collar recess (see FIG. 2a), up against the drawer, and tighten the Stop Collar using the Hex  Key (see FIG. 2b).

3. With your work piece in-between the Drill Blocks and clamp pad. Press the clamp handle down to secure your work piece.
   Never attempt to drill a hole without making sure the jig is completely secured.

DRILLING YOUR POCKET HOLES

1. Chuck the drill bit into the drill (follow your manufacturer’s instructions)

2. Insert the drill bit halfway into the drill guide bushing and then turn your drill on at full speed (min. 2,000 RPM).
   The Stop Collar needs to contact the rim of the drill guide bushing to ensure you have met your proper depth (see FIG. 2a & 2b).

3. Repeat until all holes have been drilled.

It’s recommended to use the removable Dust Port to minimize the amount of dust (see FIG. 3).
DRILL BIT NEEDS TO BE AT FULL SPEED BEFORE CONTACTING WITH THE WOOD SURFACE.
AVOID DRILLING THROUGH KNOTS.
DO NOT ATTEMPT TO DRILL WHEN HOLDING THE JIG IN YOUR HAND. THE TOOL MUST ALWAYS BE SECURED. FAILURE TO DO SO CAN  RESULT IN PERSONAL INJURY OR DAMAGE TO THE PRODUCT.

DRIVING YOUR SCREWS

1. Using the screw chart on page 4, select the appropriate screw length for your Pocket Holes. (For 1-1/4″ screws you will have the option of fine thread or coarse thread.)

2. Remove the drill bit from your drill and insert the included driver bit. Line up your boards to be joined and clamp them together in their final position (see FIG. 1a-1c).

3. Drive your pocket screw into the Pocket Hole. Make sure the screw goes into the second board to create a strong joint (see FIG. 2). Repeat steps until all screws have been driven into the Pocket Holes.
   ****Due to the varying material hardness, we recommend that you drive a few test screws to ensure that the resulting joint is satisfactory. If boards will not have to be  disassembled later, glue can be used for additional strength.

4. Your Pocket Holes are designed to accept standard 3/8″ Pocket Plugs. Be sure to place a small amount of glue into the Pocket Hole and on the pocket plug, slide it into the Pocket Hole. Do not push the plug in too far, it should sit above or flush with the surface of your work piece (see FIG. 3). Some sanding may be required for a flush  surface after the pocket plug has set.

USING THE PORTABLE L-BASE

1. The L-Base can be detached to use as a portable unit.
   Turn the jig over, remove the two hex screws that keep the L-Base secured to the Main Base. (see FIG. 1).

2. Refer to the table on page 4 to select the correct Screw, Jig and Stop Collar settings for your repair.

3. For unassembled pieces, use the included Fence. With the Hex Key, use the hex screws that secured Portable L-Base to fasten the Fence (see FIG. 2). Make sure the Fence is facing down.

4. With your work piece on a support board and/or workbench, align the Portable L-Base flush to the edge of the work piece. Clamp your work piece and Portable L-Base  as shown (See FIG. 3). The Portable L-Base has a recessed clamp pocket for using a Milescraft® FaceClamp™ or similar.

5. The L-Base can be used without the Fence for making repairs with restrictive access. Locate the L-Base as necessary to drill for Pocket Hole Screw placement.
   Smaller repairs may only require one screw. Center one Drill Block for single screw repair (See FIG 4).

Never attempt to drill a hole without making sure the jig is completely secured.

MOUNTING BASE PLAN

REPLACEMENT PARTS

© 2022 Milescraft, Inc.
Patent Pending
milescraft.com

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