Porter-Cable OMNIJIG 5116

The Porter-Cable OMNIJIG® is a professional power tool designed for creating various types of woodworking joints, primarily dovetails and box joints. It is used in conjunction with a Porter-Cable router, templet guides, and router bits to produce precise and strong corner joints for drawers and boxes, as well as sliding joints for shelves.

Function Description

The OMNIJIG® facilitates the routing of different joint types by providing a stable clamping system for workpieces and a templet guide for the router. The user secures the wood pieces in the jig, positions the appropriate templet, and then guides a router with a specific bit along the templet's contours to cut the desired joint. This process ensures consistent and accurate cuts, making it suitable for both hobbyists and professional woodworkers.

Important Technical Specifications

The OMNIJIG® comes in two main models:

Model 5116 (16"): Accommodates stock up to 16" wide and 5/16" to 1" thick.
Model 7116 (24"): Accommodates stock up to 24" wide and 5/16" to 1" thick.

Accessory Templets and Bits: The manual lists several accessory templets and corresponding router bits for different joint types:

1/2" Half-Blind Dovetails:
- Templets: Model 5117 (16"), Model 7117 (24")
- Dovetail Bit: 43640 (High Speed Steel) or 43705 (Carbide Tipped)
- Templet Guide: 42046 (5/8")
- Lock Nut: 42237
1/4" Half-Blind Dovetails:
- Templets: Model 5120 (16"), Model 7120 (24")
- Dovetail Bit: 43639 (High Speed Steel)
- Templet Guide: 42054 (5/16")
- Lock Nut: 42237
1/2" Hand Dovetails (2" Spacing):
- PINS Templets: Model 5118 (16"), Model 7118 (24")
- TAILS Templets: Model 5119 (16"), Model 7119 (24")
- Dovetail Bit: 43640 (High Speed Steel) or 43705 (Carbide Tipped)
- Templet Guide: 42046 (5/8")
- Lock Nut: 42237
Adjustable Through Dovetails:
- Templets: Model 5122 (16"), Model 7122 (24")
- For 3/4" Dovetails (stock up to 13/16" thick):
  - Dovetail Bit: 43775 (Carbide Tipped, 1/2" Shank) or 43774 (Carbide Tipped, 1/4" Shank)
  - Straight Bit: 43303 (High Speed Steel) or 43300 (Carbide Tipped)
  - Templet Guide: 42046 (5/8")
  - Lock Nut: 42237
- For 1/2" Dovetails (stock up to 1/2" thick):
  - Dovetail Bit: 43640 (High Speed Steel) or 43705 (Carbide Tipped)
  - Straight Bit: 43328 (Carbide Tipped, 9/16" with 1/2" O.D. Bearing)
  - Templet Guide: 42046 (5/8")
  - Lock Nut: 42237
1/2" Box Joints:
- Templets: Model 5123 (16"), Model 7123 (24")
- Straight Bit: 43321 (High Speed Steel) or 43318 (Carbide Tipped)
- Templet Guide: 42046 (5/8")
- Lock Nut: 42237
Tapered Sliding Dovetails:
- Templets: Model 5121 (16"), Model 7121 (24")
- Dovetail Bit: 43640 (High Speed Steel) or 43705 (Carbide Tipped)
- Templet Guide: 42046 (5/8")
- Lock Nut: 42237

The OMNIJIG® base includes two clearance holes for 3/8" dia. bolts for secure mounting to a workbench or stand.

Usage Features

The OMNIJIG® is designed for versatility and precision in woodworking joinery. Key usage features include:

Secure Clamping System: The jig features front and top clamps (items 2 and 3 in Fig. 2) with clamp nuts (item 11) and clamping levers & knobs (item 13) to securely hold workpieces. The clamp nuts can be adjusted to maintain uniform clamping pressure.
Adjustable Templet Location: The front-to-back positioning of the templets (item 4) is adjustable using spacers (item 14) and rod nuts (item 15), allowing for fine-tuning of the templet position for different joint requirements.
Stop Bars: The jig incorporates top and front stop bars (items 6, 7, 8, 9) with locking screws (item 10) to accurately position workpieces for routing.
Router Setup: The manual provides detailed instructions for setting up the router, including inserting the correct templet guide and dovetail bit, and adjusting the bit projection for specific joint types (e.g., 19/32" for 1/2" half-blind dovetails, 5/8" for 1/4" half-blind dovetails).
Joint Types: The OMNIJIG® supports a wide range of joint types:
- Half-Blind Dovetails (1/2" and 1/4"): Primarily used for attaching drawer fronts to sides, where the dovetails are not visible from the front. The process involves clamping drawer side (pin board) and front (tail board) pieces, positioning the templet, and routing. Adjustments for joint tightness (loose or tight) are made by increasing or decreasing the depth of cut, and for overhang by adjusting the templet position.
- Half-Blind Rabbeted Dovetails (1/2" and 1/4"): Used when the drawer front overlaps the sides. This requires a pre-cut rabbet on the drawer front and separate routing of the front and sides.
- Hand Dovetails (1/2", 2" Spacing): Designed to produce widely spaced half-blind dovetails and exposed joinery, mimicking traditional hand-cut joints. This involves separate templets for pins and tails, and careful consideration of material width to ensure centered dovetails or to manage partial pins.
- Adjustable Through Dovetails: Replicates the hand-cut version found on antique furniture. This process involves cutting female dovetails (tails) first, then male dovetails (pins). It requires specific spacer configurations and careful router bit selection (dovetail bit and straight bit). Adjustments for fit are made by turning bracket rod nuts.
- Box (Finger) Joints (1/2"): Used for strong corner joints in boxes, eliminating the need for nails or screws. This involves using a straight bit and a box joint templet, with careful centering of the board and routing both ends of the material.
- Tapered Sliding Dovetails: A method for joining shelf boards to sides, common in bookcases and cabinets. The taper allows the male dovetail to slide freely and tighten when seated. This templet has two slots (male and female) requiring careful router operation. The depth of cut controls the tightness of the joint.
Safety Precautions: The manual emphasizes several safety rules, including securing the work, keeping hands clear of cutters, maintaining a firm grip on the router, ensuring the motor has stopped before adjustments, and using safety glasses and ear protection. It also warns about toxic preservatives in some wood and the importance of reading all instructions.

Maintenance Features

The OMNIJIG® requires minimal but consistent maintenance to ensure longevity and proper function:

Cleaning: All plastic parts should be cleaned with a soft cloth. Solvents should be avoided as they can damage the material.
Rust Prevention: Steel parts of the clamp assemblies should be periodically coated with wax to protect against rust.
Part Replacement: When servicing, only identical replacement parts should be used.
Cord Inspection: Power cords and strain relievers should be inspected periodically and replaced if damaged or worn.
Tool Inspection: Tools should be kept sharp and clean. All worn, broken, or lost parts should be replaced immediately. Handles should be kept dry, clean, and free from oil and grease.
Warranty: Porter-Cable offers a one-year limited warranty covering defects in workmanship or material. For warranty service, tools should be returned to an authorized service center. The warranty does not cover misuse, abuse, normal wear and tear, or repairs attempted by unauthorized personnel.

The OMNIJIG® is a robust and versatile tool designed to simplify complex woodworking joinery, offering precision and repeatability for a variety of projects.