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Am:RICAN

WOOlIII'OR KER.

JIGS, FIXTURES, AND TRICKS TO


UNLEASH YOUR ROUTER'S
POTENTIAL

BILL HYLTON
Coauthor of WOODWORKING WITH THE ROUTER

More than 140,000 Sold!

JIGS, FIXTURES, AND TRICKS

ro

UNLEASH YOUR ROUTER'S

FULL POTENTIAL

Bill Hylton
Mitch Mandel
", .. " .. i.", b, Bili Hylton and Frank Rohrbach
Photog",h. b,

TI'~

lEADors DlGIiST MSOCIATlON . INe.

Um il now, il's gone witho ul 5:1)'ing.


To J udi. Alwa)'lo lO jud i.

Copyrig'u C 1996 by ne R~adc:r'$ Oi,<:$! """,,,".ion 'lOC.


COf')Ti&hI C 1996 by ne Roador~ Digesl AMOciaIioa (c.n.da) ud
AU n"'l> rncr"\"Cd. N" pa" "r.bi. publicaI""'may be n:pruduccd
-.,,1Itd III 011)' r<>ml OI" II)' la)" means. ......".",'" III" nlOcllaniclol.
"",h.,,!;,,, pOOIocapy. ~i .... Of ...,. OIhet
SI<ngc
an<! ""n.,...1 ')"'Iom. " 'uhoul oM
prnn;ss;on "r thc ""bholocr.
OI"

....nllm

inr"""".;.,..

""'.on

"The IU'hor ond


who comp,l~ .h .. book have IneCI la make
ali of doe COIIImU U _urale and lIS lXIrT<:CI u I"JSISI*. I'lans.
ilh.....alioftl, phoIost;lj)los. and ..... h.a,.., aII beo> ..... fully o"edcd
Ind cross-dxdcd. II""""",,". due la doe vanabilily of Ioal coodi.iona,
~_1IWcnaIJ. po:rs.ooaI sIol"- :n;Itoon. Mllher ,1Ie IU'hor

_ R"od<.~ D'g." 'f.SUIMS""y rcsponsib,h,y fo. any inJ""'"


wlfcn:d or for damIga: Of othCI" Iosses IIIcurrcd .ho ..,..,1. rrom m.
.... '.,.;11 p='cd hmc .... AU lI\SIn>ctIOnS and 1'1.... should be
ca.efUlly on.dM:d """ cal)" lRIcn400d bof"", J>e:&omon& ........a_.

lIylton, Sili.
Route, /lUlgic

""'..-eI,

JIP.
and .ne.... o unleash)'OU, n:.."","
full poIe"""] I n~llIyIuI : ~ by M,tdo M>ndcl
illUSU3l""" by tiin I/yllooo and Fran~ RoIubach.

c....

p.

ISIlN 1).7(.2I..(lISS' (~ k)
1 R""""" (TooI.)
2. Wood",,",

1. JIII Ind fiAru= .

TI'le:.
1T203') 1/<).1

1999

684 .IlS} <1<21

9924915

R F.... ,IUS OKII:ST IlllJS"n.AHD REH.ADICH IlooI:s


li:dllo .... ln-C ..kf Chnsoopber c.""l\(I.u,,"

An m ......... .Iooa Mazreo


~ .... ~ ,\Iu.~r Wilham

J. Cassody

Addrns any comltlCl1l$ .bouI R _ A,.... Ia:


Readcr~

I>ogc>l

Edil..,........chief. Ulustraltd R"rtomec 800k.


Ro:adc.~

I},&O>I Ro.d

1'1<1I<anl .. llt. /'IV

I~ 70

ROIIdcr~ 0."", an<! ,loc: ""&AIUI .... "'" n:gist=d ondcrna,1<s


of doe Roador 's Oi,aI A.wIcw ...... . ...

Amtncan W,-".J>W<1<cr
Publica .." ..... 1""

Vi,il our _bMIC II .

Pnnltd In thc:

Wl[lIt

Uru~

"910164

i I ~ .~

1'A'k....ljI-est gM

S...," or i\1nImCI

of RD

Contents
I~

Offset &aseplate Trid-~ "'sic

SORING

LUSH-TRINMINC

Croull"ir Bastplalt

Slotte<! Pilot Templalt

80rlng Templatts
Shelf Support Template

ROUler Dupllcator

FlushTrimmlng B.lseplate Trlct'lajI ....le

"'

Mortising jig Tnct ..... "'sic

124

Shop'Bulit Siot Mortlser

Ili

Template-Mortising

14'

12

19

CIRCLE CUTTINC
Tr<lmmel Baseplalt Trlck-&lg B<lJIc"
Vacuum Trammel

vacuum (lamplng

19

C!.Islam Rouler Table Top

15'

44

Unil/usal Router Mountln.g Pliue

163
173

'O

CUSTOM BASEPLATES
The Generlc Basl!plate

6l

8it Ope";"g 'nserts


Rouler Crank

177

Tabll! Saw Extensian Rouler Table

183

Horl:lontal Rouler Table

191

knch-rop Rouler Tablt

203

Floor'Slanding Rouler Table

212

Splll Fenct

217

Sltds

246
256

264

T-Squue Trlc.-1IJg &tIsic

69

FtalhuDoards

ROl.lll"9 St ralg'"edge

75
81
8S

Surfacing Baseplalt Trki'8Qg IJtJsic

FfillCllonil1ing Baseplate Trlct~ B/JsiC


Centtr'finding Baseplalt

DOWEl: JOINERY
Dowellll9 Ji9

"'

URHIHC

"

Router La l ht

269

Jig-MakJng Maurials and Hardwart

298

UKJHG
Dowel-Making Fh(ture

Oowel-Turnlng Ji9

97
102

...._._!!
JN!!!D~
EX _ _..

308

DRAWER MAKIN
Slot<utter Drawer Jolnery

112

III

Introduction
11'1 mapd
KJnd of a hiICl<rqnl <bitt, ion', II? It ,.,.,mro JfOOd .,.
l.;uncd ,hi> book projt. 1kII as I coIlt<.'<l :uK! n::finc<llho:
kka ..... pbM r"r.he jig:! md ru .....,:and p.crn.,,; In this
boGIe, I ht1nl """ry put_n .nd jibr and
to 'I,c
.1Icmoc rould ........
'WOO<>!
gic.
llu1 .. "'" booIc nn ... rompkllofl, .hc: .iIornIt ... Ui .....-b
ror ..... Whm I FI In.o 'M >hup :tnd ' l1' 001 ""'" .." lief
111"'''0 1\'<: 1tU<k-..... It WOIlKSI_ .... ~U. ,hen:: b. ~
Ab",~.. ,bMI

!OIl.,.

I'' .....

'lJWI'.

""""" me, b:K1< <kxw. ItId h",po hi> roul1ll ~a",


And rou ""Y. ' /low'" he do tN"" ..... '"" .......... )'011. il b ..
,rid If )'OIIknuw the ' rick. )'OII
any JPtttlI >kIll_
' 0 rq>IbIe 1hr; perform""", In thb ...rtkubr C2>C:. )'lilt
.........:l ~ <'qulpmml.. twIn.-.
WIw ,'"" put In IlOUI#r M"Ji.k '" .ttk:1Iy ,-.y And
01 rou ...... IM point b III IdI )'IJtr CUClIy "'Nt lhe pmmlck
i>. Whl'" I do w.lIll rou 10 he du:>kd, I :tbo W:L/It (0)'011 "'Y.
- Hey' I """ do .Iull!'

tIan, """

JlOUtff MuXk b whok IDg 111 ..... Irkl<.$ for doing

"~1Ing [0 II.

"," .he "m'!II<:" lho:nlc W>D b<-~ &clf.....b/kd


Itt!ing .. hen I a'OfIlplbh >Omfth,"- In .he >hop. II
xb.",,1t:<lgo Ih:n I "" 0111><'
aU ""[ll:'ric""",,
in ~ ,,"em I_ frum
'MIL
llIn't "'" thlft' kIn<b of m.tdc. 1n "'f mind.

"uc.""ooa .....

It_oj.., ""

liU"""'"
2. oJridl.41w>d
~ .rkkry

" '00,1''''00'''1111 LbinJI _ ..... ,...., Irs for the buoy pmIOO who
.......... '0 k"".... ,he 'rkks 50 II<: C2fl CUt "' tbr: _
. ... she:
can III't .."",.., done In los Il"'" h'~ lor Iho: _ e r
who .~ Iw a oout .... and !>lUi and tI!ld 'h<1n ~
In his ,,,. lin ~ "'" Ilw" .... ilI''$k b at.o lor lhe
woodWOfk.... who h:b III<: miller Ilnllljl on a shc:lf ...hlk ....
"",I", fur il 10 show otr "" m ...1H.... lru ,ttSOIUioy 1f)'Ollllo
tllb I."'er .......,tlpliod. this b 1M book lN111 l1. m rou InCO
.. ",,"<:f

1II... lon is ,"",pI)' ,..., IUfI$kIft. It'" hocus-pocus. Wl\al

you UI; :scd"" is ,101 wtlat'. I'l2lIy happenl"". Al .he r."nlly


picnic. Unck Ilud .hso~"'dy U_7 .he tiltloo kid> by p<dllng
off hi$ thumb III' ",omcn,..nly, ,horn pun~ ~ back I"~ lUll'
in "'" "'3)' ""' hold> hl. h:otu.b. "'c <>klcr kkb rnlitt
ll>c...5 110M of this ~"'''' ... heft, """"'...., ,."..,
kepl.he III"*"'> OUI of ROil"'" !II'IJi'c. It 'lluot 1IOO"i.... ~

co..,. ",,~ ...... nh. procI~l" ",oodworldnS

",1LtnJ

1f)'Oll ~'" Juot ...."1011 out. for cnmplc. )'OII m:ly ""'"'
to Mup '" me, !IA! and fIxt""", nurkal ... [Ih the 1"tldr1IaJI
BNc' .,-mhoI,Thc: ",,",hoi idmtifics 1hr; """",. ~
thot ""'~ rolle:lgua and I ~ ... the: .......
........ul lOr ,he ~,~ """""',,"'er to N'..... In M b:qj 0'

,n,""" trid<.~

"""II "

roilier

SIclsh. -o(hand b ~~""_ In 'OO'OQd"'Qr1<inll- To n",.


>kiIlh.4./wld is 1wId11"ll wtlns.lnt,kau, Up<T., k)n 10
quickly and fluid!t' lh>l 11_..,..,. I,'s h:on<Ulng.he I:bk
in. ""3J
pruwko ,h., ' lfQw'd br: do Ih;o,l/'
'J'b< ~:oo::ornt .....oowurl.= chop OU, oo...,ails quWflCl ...

,Iu.

""pun""

1c'8l"""-~'
'J'b< "",eh ..'IIh ""=iKh,.o(IwHl.o."d ,"" IftIiOn I...... "''''
I, OUt 01 /rut. ,~ ,1IdJ:1c, b ,hi, II ~ 0", 01 dt:dIo:1Kd,
aim"", .>I!!I<:Mi..., pnctIco:. 1f rou'd IwHl cu' <Iuwulb fur a
1WC.... m:n dr.!"""",",,-,,), ......n1na Iby lOr 2S or)l) yan>.
bcconK' adroit ~, II.

,....d

Trickery I, ",hi, IIIb book Is all ""-ot. Tridell' I!i


>Imply a.....-utinv ~ ""cll-<k"Ybcd .. "',.,.,..,., put~ 111m,
mldL '0 'to<IR. on:oklnjl. u:;o, "f 1'....:1:.01 <kvin' or Ippo.r;LIUI .
Thi' i> lhe: found.uiooo 01 boIh 111"" nt>gIc:and"n' . . . -

-..."..

I~ ' rid. lhe: 110ft

vi>ioo

rou"" ...,," pc:rtOnncd on ,do:>

bf """ n.mboyanl ~nun or ."'~h<:r. lle lfUOoIeI

up Ill. )'IKl'IJj, """''''''-, puu lin In .. .....oo.lt-" ~r.'., . ,hen

hoi..., In.,,

pu:>I'IU II oIf th~


,Ilt! m ..... below '" ,"e ...... Ied<>oo "'..... 1hr; ct:IIC.' 6mo pun. up. The """,'m"" ILln-.

I"

Trick' Bllg Bilsic

'00.

lIoute,

~IC

kaflluou#llhe book and We .. 100II '" lhex ~


'\",'lllnd lh<:tn rdoll.-dy qWd< ;onoJ n.;y L<, build, ohm 01
)\M> :obndy N"" In )'ULlf . hop. 1.<::, "iC
11<:", IN t Ih15 G not no.- ,11"84' /i,... ''''' It Is NOT - _
Stulf yuu ""n do Willi thi! iDf;:rediblc .....Ier frum _nothn
sa!Hyl' 'bur ...n<bnJ """.... will do ju5I lim for """'" of

ocr.""

,hac "".

""'fIIwoi'"

If """ .......n: IIItou@JI [lie hooIl uod >Iud: )'OW' 1>;<11 o


l'01IIer ,rid> wUh "'.. tllOC' b;uiia. )'0..11 bqr;In ... appno-

dac~

chc ,,,,,,,clJicy <A )'Our rouc" . U.itIg che "Trid;.1Iq


co ~ I >iflnlflcanl
'""'" or upc .... UOl.
Whh ~II" lik~ chc T-&j....a 1U>d chc Ft;JCclon:ollnjt
II.t>q)b'f,)'OU1I RJUI. ",~l) po$ilinncd 1U>d ~'.l ...... dn<:o.
~ond ~bbn:s.."'" muhlJ>Urpo!Ie Smt.ocll1lllWq>bl~
<qIIIr- ,.,.... lOUIer lOr pbtIJr\jIlumbc:r. funnl"ll "'P"", n.:n
C1IIllrIa cin;:k:J ond oIu.p!nM C'dl!<' . ..' Icllooc Lhc ..,ipo nll:>Cd
br boIlbIc> and ti~ or Ihc: n)uCer. Thc ~lU5h-Tri ......inI!:
J:i5c'pla1" wl1l hdp )'OU , ,, pltC plup ond IhfOU&lllCnOll!l
:tOO 'o Irim ~ndin8.
J ""f'"blly lik.. chc Tl2llImd 1bKpLu~ btt:o_ 1, Is
ju6t 6UdI I P'f'I' ulmmd. W"J1h 1' , )'OU 0;":11' cuC dbb (or
hoIts) r.onaInI! in <lbmeter from , Inch .. p 10 lbooc 11
loIchc:f. Bel,"" n",. Ihll II a ,-cry h.ndy r.nstc. espttially on
Ibc: __ .. nd. Cutll"ll el",l"" b OI'" 01 chc: Ihl"8' Ih:lC
routCT> do best,1'hl, 1. I ",bli''''1y sm;oU projec1-1D11da1c
...ou..! of
illJ , "nly ,..... "''' .... _ .... ~ ...iU h:ln: I>ig
Im~ un tUllr woodw!l<tJng.
Anothcr 01 mr uick-Ntl r....:.ma II thc: M,,"bllIjl Jig.
1I>!Ic"~, )'DU1I "" ~bIc

m.,...

Mort .... II 0i0I'I>Clhir Iha' pI\Ir1W """"'" do ~


__ ThD jig .. gnI btt:o...., ~ I!< '1uile simple 10 III.1ke. 11 I!<
JOIid and dw:lble .... "" M",-""
Gib.-.ltu.1U>d 1. '" c:osr 10
_ . l'>l<c r_ .....= mlnu."" 10 "" 1, "p.!hen )'OU an _

or

""' . cnon-'mlnUl". And ~ mort""...;a "" thc: """",,


I\o::yond 'h" .,\ick-llo3 &.Jo,," 1'0"11 Iind doot<:n OI'
"""'" >OIld ~ Uw ftUIbko
~I

1'0" .0 ltIC !ha. ""'Ier In

WIClIpCl"1~"",

w;oy5. ",., lriek. ruu


pomn..-horiIl,g hoIes. lOr cnmplc. Of n"i"ll dowd. 1U>d
_.,. join...-..ill mlkr iC Clt-M CO Imi JUOl how "o: ..... 'ik
ihc ltlUCer an !)r, ""'" "" )"OU ,ad<k: cha;c opcn.\(I<U;, your
,.,...,. _ _ _ wCU t"""""" mo", .,.n".ncrd.

Ind <:rmlnly

!lui III.1t...... )"OU reci )"OU" '" aln:;r.dy _ani thc """er,
...,ma .... yuu al~ ..... tuu. "",'c:r lOr .hc klnlh 01 opct:>.
lloo.. 1\., din!. ' >un'I puI'hc boot ......n )<OI, ro. 1'0,1 ~kc CO

thlnk '''''1 C\<Ofl 1!ICUOfI<'d wood .."O<kcr wlU dill<:<,.... r n.....


critb ond Ic:chniqueo In tm..'w ,II"Il/c.
~ ....,. I pietII'" Ihlt booIt .... nujlk" ~ . a
....... ro. lmidcD. an opportunl!y tur !hf ~ .0
~ Infunn:llion .nd kk......, wllh an audinK'or 0I1hcIr
11""" V..... know, tllc",', .... betI .... I~ ro. ....pc
locr nugi<:Wls. s..n:,. thc .....;IicIcr w\y tnow I
lot
, 1Ie1<>:and ..iU "" abk kl pld: .pan I p."fum ..,.cr
10 fIguc<O OUl 1"" "'hcr tricb. 80......gIcbn>-like woOO'
""<lfUn-~ ~ un .hc Iookout k" new IWb:!., ~h,1e
Impmemrn ... and cspedally In ........ Uon .
In Ihi> liglll, a wuod","Urkc, w;U 1""" al ;;. O< liItu'"
_ Of h,.,., 1U>d .......... Ie II . '1 .. II bc:en ....,.. """"'1 J)oa;
MWOIlK?" II ...,.,Uy lJ<'f,m Or """ difkTcnl> l.Jocs it
liOrDt." ncxihlli'y, or In: il> appt;el'i(Ins ..",. opc:ciIkl I!! i,
"""",hing '0 I<ttp In mindl Or ~111II Co M huill

.,.,... .""n ,..


of,,,,,

h:I,..,

OIr.lght:tw3y?

l'ou apnit:ntl """"''''''''ers

:Ihookl "ud)' nch j~

..... Il ......, In!hl:l bouk wl.h. crltiCII) CI" I ~ruInt). h...,.

h,,,,,

mr .....,.,.jworklnJC roIl""gDQ,
Tbt: kk:;Io r.... I",*, 1111", n~tun::s.1U>d . - CUftX' fton\
1 nrlnr of ...... ,.,.".. My juli ro..hc ..... )"Cal" tw bc:cn 10
lInt1 o:k:>dop. Iesi. Ind fillMun(' ,hale dt:rio::u. I "'" ""Iy
>nOI ...

lc:Jul<cd In boob .nd IItlIjCnIncI for ~ 1 "",1lICtC'd ....x.J.


wot!<e", f. r aI1<I ..i<k. 100I<I..... lOr onti"" ~ :and
bul'S'~. Thr bat 01 lha;c projc<.u. I chink . .....,n: .,....,"'IctJ
hr om.Jl cirde 0I ..~ eollcaguocl hen: al 1I<><b1e
....... rd 03)' ' " 1 rrlc:nd. "Wh>1 It l"'" wan.n! 10 III<' thc
1OUIc:r ,,, . r And ....,'d turn c"" kIc". Orullnd ",,0,1 .... 11 II "..."..
and Idk U chin and "lek II' butI . ... ""'C il a ~"k and
chaor II ."",nd chc bloek. rd ""~1ch I plan ond bulld and try
it . OOetl. 1'0,1
I ~pcc!C'd "'~ 1" oomc lIP ..ith.
J>n>I"'ypc. 1l>cn: w.:'" rolbbor:lllonf, ,.,....,.., ""'" """"'"
would bolid I bule 1'- and othcn would oITrr ~Ion~
for implU'lnncn ........ ~ .. ll)om)"..-W ......1>asI>cdIy. "IlItf<O ~ .a/\c:r aU. k-w kIc:a:t th:I. 'hc wn """"'1 alJndy

:0.'"

--

In .hc cnd. I ... I sw<:U roIlttlion of ma~ Ippar.ilLl>


ond /OUtc:r lrickf.. Ukc I 11<100 nla8iC ........ tm..w M aaic Is
.... lxI"'" 01 bIs'" 'rlcb ond !Om( unusual .. unu 1 oprnly
Idmh . !I<JIttC of ti ... jlp hcftin ..."... oId:lUA\lUdt. 'tUoJ"U
ligo Ind u1cks hen: lhal 1'O"'n:......" rbcwl>c", 11 ..1 1
'hlnl< l""'11 cmbrac:c 'hc ...,.......:ba ""'cn hen:: they an:
iOIid ond ~. I"'" IWIi<lrd oen:wt' 'l! up I II'lJOIlIiB
,.... ro. Ihc Altr 01 m:Wn.R h linie tllffrn:m.
ThI!o ... pan of.hc
cn .p~ OII l"undlmcnw.. To
puii oItlhc 10,1'4"""" lriekl, l"'" ha,.., .0 h.", I _.".,. 01
'hc b;uicJ, So he'" .nd Ihen: In .hc bouk ~ chapl~ lhat
cnminc furutu..etlW ""'..... jJs ~"'""" CoC1Ic1k ~
pl~'c " 10 ~ good ",,,.ml*-- About dmIm of Ihc romcr
fullun::s ;" chl!< boot Inoo/vc nulei", I n:pl;tc~mcnc 1>2......
pll.~ lOr )'OUr 1O\.I,c:r. Tbc joi> ;" ""'1)', bUl ~Idom "" CI>)''''
"""'" ,,""""'v<i<llljl 1>0<>1<. III.1kr le ....,m. "'""" CoC1Ic1k
1Wq>b ' ~ " <kuilo OOW ", [110 .l)Ouc .h lo acn.iiI """""-And
..tocn I .al' It dul"III how 10 do le. 1 """'" k JIivct l"'"
,"" l"''''lcul~'''.
Il"uln MURk...,., lUcuo,Q OII """,tfllpot'Mf III.1.CfU]o
",,0,1 'dInoIogk:oo. KnowIl1II abouc !IloOl.km """mls Ind
lutd.... ", ( anoJ ,,hcft .0 FI thctn) 10 imponant
""'3imn. I'IIC1IOlIc pb>tk , .'oIOf ThAAk wm ..... 1'.:a.')'OfI~hc.
hands pb>tic knol.And knowln,obout unusual ccdJnolo:>.
pe.""
wl!hln th" "",ch or . "" orttalkbop ~
.nd ,bc hobby woOOworko:r " Importlnl . 1"". Utloa
vxuum fur d.mplng. Usini 1i:In:kU. Oow 'o Iifi: ",utr onoJ
""Ip )"OU """'" II
Wich ,U,,,,, il""" on fundomcncal5 ond .... Iml~.nd
lechnolofn', duo 'I ,hink .hii! S .. oo,w .. urr. In .,...~..,. lI'lJOIl
_
, """".. II Inot ""'" ""1I'.... lIIn"" II .. , poN,""'1y mU:.
tIown. And I'n: ... Ih..,., urfour<A 'c:m In ~
looI< ., ,"" nlth """peer, " 11001'" l>Uplia'or." M2)"br
)'DU"'" ..,.,n ";mib, tlocvlca In wootl ..ortdnSt ntaJoss. Tbt:
kb 1. c" c..... 'e an objc:ct In wootl-a nn'in,J. ....... td1owC'd """1. 1 .....11ow JIb'~ ur t>o..1-1ht<JUSh thc par.llk:1
mO~cn .. of 'hc dupllau ...... "'-... """"'" AI )'00' "II:ICC'"
'hrc:codlmcnoion:ol ~""rn wi.h ilyl"" """,nlC'd on """
bc:am, "'" lOIId hom duplk'oc"", Chc """.."".,n1S of ltoc
n.... o ....., chc """er llIO\,m~"", on i, 10 ",plOduce: thc
objt bclnt ,r.oo;:W.I,',. whl"",,,,"lI lriel<.
AIMI ,,, n.. k" II bt.,,~ r, tbc Rou!c:r M"Itic dupl"."aor .... 1
I"'1'I""l un [";III, ' >r """",'ed Of! tund. It ij,cnlly noo. .. ()n
air. 11.., lS ""'III"!

.e"

bo,,"',

..u

'u"

,,'"

,.,... """*'

Inu odYWGn

Now fOU ClII buy a .... pIia'or I( 1"'01 Iu .,

""""'IdI

DKJnq, or fOI' ....An mUC' <IX' 1touIc:r M.>.lPC tlupl"''OI'" lOr- a


mnarbbty n~ """""'I of ...........,. :and >hop t1nl~ , .....
orith all <IX' ~ I.. ROUln ,I/'IJIIc, lhe pions lOr bulldlfl.ll
:and """'K lhe .... plialor :lit: IkWIN :and "",cd.
(1n me n.,II' """,nth" 'lnlly 11131 .11 of 1M f""Icct
dI' plcn indIldoo a II.a of lhe p:o"~ :and the IPn.tw2n: )'0\'
".,.,;.J tor huik1in8 tho:: il"'" In ql>C>tioo. The rorutNCtlon
dltol<:llun.,; .n: R><thodicaI :and lhorough. L<IU of dn ... ~
:and photos of po11nml pmo:Uun:o "'" induda111.., III..,.,.
tIooac fur usin.g <3Ch I\Il: or flJ<tUR: "'" liIt..w"" IhoruuJlh :and
""'I...... tIal..l don'llb/". roo ...... 110 ........
I'Dak:oJ o.kull b
dwxt,m,uc 01 R","","
,11('81<" Ft MCtlktl by "'1' coIlcaJ!uo fur IIcing Ion~
will<kd,:and I :lIII, Hut " m ttyinJ( tv m.al<C''''''' .'" npbined
me, full Inl ...."XIcs 01 no:h pnojca (")Aen. when I ,..,...;l
II"II'Wl!J1 _><ho."Qlltlng boob, I 11"1 {"""r.u"" by 1M mh;o..
~ "k:ccs oIlnform;JUOn- !hoooe viul dL.... i/s and .subtk
nuant'n 0( Itth niq"" tlu! _
,,'" dIIT",,,,,"cC' 1'<'1.......,..
~ ond (ru>lr.uion '''' trinl I., ftx:uj NO'll.... "" 'JIit' ...
tbC' !!rillY lImlils ,lut m,ke IhC' """ illCl"C'rn>a:..)
ponIon 0( NQIII.... ,1I<k is IIiYm .... c:r '0 mute.
lablet :and routn Iahk ~.1hIt is :lII ''''It:I.~
01 ~ ubklI :and "'"",,",rio., ~ fn)m IWU di/.
("""U ..." ... _
hori-.c:ol :and one: ..",k:a/- t ...........,
lhe ..,...,n 10 I"" table _ . tllrough v.lrktr of sIC'do and
"'"-th<11>o......, to nlfIy bcndHOfllUUtc:r ",hi!:.
Let me talk ,">me: _bout \be" Jknch.Top Ho",~'111hk.
WbIk b lUiy not ~"'P tho:: ........ ,.. )'OU, II ~ ,urn OUt b Ier
I.. h;n.,
lOr you. ln omoJl .tIop, 1hIIi ..,...cr ..' " I,
~ ben ...... II is ronlp:ocl Inti doon', ""'-"'Pr lUi OWn
"Ic 011"" fluor Set on wuo1<bcndt.II "dcftICd oboI,.,
II>c standartl ~ hdI!h'. pull ing ,"" X'I!on dooiorr 10
)''.>It II" ""'Y JIOfUIlk, ..., I..... ~;m arTY II 10. maodcIinA
>ile ..... b;w:kyANI Job I """ irlcOi POI"''''' thttt ~"
apc::rtinp In . he: """'" 10 nWtc If a." 10 nIT)' (or 10 1wIg ....

..-iaJ

. . "'*"

_n "

.."'" ruD tor "'OIIJI<').


IIut 111m;: <Iaojtll t<::o,Uf"Q IIW<C' lhis router I. IIk 8""""

-'"
FInI, II's dcsigncd ..,...ntl ,...;aU, Ib",","",

mulC'r,
...hlctl lot of hobby ...""" .... .,n."'" b ...,.
S-ond. Y"" 011 inMall .IIOJ ""rr,., 1M routc:r &om ,he
"'hie In ,en itC'QOds. In od.,.,.
,he router .... 1 1ioN

......u..

\Ii

Rou,,,, ..... 91c:

"p . .... lM:n II'. In ,Itls routo:t ullk, .... hid< .. Inv.ltbhlr II>c
"'""" ....... other routo:t lal* ~(M JVU knoov. you ... ,~
:0.11)" """" 10 """',.,... Ibm;: or four sano.... """""c . he
r(>UIo:t &om ."" mountln\! pI.11C. ohm rdrua1I 1M owck
""'"'pbl'" !If ~ I"""" II""" or four "'.......,. 'P.d<a
I hn."'C-' 10 II>.... min ..
and a """-",,tlri""",)A
of I<JI!SIc
damP>' hold lhe ..,....". uttoekrnnth Ihls nlU" ',. IWk',1Op
)'au <ion '1 "",n """"'" tho:: 5101.'11 b;uqlbu, '" tnOtIIU .he
routo:t uod<:r Ibe ubk:top.
ThiRi. a UfHop fral"'" mako it ~ 10 tru ~ e bll
~ and bi.1\dgh1 atlj .... mno ... Thi> . . . mill..,
UNIQUIlIO ~11 router 1:thIes,
'fhc """ """'.... opp<1-'
Magk ..... lI.he fabu.
kIttS ~~~ ROUtcrnbk. 11 ~ the Iifi-top .... IUIC'
.hop.mode rout"" adju>lmcnl cr..mk. rouler 1>11 OIOfaW!,dlt!.I
moJ chip coIkction. and """".
AU In aJl. 1h<:tc "'" unIqut rouu:r t:tbIa. YOu ...... 't buy

I<'"

<'OU"""

1/,,,,,.,.-

IUcc them "'I'o'YWlttltE!

"'</OIw............. Iuo 10 he 1M Rouler U lhC'.


Ir.th ,II. >hop-bt'lll tnh;t"Ism, you an !V.IICum" p05IS
and Icp and opInLlIcII and fin""" wl, h rt.np and C'U"a and
..pen 11m Ito """ opn:Dhy i< ~plt:lt., whldt arc
lhe
~"IIp:ohIlhlat of <-"'DIlhe . - ""PCmIYC 10'00 and 1M _
.Id lktl lu rnc:"," You _
CUI ,...,.., ltlnc.b of . umlRfll' on a
tlcvi like 1111:0. or y.... "....., Ihc:cn by 1wMl.
~

"""unci

If you "'On' ,0 buy OPe 01 IhQc: <IniceI, you h:" ., I .....


cholcc5--an Iocl"'C-'dihly
induoubl m.rnlnc or.
d>o~ one. Our n>llfer Whc is quile no;r '0 build
u.>in!I !OIDC bK'yd<: ISProdi:ns and _
, """" oIJ~1f
hnti... oncI ~ ond oomc plywood." " tl...-.:. fk:dbk.
.'U1d u<Uq"". No " .., """ pubIi>-hc:d pI>. ... lOr ....:t. ~
You .... y .....". build """, bul II ..'III be .... '" 10 v>b,......
aU""I"''''.
If n.,r .IIe"" ......... RiOl. ......... hlz rouler glm>o,
Ihlo i< II

""""mi.,

""*'

IIri>n: lumlng you


In lhe ohop, I<:! me o;oy tII;1I II",
Rnl 5Icp 10 bomi"ll" cc"if"'" IOUI"" ..'b:2nI .. '" ... that
ruwc:roft'lbt !bdf. Tltocn you'" got 10 fill that IL1lt O' lOUIn
1mb You an buy. lot 01 IP""'" out of ~ btIIlM
oM'O<1C"$' . _
fu1/lUa.. ,rid::< "'" til.- }"" c~lc yound/
So taC' 11m book 1n10 the ohop ond IIiCI buoy.

Crosshair
Baseplate

.,-g'.

(.;lI1ch 'ayout muks in your

roulers c:ross ha irs 10


phlftge-bore on-li1I rg t t holu.

CI

IIoujh

It ",III n("CI' rq>btt tbc: dtill and dnU

p,..".,

roulC, \!1 an acdk'nl borI"JI 1001 . Sun"


;I 1'11111" Ind I'kltll>ill.y "'" """"""M' !Imlt"". 1>1"
Ihrn."...., .......... ppllcaIlOl" in ",hle" II ""Ipnmrm$ .InUl.
AneI il you Il00 ', "'ve driU p~ I an kImeIlmcs bc.
WOfbbk 5Ubsti'u'e
Tbo: ~ oIUI<' plurtjll: tQUtn ~ !he pun.lI'"
d\ftc dt'Ill,of COlIIlI<'. Is !lutlt borr.
th:lIs pnfn:tly
~ 10!!It...onr ."rfacr. A"" altbou&h It <:an ', hore.
dftp hok: . it an hore 10 ~ dcpth.
This.spial ~,,: can nuIi:( il n,;rr 10 ..,...." " CIy
pIa<'t tM - ) ' O U horc 'NIth. plun"" rotI.n. Whm ... Ing
""""'" !'OUl ...., il ', diff\cul! 10 cyd>all lhe aan 1001100 o(
thr hok. Tbo bit docsn ', ha'-" a cnunpoim 10 line upoo .
m.uI<.>Zld lbc bulk o r ,/le MOI'" nulIa; it imp<>!6ibk: tn oIWI'
~ OI> IM bit ,."" ~YUoiSIul, '-!>bIr hei"" ""' ....u.""
hb pn.obkm. I aU It Ilie ~Ir bo>q>btr Ixa""" II 1.
llimply pK 01 da.. pLuti<: ";th crooo.hairJ dclina. lnH
thc: ccmcrpoinl oIlhc bit.
Tu . . Ihc ~pll.. c. )'0" mUSl!zy.,.. hok loc,"ion> .."
~ ........pittt ~ t""" Un~ ~.I nghI Inp... Set
'hc: """ft" on thc: wori<, and II"" "p thc h;i.""pbU" 5
.hc:

plUI'IJI(:

"'*

~"".."

tI><:

"'* wlU Ilo:: lu "

"')'<lUI. tUd< on ,.... I'OUIct:ond plun""

wlH:n;: )'OU w:ont II.


ThIo t-plalc ... orb opbIIy ....,U ",ilh l~
$MIdI rouIcn. Il< .. thc lIo!Idl pI~ ..hlch allow }'OI' 10
....iKh u.., ruuICT un ami ,Jif 1"" ......Y ,.... """'""'-1 drill.
TlI(

Making the Basep late


II >hould "" omious Ihal }"OU must U$C :o dcu p/ulic lOr
<hc ba$q>Wt. You nil US<:
~ Olt p<.>/yUrt>on:IIC.
I......J Xf}11c.
n~ on "",,",ing Ih"mH'''''''lnfI. pUMa OII bol: '0"00 In
l/le appcndill:.

ci,,,,,,

1. eul thc: bbn k. Cu, *1 ....... oIl1!ht1r """'"' Uun


pI""l.II"'"
~plal". Mili ""~
bbnk ..
1nlly"'llW"<" t.n.-.: tIK" P"I'<"' focIng "" 1"" bbnk.
)"OUl"

rotiI"'.

1""

2. MOlIDt It o n 1"" rouln". ~ lhe rotI''''


aod. tI5ing <loublt<kkkd !apt, bond h
t/w..

b:uq>b'"

'o

bbnk. Gulokd I>r II>c moumlng.,;clni hoIc>; in ,m, OIock


ba...-pbtc. >dcct ,II<: appropri' le;;i~ drill:u.:l bono hoks in

CIt~HAllt

IASEPLATE LAYO!JT

Iu.e~~e bl~nk

CI'
C

.-.
CI

III

Is slzed 10 fk 'OUIUS but,

Olmple cenle. of 1>io'~le


wlIlI V"9,oovlnll bit wllen
I>ioffpl~te 15 "loKhed to
tlle 'OUtt .

Sui'" c.oss .... lrf tll.ough


tlle centtf_rk u,ln.g
~ ,c'~lch IWI.

Plung<'bo.e ~he bilopltnln.g


aflu scribing (fOI.... I.
Ofili hol" for
mounllng SCrewt.

Cunlng Ust
Qty,

Dlmenslons

Material

Ilie: !>lan" Swllch 10 3 counlenink. 300 cOllm~rslnk Ihc


holal 110 Ihc n.thod ~ )'OU t$: wiU JCI bdo... Ihc
~1<'

...n:oo......

SCJt.>r:>I( Ihc bUnk front Ihe Slock l>ucpblc. 1"hc


PA)l.,..,.;v" ""IX" wiU ptQb;lbIy jlttl off 'hc bbnIi: """h Ihc
arpct tap<'; 11w', oby )loum Ilie blank on Ilie ""'1(',
3. Muk tIM: bit o".,nlng ~ntcrpolm, fiI v'

......ins I>it in Ilie roul~'. I'I",lSIC Ihc bir ~ Ihc bbnk.


1)on 'I ~ plog 'hc roule. in: jusI luro Ihc hit. r..... timts
by 1wId,.oror!IIJ! ~ ct:nlcrowlc InlO Ihc bbnI<.
!te"""", Ihe !>bnk (rom Ilie rtlUler. (In thc drill pn:so,
drlii Ilie .....1IoI-diam<1er ""'" )'OU .,.., Ih""4h Ilie bIank
.1 Ilie: ""nlcrm.rk.
4. Scribc the Cf"OMhaln. ""'" thc proIC<.1lve

rrom II", blam: (lf II ....llIrndy ...",..,...,.j). U"ng .

'''''',KW"C

D,IIII"" !h..,mos.." ln!! pluti, .~ulfts a hlgll


(huCk sj)Hd ~nd ..
I n~nd-OU1 feed ~ctlon . fHd
the bit ..... p/y fo< ""Iy ~ moment, then ft tflet II c~'"
of Ihe pl .. nle. fftd .hirply I9"ln, bUl onl.,. b.lefly.
Rtlratl
bit. Thl. In ~nd-oul actlon kup. IM bit
cool tnough Ih ..1 It won' mellihe pllSlk,

,"p;d

m.

""per

!oq"''''

and JC ..,dI
Ihc ~ on the bQI1On1 oIthc
N.nk AJIPIr dattr..colon:d palnl to ,he """mi Iln .....ltb.
fi"" bnOO. tIIC1I ""'pc: Ilie """""laiC ck"". "Th<: palnl wiIl
dinfI 10 thc """,lehD, hljVllif!;htlnlt !lte Iincs. <N an a1tcm:o.
ti"",)'OU an 1')' 1bI"II fine.flppro .... rkn- to color and
hishlighl Ihc """,lchI ,,""""""'1, lina.)
5 . 8on: Ihe bit openln", Vou an lxR Ihi> hok ""
thc driII pn:ss with a ufJIC'<IloJI\CIer I:0Il. Or mnount l!>oo

....... I:worplatc OII Ilie .....,1 ..... anei


~I"I!.

pI~

,1Ie bi'

",ith. bfJjll>mctcr .. ~t bit.

Using the Baseplate


b Ihi< an """Y Of'<'rAllun? y"" "'" l' b . Sd up ,1Ie ""'I~r
with tho: cro:I6hair I:tasepl'uc ond Ilie contt1 bit. lhen k1
tho: <:On"ttI p/w>J!" <k Il' h.
",., >ltc o( """f)" hule mu.... lIe Iakl ou, with CI"I-"'OC<I
byout ~nea. Set tlle routcr...-a tlle marb, anei /ll=t tbc bascplat.... cnmcd ~ dl'~:11y tM."r thc byout nwb. s."jlch
Ilie NUl .... "" and plunJIC Ihc bit.

TO c, ..... .... c ..... ' " .ln. wo,k In 1I00d lilIlI. wrell"
sqUIrl! and se".'" awl Hop). Un~ IIP'~ ~uarl! 00 k
bln,t. t"" tony ,.ntenNrk hole. Thoen draw t"" ilwI
n,mly alo"llthoe ~""rl!'J blJldt, "o'lng 1"" plU11(: as
OHply as po5olb~. Aft~, botll IIn~. are se'.tehtd into
t.... lNupi.Jte. lIighlight 1""'''' with dar~-<oIortd p;llnt
(boltom). U~ li Ilny an.!,I'J b, u,h 10 apply .. bud of
polnll!ong tlle
~"f'. Wipe Ihe uceu from
t .... plUllc, IUvl"ll JU" a Ih'ud of It In the "".ICheO.

1I"s 101"110 '"' a bull"s~d Yau c",,\ look dll"tCIIy


down on thoe em..""in ind SH wi,h""t dlslonlon
how \hey line up ""'Ih Ihe IJlVOUt llnes . BUllhe
cm h"l .. of thlo b.lupl"tt .... ke It d,.matkally
usie, 10 line up Ihe route' fOt plunoeborlng.

,,"'te""eI

c .....""" ,,"uplate

&'
...-.

"

IlO

Siotted Pilot
Tem plate
Now pilot

-~.'".
c

s/ol~

lire

usy 10 make as
pilot holu .

buiIdin (umil",,",

,~ atr: timei "'Mn )'OU na'd 10

palid Uw eNRIJO" ..1dth >nOOnally or fa>l~" a


pand .11:>. ~ width 10 >INel"", ,h;t\ doc>.fI. If
you ...... " ~ any :alk;no~ lot this [[)('cn",n,. SUtface
buckk _
joInuI_, doon ......,", 01"-''' and tirA"'''''' ",m.
Ir IIM: rnrmbc'r Uw """"";.- lastcncd 'O the rlXro membcr
"",.11 ",'""'" ,..., ~ :Ih2ru: :and held ,lIouId sIklr: in an
dorIpInI c:hannd OI" >lot.
'IlII:.rk1c 10: ho)w 10 m.:tkc .hc ...:ry ""mlW sIots .1\.:0. an:
~ Try <lrlUi". ~vCft.I holcs In I linc, esflial/r usIng
~rrblf. 1I doon', woriI ,bccalOK tI><: bit "'' '''b
10 ~"ct C>IJ tII<: .... <1< In,o ,lIe p""'~r tlrillal hok.
Ile"'. thc n\lop::ol ouIuilon; Ihc: plu "&l' ""'''' ' , It il; ,""
ldnI iOOI 10 cui I~ ..... f . AII )"'" , ..,.,.j It I
pLIlc 10 jlukk thc nuchlnc.

iim.,...

Im>-

Making the Template


'IlII: ,,, .... plate Il ~"Y 'u " ..ke. l!dtJR, bcglnnln& ,Ix
.cUlly ."'" '''",plo,e ""roti! .ho"" In IIM: oi ... " Ina.

....n:.

1. Cu h e ,,,mplal" blank. Muc ,..., ' CfJlpWc OUl

...--ro.

of .1/0. OI \I.lnd'I~hld< pIywood . ...


o. acryllc.
PIy .."UOd .. prub;ahly thc _
pn<'IbI . r kk<: tu Jut ...... '"
:md Iayoul matb 00 ...... pb ..... aod I Ilnd It dUlkul1 ro:ICC
..,. rnarb nude 0<1 ~ I'Q6ilIonIfll; an ..:ryIlc: ,cmplate b t:3Sf bcca...., k i> drar, ..... Ilo: amul ... ,.11 d " m"",
M:.,.uc con Ix broUn.
Tbt
$hoUkl tot lr200 ""Itt "" Ionjj ... , ""
da ...... .". 01 your """... ""'" and I Y.t ti""", wkln". n..,
u:mpblc >I'oowo'n In ,IM: .nwI"II'> b lalll'"l" 'h.:In , Iw. /Iu' 1,
p~ plen!)' oi d.bn.,..,.IiUtb. II) )'OU ntI c..... p 1, ,O
, .... worl; "'ilhoolln,nfn"i1lJl .."IIh rouIn" """""'''''''

''''''JIU,e

2 . ScrIbr the cr"OI!\/;h:Hno. \"QU ntI lncorpoor:a'" 'hOl<:


hd pfill aIijtnmmf inO only If )'OU "'" maldllj( ytMlr l~m
uf dnr pb!.I:ic. rnci>;c
llnes wlth ~ u,jli, ) k .. lr~
"'" IK"tMch _1 :anii "$'IU2lt. Cut rigii. 'h"-"'fIh ,.... nuskiIIA
paprr !hal pnM"':b ,IM: pb.stks >urf:1ce.

pb'" _

1""

3 . RoUl ttoc: s lol!J. GuidillJl }'OUr n:lU'"," opinst ~


... lgIM ..... mu, " oIot In , .... ttn'n" of ,he ,empla,e wilh "
'!i..inct>-di>""""," M",IIjll' hit
m:uch ~ 't.lnck-<Ii>mc:'.:r
pokIeboln&

'o

thc tempLoce O>'CT thc byoul mari< ro. IhI: >lut l\J!;iuon tht
clam!'" wh,,~ thcy _ ', in.crfc"" whh Iht "",Iu

SlOTTEO 'ILOT TEN'LA TE LA YOUT


Scri!>e crou~rs !>efort 'wUng ctmpl.ue sloti

rr. ,.""*L
J

f- ... '>.

'i.

"

1-1\-(. ::

IOW

"Yt:l:fs'1'W-101o9
pilot slot

7J1\.----I

3. Roul tJ>t .,....ntemon:, Olud: ct.. ~ bit In


Ilie routCL Sd thc ""tin", depth &lOp ro ~. ind> hcyo)nd Ilie
.hlcll"c. 01 thc Icmpl;o'C . Sl1 ,Ile rouI.". Of! thc ''''''pb,t,
""'" thc: gui<k In thc: Icmpto.c" $101. Swildt Of! thc ""',."..

"-

pltIfIIIIC cite cun."., and mul.

Yltld)oW'. Ibr::
polo! siot

1.....-- 7\o\"----:l

17\1i"
\, y,'thkk acry lIe
ood

p""'"

Of

N,dbo.ud

4. Rom tJ>e SIoL Swildt 10 thc """lin bI,. RC5Cl Iht


CUt';"II <lq>th "op 10 thc ,hicknao 01 tht wtOftpktt pl ...
th:11 oIcht .empL. ..:. Reu thc ....
NI you CUI, ",n .. nlbr:, Uw. you "'" U!oInit toIIy fr>iJ bit.
,. '" veI')' ca>J to ohcar o/f thc CUllinil ilp 011 h.indt OI' t\o..
Incll blI. Sa - . , I Jftb 01"'1' ~Iow cu\.!<'u """ Ille oIot.

CUlti", Ust
Qly.

D l menJlon s

M;Uer!;J,1

WlC IOWlC 17\1i'

"~""

Using the Template


n., C)'JII<'aI 'oj,.Inch suKJ<: bushing Itas I roIW ."'. .. """ Ind!
1orc.1Icfon: you non """ c....." b ct chlnntr .1wI .haI _ ~nd

....... ,,ha. 1\'0: dim:1td )'OU co m:U:c-you ncnIlO gnnd


dooo'1l thc toIbt.

l. Sc:t up ti", rOllCer. To rom I $101, )'OU'I ncnI a


pIuow: rouIU. .. noe c..... plaCt ""Ido ( Ilie loiHncb-O.D. oile).
bi.o----aoe il>r thc: ct>lUlccrbo.><c for clle
"""'" hc:td and I !IiIl'CrmI onr "'" tht...,""'" sIunI< sloi. For
- \O "",ntlhtad "",",". ..,;e Jt.inch-dbm~lu bil 10 CUI Ilie
counlc~.nd I ~"te1 hl. ~ .. . hc ~ sloi.
For. <08 or -6..,..,... """ cht *'-"inch bll for tM rounttftI<IK
...... !.ind> bit ro. thc: 6hanlt ~c

_ .""" "raW>'

2. Oamp Ibc 'empbtc 10 tho: ...orkplc:.

u... up

II.OUI s lolled pllOH In thlt d .... H Ihit you uSt In


i tliehlng i tabitcOp 10 IIM !eg-andipron lSstmblv.
Tht onew. d,l ~n th<O\l9h tlle cleat Into Ihe tlbltlOp
thus will bt Iblt 10 mov.. I Iiltit 10 ,ht top u.""n<Is
Ind cont"'Cll.

TEMI'lATE CUTAWAY

'- .,~.. l\6" .Iot.


'-..." .," ,~,,,. bit

ca
~

caS'

Boring
Templates
Roullng hatu m .. y be hori",.
but wlth ueh of thue templatu,
"OU Ciln gel soml! preuy Ueili",
raults: difftre"' slzes. through
or blind holes, fiiiI or Itepped
bottoms. evtn drc:.. lar grooves.

b<J.red wj. h """'Ule. !>Ils.


hole "W'. ~nd flycuuc .., y"" can usc: ro.Ucr and

aflllNlian,,,,~r hol~ '"

Ir,omrucJ (anII ,.."kly,.ve 1>;".., coup~ of lI""'l .nm

"",1> i n ,hl' I>00I<).

Of """""".""1' l>ooinJI

opcr&'''''''''''' limit;>,1on

tmlpbte gukk
OI" IWO

1'0< c:nrn,*,'

a hand-h""l titlU, nuklng 5<0'" lhc hQk: iii


*I~ 10 ,h~ surfocc b LI'" p"",*m
. y"" ",,"' 1 ",.". flycunc. In. h:lf>li.hcld driU.
. l~bmc'er ~nc:r hitJ
C06IIy, I>OO2dJusubk.
anei ~"",",". SU II ~_ 101 to ......., ""'" 01
~

""" .".,afic

W,,,,....,,.

_ Nclthcr _
.""..,

$1'" . -

ny" "w:r ..-an

(tel'"

Thc Ibt couId JO O<l ,(lt l 'd ..... Uy . hink .Ilc>u' "). HIn
r.,I\cr,han bdabot II, le, m~ ...y ,h.,. rou''''' and ,erupb'"
an pt(KIu l.:org<... .II.m"'.". IIo!lk
)'OU ..'horn <>chef
opp""'d"", an:: M)'mk<l by thcit Ilmlu.k,.."

ro..

u..

fOUkr

thtouIth

u.. C\L If)'OU

Rd

th.roush

hoIc. IuSt kttp cutd"ll dper untU ,t", dbk 01


....... c iscu' fttt 01 ,Ile wurkpic<oc. lh 6'Oppcd holc Is ",ha,
)"OU need. roti, :uuund ,1Ie ",,<lule,er of thc ,emplll' e

1"*

'o

f,..... u..: driU prcu.)'CU iim: !le .bIe 10 pe!d! Ilie


"""" an "'" madlin<:'. ~"k oahk. U thc wor1<pk....., il<
100 bif; ar un_kIy. 1f IM hoit !$n '1 ",tlfl''''1y d""" ,n
,lor wotkpic<:c NtF.hc "rill p"""" ~.. n" ..... th~ joh.
'I)'tIU

,tmp!>,.,.

5ohown t.rn. ..., I bo' d! 01


wilh II<>IQ <.'VI in
'hc:m.1b rout ma,d!,"#1 hoIc. )"OII ..... pty damp ,~ Imtpbte 'o tb(, ""00"II. fit I p""cm bi' in your ro,"n. arid ici ,~

unIII youVc: CUI 10 Ihe nml lk'peh . tllm wort b3d 200 lOnh
,,, Cl<C>'''''c aU 'hc ....~ .
Now <Ion', ,hlnJ< )'OU ...., tirru,td ,o <q>roducInjj ,...,

hole In 'hc ''''''pble . It)"Oll....,. ~ bu>hlng. " 'hkh 0/1"


bit rrom tb(, 'empl&le cdF. ,..., hoIc 5itt It tNuccd.
'00 CWl ...., _
:onr ~ bi' wi,h pokk
buohing.1Iy "';11.\1 diIJCrm' lUidc ~.-.lght bi' rom.
bi ...,iooo. )OU C<UI ...., CIoCh ''''''pble hoIc 10 roti,
lea>!
tnm differm, i .... of hoIc If)'OU usc I ~..tnch bi' ",1,1t
/luIdr bushlng wl,h In ou'>kk dl>.n,<~~r of l-< incit . It
mI...co thc dlamc,er of 'I\e 'empl.>'c hoIc by \0'0 Ind!
T11c ,a!)le .,....... pb'c Si 1I2Jlw::>t" <)fi pali<' I I ..,.. 0lIl
,11e 5p11k!i for )\MI. " 11>1> the Ji>:a 01
that C<UI ""
....IItd ""'ng u.. 'cmpl;uu. anei It b kJnt.. fiu, 'o cut aU n
ni , h~ hoIc ~. )'OII nttd an.,. th ..... gui<Ie ~ :&nd
four bi .....U COIIImon ......
One b>t
~
roundC"d
!ieU ' Ile

a,

"'*"

'h'"

oi,,,,, ,,,,,,pIa,,,,, ho,..,

<:OtnCtS.llIosc C"mL"'" "",,"', .oUJ><kd

it-L"- (or

I"ol".~

Making the Templates

' hey

iti.. I PUl"J"lll"'. ( b mp I ''''''plll,e a, , L....".,r o(somdh~

!ike , ..bk'op, "mi )'OI' ain momi Ihc romcr USilljl ro"r
lOIIta:u>d p:ll1Cnl bil. No s;ow ,""ro 10 sond ;ow;ty, no lip"
pin or Ibl ' 1"',"", Usc: 'hc .am.: ,<:mpblc ., cach cu.....,r un
lhr toblftop, ro.. """mple, Ind yo" <OUl round lhe~ ...
woothly and consislcn'ly.
Thc tcmpW.cs ~ )'OU romcr-round glli<lc> >Wting 2' I
t..Jnch r.odi ... :u>d funlp/ng In Y..mdl1ncrnnm1S 3 In<:he:!..
1"0 "",kc il I linie C<lSicr 10 poSi'OI1 ,hc com<:I'
rounding 'cn'pl.,,,,,, 1 m.atk: linie plll..,. lc OIUP; ,''''' )'ou
.<tach 'o ,hc ~ of ,,,., 'emplll'r5. llIc Ido " II.. , )'OU
makc IWO, ,hen a .. ach Ihcm Of! Cleh .ide of whichc:vcr
comer """cm )'Ou an: "'Ing. Wht:n )'OU usc " d ifkn:n,
..w"" comer, jtJ>l m",,, 'hc ...~ n", n",un'ing ":IC1t:WS'
iti.., pIa:lllC lmob5 1"'" n.. kc Il casy.

TIt .. " a Simple ntaner.Tcmplau. 1"fOIl1S""" sIlown In u..,


d... wil\jl.. You ca .. ""'~c Indi'idual 'cmpl:ncs-""" ro.. odI
si"" o( bok_hu. g>ngltlj; <ilc omaJk. holcs gl,-es)'Oll JpaCedtkirnl dampltlj; UC'A wi,houl ""'"'-lng '"",plllte ..od: Imi
with"u, "",kinllll>c Icmpbl~ unwiddy.

,O

Cutting List
P.rt

Q<y.

Templale 1
Templale 2- 5
5,ops

Dimensions

Material

Y.t"><6'>< 18'

""
""

W>< 12" >< 1.'


l-t"><2"x3"

Plastic

Hardware
2 hu nUIS, \<i"
2 knurled plaStIC knobs,
Ihread~d

in",":

'[)1(-]2 from Reld Tool Supply Co, (800-253'0421)

4 Hathud wood .erew.,'6

><~"

elReLE TEMPLATE LAYOUT5

.-

3Y,"

"':as,

2. Orill o . toul,h., boles, )ou ",n "",ke ehe hoIes


In S<-"Vt.T.at ""2fl'. 1 uscd a <x>upk. 1 uscd I'onlner b'15 In , dril1
ptnll tu ~ thc IOur,;m:ol1eSl. holcs. fur 'hc 1arJ!t-"t U<>Q. 1
uscd ~ router "'Iulp"",", w1,h ,ile Tr.ltunlCl 8aS<:p"l~ on
""l!C 3'. You <OUl ~Iso t.t6C fI)"euuer In a drilJ prc6O, or
holc "'''''',
lay out ,h~ CC1\ICrp<>lnts on l!te varlou:;
Ilo'"
II100se 1""1 )'OU " '" rnaJtinJI wi,h FotSllK'r bits. . flyculler. OI"
hol<: ... ws. ML..U,.... bc no, ,1Ie hol<:s mu>< he pn:.:i:s<:1y ./zed
bul ntII p...-dscly ""-",ffi.
for elto5c eh., wilJ bc routed, locate :mII IIrll! 1IHnchhule>. Sel up 'he tOI"er ami 'r:tmmel, "mi
IIl1mctcr
rout 'hc ""Ies. J fuunIl i, hcnt:fld:t.l 'U "'-"' up <il., mo'e' :uwJ
make ~ .CSl p:I"" OI' scnp tt) en5UJ"'-" , "", .he Ir.unmel """In~
WU ~Iy WM' J nttdcd.

C\""

''''''pili''''

3. Ro"nd 1"" COrno:nl. 1'wo ~pproach"" corn,' 10


mimi he",. 1 "S! 'hc: ' ... mmel. bltI }'OU L;tn abu .imply ""mi
~ com<'f5 10 I 1')"0"1 line. TIte lru,h ... i, 's ,ough 10 con>pk1ely
difqling ,he etlgic> \tIhen routll\jl. .he comcn,
, - Hanglng.up hoit

'J~",;,;,:;,,:,;,,.,., 2Y," rad .

5" dia.

"

L w

rad.
_

3" rad .
H.i1ngingup hoit

Q;o 1
,,.

Hangingup
hOle ' - . _

IWrad.

.g

.,"Oid

3"

wood, n=lium-dcnoity fihcrboard (MOf), OI" pank:leboard. ...,


Thc "oek shoukl b<; ..
~ ineh <ilick. It)"OU,...., :p ro- lIudng ,I>c trn,pb'c -'Ct .1I"wtI In 'hc Il ... wlng C/rrk
Templule w)'oulS. cut thc: bbnb 'o Ilie .. ~s specIfie<J by
.h<: ("ning [... .

[>i'''''

1"'"""2 ha"'ll~r bolt., 14" >< 2"

," dia, with \4"

1. Cul , he blanks. Tcmplll,,,,,an;: usu:dl)' m:t<k:o(ply-

,W rad.

6" doa .

".

IIoring Ttmpla,ts

STOP' OETAJL

........ t

PlAT[ l,AyOlJf

,_"""e Il0l6 _ u_lII. When


usl/I9 I " .......... 11\ wonk In. tn;IUbIo 10 .... kt ~ ltSI
CUl In sa.p Ind _lSurt M btfotl! cU!tJng ItIt 'tmplillt.
","cu~'''r .I~M

... ......., .. ndI~ 1. IftC>'iI;>bk. , 'uu do Dd .mooth. nJck


(n:c "<ljoef ......"" 'rtI.pbtc> tu "".......nh ....,

4. UriI! 1o""lIholl 00""'. 1f yuu I'l:on 10 "'~ tlK"""pUt.,. by h.n!li""


1If>. hy:all nll:a ... onaI<c I bok iti
nch opln~'al1y ..... thal, """, lwtjllnjI h,,'" Innriably II"b
nk,,":rnd <knlf from tloc .... nk o( I"" ... U from ""hk:h It
h.:onp. You d<Jn 't ...... ' ,~ Injutks inI1lct~ on tllI: ,,,,,..
pb.c bok. hrn...., ,....,.11 tr..."," to tn.: 1><010 TU"!OUl.

\oi' X , 'pilot hoit

,,'"

t""..

, . M.. kc Ilo" "IOp pl .. leli. Wk .. fU" nd.",

t_

l x .H ".. k pIoecC" o( "",np I u>Cd pLuck 10:1\ """r (tOm


..... k'~ tMoepbln "",,U!IC 1 lLad il anii It Iook. cooI, _
p/f'"'oooI .....".ud .... rI< ...cU. as ... >UId thin I\:onJ..-ood
~

'

""'" .."" pblt Iwi IWO poInb on nch Mic o( I

hok. ""'" l<)lnt5 ditt ...... 1ht ocmplaoc _


tlll< - - . . . . . ,......... llI\hImnl,.....
JIOp
fNml_ ....
Cool ohio ..",.,," '1' ..u.. cl\:omrcr ,"" . . . . on
1"011\"" WIk, ,bm ..,. OUl 'hio hoIn. u ...... In thc
<IRoI.i nl Slop V.1idL T1k ttfI .,.. huk _
I"oold< dcar2I>Ce
,in4! knub, 00 It
bIjqto:. , .....
,"'" ,krndrtllC<'lOon o( thc oNnt. nrtll pliou lOt 1"" ' WO
.......U....~

1""""" ,""

t""

lOr."" .......

"""'*' ""

>hl..-w~b

DrM ,"" """'"'" Inl .. 1ht Ionc< IWO hoIo.


6. 1ns&aU thc MOJ*. 1b mount lhc- MOpO. I ",",,".((110
1..,.., I 10(,"" . . ltlt pbstk: k....... (MI It. No unc (.1.., I """'-'
o( ) m.n I ..1IOl<kd pi:t>l.k knob wIth Ulf'C"rN thmod. So
I ......J I 1..1lJICI" bt~, .. hlctt Iwi rnacI1lnc thrnd on OM
cnd. I III'Cf"<l thrnd un ,1Ie OI"". 1um I nUl on ,""
ohInk. 'hc:n ,"" u.ob pm .hc mtl
.hc 1u1ob.
!Ion: ,"" pllUI I"I<oi<:> Imo .hc teftlpLotc cdgc> fur lhc0iI"",.1b """,n, ,. OiIOj'. hokI ~ In po$Itlon. in....,n ,"" ~
.... nk intu tlle hok. lnd tlW>.en.1\( ",n:w

op''''''

Monbl", SIOPS m~k", It MI,/, tO pos~oon

t'"

COfn", ..

..,.,ndln9 templaCtf. A ',..,,_: madt up of a hange,


bok and I planle kr>Oll. is , .... ""'" tir hand InlO I pllo!

hoit In che edgt of Ilie templat",. " " oehlng tlle pI.stlC
stop. Tht stOp. Ultelt un th tdgt' of tllt wOfkplec"
ens",lng IIIaI tM lempll" 15 Illgntd ""sh .

Using the Templates

'ia/I'

'e'''pIa'c. K&:rp thc coUu


'~fISl ' II" 'cn,p""" rugc ...
wotk. 1'1""8'" liltk .sn:pc. for thc l<'COnd rc-voIullon,
anei 110 10 Ihc: fuU dIrpIh ro.- ,hc: ,hIN ..... nd.
If ,..,.. 2n;: n>ady lOUIinJI;. m:uot. kltlng thc <kp<h o(

)'OII

Tho:: bsic 'L'Chnlquc I 0I ...1alnlbno.-.ud: C1amp It.. .c:mpbl"


10 lh<: """"1'1,' ..:", ....1 up . IM: " ".U<'1".:md IOUI.

1'''''

""""'" Ihc: wod:pi'r, and M .. a b;g hok. CuI ... nwar


dItou(I:II tI>e .....-.rl;pIa..." and
:> 1IfOO''' OI' m.~
...,.,.., 'o..",lnll 1>1....111> p",rtlc-. ",,",ho~ bI . tOt
~. OI' p/unftInf!; l'OIIII<kr."I' hi, _.oo )'OU an furm

eu .. pn:tty imp<lO'Ull'. l'IurW 10 ,Iw Ikplh and """


:lroIInd .hc: l""'pI1IC:. Thm ....,..., IIM: fOlIl<'1" bac:k anii
furth, dori"8 thc ,.,utc rrom 'hc: mkl<lc o( tI'III: m:uot.'Tht:
,nnp""" and gu;dc hushlna _
~ .... , )'OU <Ionl
.....:...d", .... , o( thc: ddlned am (......"hl\llllw 5 no)' 10 do

~ buI'~"" OI" ....."UeI..

when ftrchandinll

Wbm rou du 'h'"

11'-1 :> tin:k_ QJ, <:Omplel:tiy

1.',

u.e

1. Clamp tll.. . " m p la.r '0 .hc ... o .. k"iI'....'.


!lrpnI<fi1l8 "poli ""-'n: ,hr cUnIbr <."\II mllM "" ......... any
01. - r ni cbmpflK ,~ ""'f br in onkr. I( ,IM:
loc:uion II dolic 'o an
an ..... ptr cbmp w.emWUf'kp\'r If i, .. bqond. cbmp. onch . .....
<:2I'fICI "pc , ... I>,,(md' gluc:.
Untns! up ' hc ,,,mp""" r..... " cu, ,Iw mllll "" plxnl
~Iy I. Uulc 'rieky. V"" c:ln octihc " ......... 1... on ,hr
,oompI:t'c. th"n.I'}"o align ,hem
sl ml"' ..
"n ,1><:
...:npl". v" .. an .tso ..,ribo::" dtel", on ,11e "'Qf\:pi,"",,
\lut il ,""
the '''nlpI:Il'' upc:nlng. Un", up thc:
IftIIpIaIc""'1M: circk

ruw::.}'011

pU'" ",.IM:

",i,"

ni,"'''

_..,:<1 ""

2. Sd .. p ,Il" rouln". Du yuur PUII>. OI" coruul. thr


..., tabk .... P"JIII' 1 1. Stl.ce ,hr hil .n11 ,hr JUi<Ic hushlnll
romhln;o,ion nccdcd lOr ,1><: sitt bok -,ou an:: JD<>inII ' o ftJUl ,
Oll.o:k ,IM: bu In .Ioc coIk:1. and r" thc """"Ina 10 thc ~
pUlc. kI .tIc plUIljlIe Ikplh

"''''''1'''''

3. Ro .. "Joc hule. Sn .hc


,IM: ,rmpla,e "';Ih
Iht roIb .. ,iglu agaln..;! ' he ~. .. Swhch OII d le
~ ,tir
"nd !i';cd ' he ",.IIe' d od:wbc: """'nd tI>e

hi'.

"""CI'.

~).

~.

Roundlng Corners

liG

1. Altacb lhr alo"" 10 Ibr irmplalc, PId: thr


Innpla,e <:OmrI" ,ha, tw. Ihr l3dIus )'OU ......., 10 1l'iC.
l Mop OII "adi &kk 01 thc: CQn"ICt, lrtKrt ,""
"",.. n'ing .'..n ...... 'I>roualI thc hok: In IIM: >lop. and r....i It
Imo ,h~ pilot hol~ In Ihe lempl:o,c cdtIc: .u)'OU I~I"" IIM:

"'lid>

te,..,...

se,..,.... Ihc:
poInts on cam .idc: 01 .1><: tnO\ltI~
""~ ,..ill ,II" Inl... . hc: I~mpl:o,e nJsi;<: 10 kttp , IM: ><op
from rotOllng.
2, Cbn,p . hI: l emplale 10 tbc wo ..k"lccr. TIM:
.wp:!i ma](" pIIl"Il""""8 Ihc: ."mpbte """l'. Set 'OC ,cnlpla,r
OII lheo ..-odplcc" and slid<: It di:igon2lIy 0010 ti.., RUf:o
umil bOII> owpo ""III"'" .hc: ....... OII cam _
o( ,he

n.m apply a couplc


inlcrfi:n: ..-ith 'heo fOlI,n.

<:Omrr.

o(

elam", .... ""'" tht.-y .........

3, Set up lhr 1'OU1lef'. Ib noI<:d. fOII "'"' a ",1Int! bit


' h. '>pcra'ion. l"hc CUIlIna c<W doQn' , """'" .0 ""
lonl!Cr ,han ,"" oIod:
but ,tic br2nng OI .... hc In
~...... 'OICI w l,1! ' hc 'c"'plale OR C'\'ery ........ So in adi .... i""" 'heo
",,'dnll t.lcp 'h . )'I,1t ,,:aUy ha..., ' ... :<imply .""nwl ' hc hi' tulIy,
"" u.e, oIwIkmoun,"" "'-"'ring'" ClIpos<'d:md nn con!:....

,IM:

,hlcIuIoo.

Ic:mpl:"~

4. Roul .br oorlKT .......y, Whal I usu:tUy do '" .ak"


.......... cuu bac:k and btll. nlhbli"ll away al .bc comcr of
'bc """"pi'r .11La>T thc: ",""pl1'c Ila' OR 'heo 'cmpt:&t.e, bu'
tI>e bo:2ri ....
q:a; .... thc Icn>pbtt; tI>e bI. l> OUl OI thc
c<W o( ,hc: worI!pIca. 1b Ibc comcr o fOlI.<:d ....7)'. 'bc
bo:2ri"8 ",,".1 ,,-", OII thc ,nnpl1' c, and a ftn:al """" aIonII
,he ''''''1'''''' ....... pIeI:'" Ihc: eu.
Now. boo, bil Imgth. Ir)'Oll ha.", a ..."em bit ..itI> a
1lnch cltu in" k:O\SI'h. )'OU ha,.., '0 mal<r. ful l-<kpth eu; )'OU
<:an', e"-,,,p <iown 10 fuU <kp<h In incrnn""l> . ..'hk:h 1. lhe
......1 ro... lnll ap-pro:>eh . W'jlh a ohon
as dcrp as }'OII
m.... un ,"" li"" pus, 'hcn rcmovc u.e, 'cmp""" Ind gui<k
'loc >tt'<ond co, by ridI"3 thc """rinA on tlle Wgc ruuled ""
,he tlrst ........

Ion..,

hi'."'"

bllsh;ng . Tt>e bo,l", ,emplales Cin tlrlp yoo produce


tltrough hol" SltPf)rd hoIoc., 'Keur . II''''''''''. Ind
Iru. In oU .om of profilel .

'Tht: ......., ,cmpl1'cs <:an I>c: UK'<l ,,, ruund o/J ti... o:omrn 01
ubk:I<l>S, COW1''''''. and OIl>c:t 1"'""""'" lrutcad ,,' usi~ a
guide btMin& ,..... ...., a I"lttnt! hII, wlllch Ilas a ,h:tnk
mountcd ~.Iw rkIcI .... hc ..:mpl:o'" 10 gltidc ,hc: clOl .

r. ...

Th. ruoles " ... "n)'Chlnl 10," boring , but youv.:


go. to b<e Imlgl"",I\I" In yoo, dIoices of bils Ind gllid"

ca

V""
can """

cat! ronflnc 1"'"

wm 'o 'bc "'-"'1' ~........".. Ot )'QU

r""" $Iop 10 "'01', whlcI! wW help bknll .IM: r.u.ll...

Into ,hc: fbu


Iorl", T~mp"itS

How It Works

.-.

al

To IIM! you tt.e Idei of how IISInIi IheH t~mptalt.


.. orks, t.ere\ a lo"lng of the gul"eJblt combl/\Itlon.
ust<!, wlIl> the differenllil bet .. Hn t~ outslde "iilmeter of tht glll"e Ind tt.e ",,-mete. of 1~ bit. Whiltl
IIm ulling t,", "dlff~'tnt .. l" OS Iw>ce I~ o{fur, Wlltn
\I"rog il p.ortlCul.. gu.o./b<t comblNuon Wlth il CIf'CIe
tempLue, you Cin Cllcu~te Ilie sin of Ilie ~ YOII'II
Cut bv subt'ictinglh. d,fft,enllo1l from Ihe "lo1mettr of
the hoit ,n tht lempl'lt
You ..,II note Ihal NO combl ..... toon g!w,s \10\1 il
\-I.lncl> d,ff.ren,,"I. Ciln~ b~ "o.... Wllh ouldt bush
Ings; tlle coIl.o. ....as 10 hlve SmN wMllh..:kMSS, The
co"..,quenct. whoeh you wtll NIl. '" 1,," Ulfilpolilttd
Llblt. 'TtfllpI.o.', Siu RoIngn: 1. thli \"DU Unnot rou.
thl: ~. Inch Ind '\oI.-,nch Incre.-.an!S. lui VOu Cln tiV
thlS: 8uy il w,,nch-1.0. x ~lnch-O_O. bellln; .n" jIut

It OII the shank of. MHnd'I straIgIM bit. Use the


911" bushlftg .
(bgla AIneIb stockI bWtng of thIs slu: aWog
nurnber 196--0620. caii aoo-an2511 .)

bearInt 10 911" tIM Olt. mtMr !hin

.....
...
...

(OlIlde I ..shln, "I~' DlI'feiuIM'


0.0.
JlO.O.
\\. 0.0.
~" 0.0.
~" 0.0,
y,- 0.0.
~" 0.0.
)1,'

W'

l>'

....,.

".
.....
'

",

".

HOW ITWORkS
j,r,"-o.O.guidt .. 'th
M" stlJ,lght bil

Offsel" 14"

\t--o.O.gulOt ..ilh
M" strlighl bit

OffStl" ~."

\t".o.O. ould<! w ith


loto m .. ighl bll

O ffs~t

.. .,...

-"'\t".o.O. ould<! wlth


W .mllghl bll

Yl' patttrn bit

1O

ROUler /lUg1C

Offset .. 101&

Templale Size Ranges


TemplUt
Guide
Bit
HoIt
Olamettr Bushlng 0.0. O;;lmett r Oiamdtr
l' IIolt

,.
W

w
~.

W
~.

1y,' hoit

W
~.

W
W

2' hoit

~.

W
W
W
W

"

lYl' hoit

~.

W
W

w
)' hoit

k'

W
W
W
W

~.

"

1l1' hoit

,.
~.

,.
,.

",.
",.

....
~.

..

",

....

",.

.
W

,.

,'

......
~.

,.

",.

.
,.

",

..

,W

21'0'

l 'y,.

,.
,..

",

,y,,'

",.

,"'.
'W

SW hOit

,W

,.. '"
,.. '""

l'I<!t'

",.

l'y,.'

,..
,.

",

",.

".
.....

....

4'\oW.'

",.

4'\0'00'

~.

'1'0'

..

5 y,,'
5""

O'

",

,..

",

~.

",.

~.

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.",.
4""
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W
W
W

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,...

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,"'.
,..

,'

S' hoIe

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",

.
W
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,..

2 'Yoo'

..

2\'00'

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,..

,...
r

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,.

4)1' hole

",.

1'!o\o'

",

W
W
W

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,

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4' hOit

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,,,,.

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Template
Hoit
Guidt
Ol",meltr Bushing 0.0. Oiamtter Oiilmeltr

'W

..

.~.

,.

,,,,o

".....
,,..
,,....

..

'W
5'1'10'

".

S ...
S1<\o'

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8orw.g Templ'tfl

II

::I"~'!I

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ii- ' "

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j,. - '._1,.0,' ~ .
.;. . . ~.,~~a,.!-~5',. ~g "'~"~~ ~li~"
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ii

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Templ~le

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Pluiic ~nob
wilh SIHI Slud.

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INCREMENTAL lOR ING IAS(PLATE

Cuttlni list

"rt

Q'Y. Dime nslo ns

Material

",""",
Ha,dwood dowel

8uepl.ote

11"

10"x 10"

Indul"lil pin

W dla.xl"

lempllit

~" xI4"x32"

Fe"'.

l"x3" x30"

~~~~~!'l~ of ~')

",.",.,

........

,~

,. /

Hardware

,1

......

.//ii~~'.~::~:~
,hls

h~.

.~

.
r

1 !>ru, thrNdfll in""u. ~" I 6

1 pluti<: knob, wilh \-te.1 ,"ud" 'tI"16 x 1\oIt";


JOI(97 f,om IItt<! TooI SUpply eo. (800-lU-(l421)

2 10000It cLJmps (OtSU.(o ne 107U)

2 .porod~s, )10"18 x 2\o\t";


tTC225203 r,om IItid 1001 Supply Co.
t ~n~'d se't..., "

x ." (fo, mo ... n\lnO Ilie eLJmp.)

2 huhnd bolt<, ),6" x 1W (' o se"'e n


....,"0 plns)

_$ ."""

tktn 00 "'" d lill """",.11,1. b (:t.>I y"" an 11<1 III<' lo0Io


in. iu.iAhl
)'OU ... n 11<"1 , .... fi .... anei bit boIQ
<SaCtIy 24
11-1" ,he >fU<.i "" '" hoIco be,.....,.,n
.... ,.". Ind bsf ean \":1'1'.1".1 'f'3cl.. lnoon!il>lmcr can
bolI<> ''Prt. ","ling shd\e.llh,n~.
Sa I"m rrconutIt'ndin~ ,11:1, )'OU m:ok ~ anei uw a opIal
baoqobIc .... hk:h , ~-.JI ,II<: jll.:n: ......"taI hnring ha>c:pb,c

.....,.;tnd

,W
Rtler.n,. tdg.
loo ...., Il 'o lIukIc .11<' ruwn " 'hm h<ltInJ( ...... leh'p".e
~ Ir c l'l'(M" Crttpj ' ....0 ."" m:ok~ 011"" b:;tscp"'~. 11
"'--"t 'T ""',,,,, (In n' <>plnlon). ha.-auso; ,Ix hul<: ,,,,,,,Inll
00"1<' tc",p"'C ... 111 hc rorubtcn. """, hl,eh b du. ItlC n ....
:tnd b$llcmpllolc hoIef; ""'y hc mor.: ar lct:I INn N lI'k"hcs

,"00 " ,,,.., cun",b,"'" c ........


11e",' . n clClmplt- lf. In hc

'p;u1;

o,''''''''. ro", b;o..o.epl"c

Shelf SuppOf1 Templ."

13

CM' "1' .... ~ IM t ..."pl'lI~ tlOk-; C<"'''''cndr ' . Indo


ap;l" t""",,~ of 1 I..d, ap;ln, )'OU< tcmplale ",iti ~ li
inchc> rrom nn! hok 10 u..., nol 21 In<:h~, 1don 't ,i<-w this
as o prollk"m.
tIK ....... o~ op:.oct"tl ~"""-,I,,,,ntly. aod
ttl.: tcmpbtc ,"a" Ix ~tio<tal tu ","end llK .... nlt- of
ho)k,j "Thc 1""", .. """,,1 ,.ucIn" ";11 ..., """"""cnl. Ih""llh
t"', ,",,,"ubti"e Sfcin)( tn:q' ..... IK dD<k>rI_ So don', Ix

bt-a,,,,,,

at ~

.-.".
~

Millking the Baseplate


'I k p;lft> fu< .10" ~''''R: bll:ludc<J un ,..., CLn.~ U .. .
...en It ..... h. ........ t .... 'cmpbtc!5 b"II,. )'UU """' 1 nud IM

b>SCpUI .. an)'''''''''

'h" hI'

1. Cu, Ihc ""-""'1'13'" Jl"lI'lS."Thc 1),;0"'1'1'''" is. fIlt'


",-000 !i<.j .... R:, 1:&1'JjtL... lhlon 1"'" 1'1.... 1'Qll ,~. '. b>oc. On 1""
t.UtlinJt 1bt. 1 "I"'c'd II as a Io-lnd! "'1"""'. " -loII,, ,IK;
s/w,,,," It as. 7-1nch sq1DR:_ '>lan ",'I!h IM 10-lnctt !i<.j .... "' :
:Uter IM
hoIt;o .., hon:d and It... ~ pin 1,
1n".IIo:d . cut il do..-" to Ih" ~.jnch"",,""'" ohc. (Of c","""" . 1f
)'OU' rol....., 1\IUt'" h:u b'll"r boopn ..... bf aii m.,,,,,,,

d"'''' '1lI!

""""""'f)'

Inctr.<oe Ihc 1lnWw.-d ."" of Ihis b:lsrpbl",) "Thc ind':"'"11


pIn is a ... ~ pic <O( tHnch~ Iwtlwood

mut".

4. Cornpl,,'" thc ba,;cpbtc. (,h ... th" pin In tho

<I..... d

2. Mounl Ih" ba<ocpl:ne bl~nk " " Iho: rouler.


Ilc"""", .t..;, r.",01'} t.a.cpbtc rrom }'OU, pl"nll" ""'ta. and

""'8htt

3. I'lu f1tI'=br::rrt' Ih" bll opcnlng antI pin hok.. 11r


bwic:pW., tus 1"" , ~ hob In k. 1 Ind! .patI.
""" '" Ihe hit. lhe ,~hcT fOr IM indaintl pin Th<: hule" mUII
Ix thc """" disurK.'C fmm """ cdII<" oIthr: bl1cpLile.
10 ~ Ilie hll ",,,,n"'l!, >imP'!' III "J.Inch 01. .... 1):111 bi,
inlO tlle ..... tCT C<>llct . nd pl,,~ the hok 1Iori"ll tt.:
1n<kJJ"l!: pin 1>01< 10.1>;, n""", in...... 'Cd
Ilo Ihit Iirot fiI tIK C'<Igc )(0 ..... tn 1"" rout.,... ;urd ...,.
1. oI' 08>1..,. ''''' pIt'WOOd I"""I)U'" U.. ng Ihc nJtIr: ~
""II "II>lIn:: ,ha, Ihc pin hok ... tu bc lhe same <Ii"urro;, fruno
lhal etll\"" tIK hll "",,","II
No>\' 1'0' ",re"""", "',.." OrI ,1Ie hast'pL:Ile_ '" "'"
know how ( III """'" Ihc l\IUter ' " Ilie pin t~rIc ,""Il t..
1 inch 1nIfl1
opcntlJ..llun. ruh:: ltJIlrln>1 lhe ""'1'"
baoc, """ n..'" 1 jn<:h (rom Ihc baoc OrI 'hc b>o<'pb'"
Nat. .............. lhc ~pl;tl .. lron'lhe n>Ula Ind oond rt
101 b"", """'1' damp.:d ,,, ,Iu; wor1<bcnch. l1<o: ,,"<pc' .. pc
to ............ IM ~pl:tlc
H...IIy. ~ tiu; pin lKric Se, 1....
on 'IK .,..,..
pblC Sn"B ilS ccls<: guIr.k: IIjcJIt 0Rl1"" 'he ba;cpbte '~ c<I(It.
~Ildc tire rouIa lu Ihc ""u" p<~K1k:d un It.: ha.\epLlt .. Su...wilch un tbc: t"OUIU;lr!t\ p1u~ '''e 1>01<_

w~..

mountu'~"",-__

il in It..;, h.....pLu" bb .. k Tr."'(er 1111:


1'><'"'IK"". (l\Joililln .IK

IIK ""'1'" ... 111 he


pI~

""",minti hol"" ...

(Iri,:n,,,<! ",'hen you


,"" haIe:t In .11<" 'CltIpl;l ....) 1>nU ,...,
~...,mr,,",,""

'~ ... nK.'.... k

.IKm. ond ~Iuch IIK


p10ce nf tIK .. ock """"pu,,,

.~

hok,.

bb.n~

U> "'" .....Ia In

"'.w:

do.>l1 Ilie '-PUt.. III n.. n'lI<"Ibit


de, 'hl~ . ... ak" ''CI su~ thal Ihc ~rcm'ICC L"<ig<$
(IIC'C' tht ~pb'c dt:twing) tr::miIIfI pat1IIcl .0 llK Unc
""'.....'''n 1.... bit opcni"ll.nd II", pin, 'oo .... n .."" y<>tJl><1f
Illlk A...~
,",'hen )'\10 horto 'hc W;o hok In tht
'cmpbl" , II l'OU nW:c 1""'" etlljct "'IuklbDnt frum 1.... biI
II yotl w:tJII . c"l

A"OII

1;"""

--'

tlold otr "" ",...."."I"l1 U'" """'pl.. e on tht ...... '"


unIII ~ftcr tIK Il .... I""'pbt" hok 1> I-..d.

Millking the Templillte


~b'e complctnl. you

Il1lh the .pcci.l

.... n nuw ,um '0

'bc: ,cmpblC 1,,,,11

1.. CUI II.., lemp lalO: bbnk.. A> ""kh ,"" )pI:d2l
haoq>bk. ltI.: templ.:n~ bL:r.nl< .......1d ...,. bit O\.....w:u. ln
Ihis a"'. lhc tcallOn ha> 1<' du ",I'h jjO.",ull/I ,"" cdreS >Q\W'C
'U ,ht: ""n,~ oi tht ,cmpl:&'" ltu"". Se" tlo;pit:..
tbt
'(Io ..
Pf,an 1"""" ........Injl JUIQICSI~. ~ul lhe lempLu" 10
tIK JI~ Jpttmcd hy ,..., CLnun~ I.bt,

""ha,

""",,!

2. Ro", Ih., n"'l h" Ie.. O\tt. 'he d...wlng. lhen Ioy
of lhc ....... ~HndHIia...."cr hole In .t.:
C<>lumn Seri"" It", cent""i",, 01 lhe <VIun,.. of""""J;tI )'OU
do Ihl>. llcmcmh.:r ,1 .., )'OU11 cut do.>-n 'hc ,CltIpb' " . r,,,,
_~rc
b)' OUll .... 1Int 1>01< Ind Ihc ccnau
Imlne KCOnJritlld) Set Ihc n,,,',,, "'",. 1"" bolt Io.-.Iion
.ncl plu~ i,. (Il><: en:r."lt;ur 1Ia<q>l:t'" cart hclp )""
1oo.... le Ihl> ........ ~:ly. 1IC'C' pat:<' 1.)
out thc Iocltl,un

1""

...,I"lIlh. Indui nll pin holll i, usy II you pion


.heod. Befot-t rtmov.ng tht b"tplOlt I,om 1"" 'OUte'.
s" Iht ~ gulde agaln~1 Iht INtwpl,lte ed9". Thot
will tnsurt that both hOltS wlll be the UITlt d'Slince
I,om 1"" tdge. NUl, ~ncll an allgnmenl m.o,k lor Iht
'Oute, 00 thf: _ond hoit! wlll bt I Inch lfOI'I'Ilhe IlrSI.
i i shown, ~ unsc~w Ihe ba,eplate and pn>c:H<llo
bort Ihe hole .
1.

Route, MagIC

" "-. ,.,

3. C' OllDP Ihc rcncc In plao:. ,\"(JU.I mount ,lut


I"""'Rlmlai hoti1ll! ba"""lt Ofl II", "".ner s..~ Ilie n>lU",
OrI ,"" hlank ... nd ....1"" 'hc pin In tht fusl holc. 5,..1"11 thc

TtMI'lAT E PLAN VIEWS

TQPVlEW

".

Flrs. hol~
2"
al nc~ end _-l-l_
I~ \(," dia.

h" 16

~II$.

V.d~. typ.

ooooooooo oooooboooo oooooo"

.'"_.

b.n~

th.uded Insen

'""

EOGEVlEW

fNOVlEW - - - - -

WTTQM VI(W

at;gn ,"" bit o\u ,,,,, <Xfll~runc


Sli""
r~""" uf' 'o tIM: ~b'~. Wf!:t'. and dam!'
k 'o ,1>< ..'Uri;pi<'cc ,."., kncr WouId bt 1'>...1"'110 th~
cmtt'rli""
l'OUI(1' ' "

t""

4 . Plungebon: lhe boles.

s.. itdl OII Iht """<1' and

~.hc_-.:rnd_.lbr~"'>houIdhc.pi ....

iIxIainfI pon .JtouId "" apoUR'd n Ihc


line !de)'l>U bared. lkt.....-t I.hc bit :and >hift ,I>t n)UI<1' opin.

II-., lmec. and 'l>r

,,,,, "mi hok:f.. s ...1tch 10 ~ 'HndlnN al ,..., ' '''0 '+lneh boIcI . ..ith ,""
b. ", .tght og>l"", th~ fCn<.'C and II>< ;~i. . tril
tn
.h~ b ", hloch hole:
To hol"C ,.,e ...""",<1 ' .Ind. hok.)'OU lDIf lJCC'd 'o ohift
d ... r~",-'c ' Ullh tly. UrfKI,<lIRSl upon II>< "",ci>K>n ot yuur
1""",.. ,,,,,.-.1 bori'1JIlns<:pl.lc. l\Qth '.Ineh huk> mNSlIw
5.

Ph'n~r;:bo""

dW"<1~r hiL Ilo'" ,IM:

"""",

,.

Us i"" t he In crem e n.a l borlng bau pla'e'


Thls cuotom boISceplate ha. a pl .. pmj~c.ing (,om
II ,short distan<:~ Imm tlle bil opening (rliiItO
W'Flh 1""1 Indulng pin C,ptu,~d In a hoit lIe
mute. is essenU;,Il.,. on I trammel Ind un ani.,.
swing In In In;: .mund th,. hol... Brrng I lenee
.glllm tM 'OUIt, 11.10... anII you I.. blhlr
exa"ly wh~,~ th .. n~ ~. h.... wlll be bo,ed.
Shelf Support Templ ,

15

SEcnoN VIEW Of' PIN INDEXINC; AN D ROUTER PI.UNC;[80RINC;

CII
C

.-...

.
O

"""

1..'rfC~' 1r .lillnt:d u" .1Ie <:c".~rli"" """mi by .11 II)<, .... I><:r
holc5 ,\nd 10 ~
hok, )'OU 1..... 'o !IIm Ilie
">I"C' 1/10 "'W"'c',1<l '"e In<lainjc pin 10 "" '"e opposhc
.wcul'.hel>ll
It """d 1.." en."", . IL," lhc fcncc: ;" PfOI'N'rIy aliW><'<I .....
,~ LblI'toIr br fh,t,,1I. ,il<' '-.,.,,,,,11 hol. In .1Ie """n oncn.
1Ie ""'le' "" 1,
hc ,,'Ioen hori"!!.
bst ~ \l1111 ,1><:
"""e. ,umnI of/. plun..... Ihe Il" 000 nI II 1n' 0 ~ hok. " ill!
,1Ie ~ pin 6nrn,. ifl.o .he >1<1;:.0....... " t" ,*" It)'<>ll ,.,.., do
.Iut, ;u>tI 'hc: ~....."" S 'J!.h1 ' 1I,.mR , 1><: b.>CJ'b'c ,)oOJ "'" >CI..

,Iu, ..'"

,Iu,

",iI!

Ilut 1( 'Ile """" .. UIJ'

ohfl i' 50 i.

01 p<l!oi'lUn In ~nr Wol)', u"d.mp l.


.lIe "",'cp ..... md tt:cbmp k .

i:<'iI!h'/Y '1I"i"'"

(I;ow ~..~,dI bad: 'o ,"" ' ..Inch bI' ~nd ~ II", I>SI hok.

""",.h;' 10 101 of btlSf"'IIriI lIu! you oo/y luI"" 10 do 1.


OOCc .0 11'1 Ilie 'empb'" ...,.., I\nd h.>vinfc 'hc '"",pule
riW" will """'''' tlut)'<>ll ..,c ",..e ........., lImc you ~ l hc:
.cnlpl.. ~

6 . TrlRl 'he ' <"mpb'e. ~ undampillll thc: 1Cncc,


Slri~c a pencU Ilne.k>nI. ,1$ edgc:. Re"'....." 'IH: kntt . nd
""" 'Ile I"-.....IJ IInc_wh",h par2lkb ,1Ie .,.",I.'ftinc of . "e
.m'III:"" hol.".-Iu ,rim.hc ."",,,1011" ,n Iu; tI ...l .

Making the Fence


Tht.-I:N

p;o.n." mllkc b.hc " .">Ce

II pmll loos ' hc: 'cmp!>' c


'he ""-",, lOr 'hc '''8I!k d :' ru"",
...hidl "".:,.'" Ihc ,,,mpU'" 00 "," ,...,rit.

01\ , .......'llrilptC """ ..

1 . Iake 1100: reneo: b bnk.. CUl ,...., "rlp> o, ', ... ~"",
l' iywQod ' 0 'hc.' d'lI><:I!>ion> op1llcd by'~ ( ;unl"1I. Il>!.
Gluc ' h,.... b<'1: 'o bec 'o fotm ,1Ie 1I""h~hld:. bI. nk ftlt
'loc (en"" .

2. Cu, Ihe adJU~UllCnt . 1oot!I. TlIt: kncc 1_ IIIrtt


2-inch """" n>u,,'" In 1.. .... 11 """ bc """'..... up ' o ~ Inc .....
Th .... 1hc """'" 1" hdr "'de """ bc ........ioot:d :ulf"''''''"'
","",'ttn 1 """ j!ncoo (.om ' loc .uk') ~.
l'robabIy 'hc hcSt
10 rout 'hc.' hoks b ....,'" Iwtdhc:1t! plu .... ruulcr. I"lt.k:d .10"11 r.,n<'C dampN a<'rU6Io
, ..... .,;oritpicce 1"5 a jIlJOd Ideo ,n d .. n>p .<a:ojb ~Iot,!t cod!
stdr oI'hc .....tplo: .n "nw'de "IO'" b,:arl"l.1 lOr ,""
ruu'~r And n:1I\CnIbcr 'O >Iidc scnll unokm"",tt, 'hc....."..,.
pIc "" )"OtI ""n , ""'" Inco .1Ie brnclt IOp
1'.kc , ..... >lot Ioc;oIOn> rrom 'hc 'lltmpl"t~ , .." .... Ikl""
d"wI"lI, and 'noukr ,bem 'o thc wurl<pic.11",n )t.~ up

".r

""" rout L1>1.' >lot .

3. Altaeh the ","le Cbml'8. ! .-ti !)o:.So;Co


cbmp". ' hough <IIh~.. In",,", lnciudiItJI ni ..."""" ~nod
olTs, "'" sokI br a numhc:r 0I,...;k>t'dcr w:ndoo'$.TlIt: modd
I _
ha:! a h:m"k ~nd a lonM 1 _ fur ,"'" >f'IndIc: Tbt
lJ.b:o. cunfigu ..Uon aUo,... )'011 'o ''lU")" Ilie ~noJk pmltion.
Tht.- modI o( 'hc TCo:ZU7 ""rIo pruridt::l jIOOd fkllibtliIy III
cIaJt>ping. In f:Ilrty 'YP""" ""'''1', thc .plntIk J>I'C"<'UR' b
.ppIIcd "" Ilie br.'iit:k o( ,1Ie ICP1pll,c lloId. :dlbough w..

TEMPlAT[ FEHCE DETAII.

,.r
L
16

Roultt MagIC

~I"fIdw~.l

l i

voddl'S 1IM1S

"nn'

~I"fIdW~1 alIl
(I! pa'101' sdw.p
dNS 'l\>ONI MII UO ~1.lCIw~1 MII uOlI'wd ~IOII
PUI 1'11 'I6nOl'l 1 jMOOOlp IpOq 6u'.~ ,It p<I' nU~J
~'I.ldwil ~1 'II uo 'I""~I MII .....
'd pa
"3U~"JOM
IIlullu"l""o
~'II

11"'"
.t<t".OM ."1 "IIM

."1

.>Ili pu. ;)1""'=1

"'l""" .."", ""'1"

'rql O< pu.'p..>lI<lp dftlS


"'III~p ~'I' '"'1' ,.... ""'Il'utd< "'l' .... "'" OI :>lUP "'II ...,'0lIl

."""" NU "'1' UO ;)Iqdw), ""1 13$ roo,l "y ~ "'"


110 ;)Iqd=' :)<ll Ptotllrq .......1 ~~ "'lI'" .... WIp......,.
"'lJ. """Id'1'o .... '"'II
31~.dw,"1 "'II dWq:) 1:

o,

.tu",d IOU nrql '00 ruv .~u 'l p;>........ I ..


PlOII "41 ;o.''''III,no.l .... ' .... "'110 ""11'~111.D ,rql 01 ~
'" a.>Wj .:14' 11"1.1.>.1 WOf' a".w PUV """d <>lUI ' 1 lUEI< Pw
:o.!d~ OI :u.:>!d""...
.:11.1"""'" "'l ' .:0.""" .......
\1,'1'" 1.",", .>.1"uJ "'l' O!t'.l(1W1l "<J"U~ ""1 ....,1(11[, 1"'"."""",

''''''J)

"'II ..... ')SUd "1...,..,,1 "'1' IUl>JJ "'''''''>I~ ~odllJO.'" "'fI"


1"" II!... """'" J<> ""'1 "'II "''''1''' "'''I'W)'''f' ;)~ "'U
;o1I1'~ ~)"" :)<11 UIOJj PJPIII
" , I ."..""'" 1"'" 3II[u '''''') "'1' IUl>JJ ~1pU1 , 1 ""')li JU""II
~ ,urq p, ,,,,"- ~ ' ., I Io>'OJJo ""1 1'>' '4!t,W 00.1''1'"'1 JO
~'!'I ~ "'J .""""""
;u;o .......(

n....

d~"IHPUtll I\Iq,u~~ lfus'I!nq

':Jtdwa:o .IOJ 'JI -.:J.l!."1 s;L\d",u... JU ",...

"'II qllnnllli .t .... .meU. ,....... OI ;0.''''1 I,uop nul Jr....

''''''J

mu.

''''''J I;'''JJC> ~W ... "'l'''''' no.I


'""""J 3 ' ""U;O' "'1' PS "

....oiJp:> >IJo!q pu.


'I1t'<J
1<31'1.> <II ' UOII,>'Ud

.n

"'1011 JO .... 11 1'11 OlliU.Jfl! II'


OI I:>INJ alIl put '.qou'l I5uldw,p i'll u~14til1 "'I:>Olq
1\11 I'U'. l>UiJ 'III IPII' UalIl '110<1 'In, I'ultti.
~)()jq ")fO" I"S ' uMOII' " "104 tiu'~ipui \pn
'I6no'41 IfII'I t I.IHUI "HJlO ~41 JO 'lIPIM 'III OI piHld lJ
"'~n JO Mtdno, t put '110<1 1I>UI't\ OMI Un 'S!'II
op 01 ' Sil0'l JO _"II _4 1 OI li UI , "
. ,,1 liS

.'''.1

-"'"

~ '''''''''''''''"'' II" "'1 ~lqdW;>l "'II UJ lfI' ', ~ '11'


Pun\:>w ~lqdUP' "'1' tin ax """ dJ"'l OI S"f'!S ""'1'P'l JO
JI""" .lOII JO """ uo
JO ....... ~ 3lpJ'>S 14111111 00..

s;ouL,

l"'.:1 l'f"O'f" ".>1 JIiJp;> tIIOUO" "'II OI .>I>OP .... OI/ .


Wtu) ~ '"'''li o

'''!lI-xI ........r; PlOII 0<1' ~ do, """


~ ""1

-" .

'u"'" no.I SlIIp3 ~ ""II """'J J"I """'1 0


....."

JO ,"U"'" -'lfn'UI-'d SI

.nt>."'"r

'",.,.~ ;10<' 0 lllO,Ir(

'1

'11 OII o, ""OCi II!'d.>!i


'~"...... "4' uo alfl'l_
~'I' d OLI U~lll .o;"nQ.o 34' P5
~J "'II o.>S "!fiii

.." "'al. ' :>J~II .~ ......

;1JOQ "".

:.>.1""'"

OI il '! u.'I' .... !\ OI J"f<O"1 .:I.qdW.:l' :>lj"p.JtIOJ_ I IV

6!r .uu 6U!Sn

..'"

l~

.oi

g'
,-

'1"'1"1<1""", '1 .:11.1<1 ..... ' "'lI. iqOlq


p.>ppIIJ< "41 411." .:I1.I<lW.:o1 "4 ' OI .:I.lU3J "'l' WIR,j
~I.I"""'I "'II 1I.'ru 1 'UI'''!
>Uj ....

ILno.t .>J:>II<o. 'Io'rri

>3.1'U~1 "". ' 31.,.,....

"'lI OI .:I""":I.>Il1 dwo,:> .:II~I"'IU.:o1 .:II{I "IqUl:>!\SV ',.

"'11 ;)(I!N ,'1"'1 'P"t't', ""1 0"11 su!d lIupgpuJ ... ~"'"
SlJO<l "'I' JO ~IIO """'! 'u.>do sd'l/q;> :>ql 1P'..lI. '~
"'II 110 ;"qd=, "'lI JC> """",,>tI "'lI <Il ""'11 .... ,11: < '''''''''''''
~ ".pI 'IX pu~ p~l>"'Ip"
""llMltd< d'urp :>ql "-lU{)
'S~"'''' 'III." W"'l' U31'~ ' PUI
<>nu gq "'" I '"",'0:0,1<1<1. '1'11 111
p:oII",,,,ud JU flOI,I.:>Il
...u .. 1ilu11P< l'I"'l
4Iln".... -'I''IiI'l W""II1":I OI fUrq S. ~
llIij
"'~l!o;o<I", 01 "'"O:> 11 s;:o"..u 11 JofI'1O:>q 0fP
-<I!d< dW",~1 "" OPU' ,,;>;lIP
~'!I I '-'11 .... ' 1
~"'II~" .(r1'11l1i p..">tlwop ~11""':..o. ~

'"'1'

.\1,

00fPU"" "'"

"""'1' """'l ""'II '11JJo\"I

"""""""1
"'1'
~I'''' "'Iid :uoq
"1.jdw.:I' "'II OI OUOjlr.;JOl 101< "'II

o,

' ' ' TI

"'fi '"

~_'" """"""" JOOj 1111'" 'IJQ 1IJJ10 W'dlJ!.""'P """1_


'l"I1 UO I"'JQt/!PI! ..... wwrp "'l' JI~ <UOJI,.oo "'U
"" lilutll":l "'l ' .I'I p:oup:ods i l
~
"'LI. ~1Ik. ''''''''''''' s;L\IIOO o:T'~'-'O ....1!P1ua] ilU

""""11"'"'

""1'111"" ""4' JI 114 "'II pul


"I",,)ds :)<II '1""1 *""<q> IL""A 11.'11 JOj 11>0 Iplo.1\ .1!0<1
3'''''''''''' UO -'lP:o.rtP _1" .>Il In" s;Llpmdr :IIi' 'olIll~!II!
"""'" 3 ,qdW;)l :>q. tuCUj R,j ft P5 :UU~J :><fI 4'1"" 3(dlll'<D
.0:1 .00!1 ....!I' .u.....:o Uf '"""" :)<II :oq -'II-''''''''''''''

'."IIfOO'"

Im>pl.oI~

....."1I IIM: ...'Ultpiooa" ",,'il IIM: balVpuI cunuot"l>


th< ...'UIt 'up ~. Chn* Ih>t lhc: rn- \o l'bI "IP''''''' 'IM:
""' .... (Iin..., 80Ih 1/.., ~ """ LIK OOIL _
hc: -"'"'
th< ........ 10 pooidot'I II
.\OUp ,IK ........, dam ... duon1

6 . ( .. poo ....... ) Shlfl li"" kmpbt~ ......lIlon


6,entl the non o r holao. If lhc: llIor of huIo;:o mlbl Ilo
k>ntJc< ,,,",,, N ~hcc" ,..... _.., IIw 'C1I>pIlt,~ T1Lc
Indc:Do(I pin ...11 rmu ... tha 'IK ~ of _ _

."..-conoo_
Opcn "'"

4. Sf;,t up thr rouln. lka_ ,II<" Ltlllpb,r tu.


CIt L...tnch lIoIco in II. IM rouIa """ 10 IK oei up ",'uh a ...lncl>C dU ......" . (O 1) ) .empbu: ",ilk.fuu nn ..,.. ...,. ..", NI ,1.. ,
III
InIU 'hhI
holl Ihc.ac Ih>t u....1Iy u>alll
O ~,Ind, Uomp IIM: c11o,;m bil In . tw coIkt. ;uI(I l ru,~ 1I ltw
. . ' ... I,...,h ..........
Nu ... oei th< <kplh ""'P un Ih<- pIunjJI: nMlla Set IIM:
"",In 0f1 IIK InDpI;I.'c. Wilh lhc: j(UiLk In ~
110"0<11 lhc:
bo' lJId lud ,11<" .........
Drup tIK _&fi rod .....

'c ..

n,

..,Iok.

'c_......

..,.:""n""".

""*

'''IIIIk

da"'...

l'uII "p IIK bol!

m:.-

!loc

hok "" you r .. n _


lhc: l~mpl':l1~ d<"'"11 !loc
"""'poe Line up ,1'1<: k'>da hok ,....,.. ..'" I:.o>t bok_
bor'N. and pu..h ,1", _ do:.>om
'he: Inda
and ont
1n10 llor hoIc In 11'1<: ......n.1'"" ~ ..... th<: r......,.. t....
apinst lhe: WOtl<pIn'C cdII<. """ do;)(dam ....
Now k' cp borillJl .
;~

In".

""*

,"c: "'tQI'"

, .... It,""". Ihen ..... ill. 1""'" (u...........,..<kpIh J1"' ......


,IK huIo;:o 10 br"). l.ud< lhc: rod""" unIock ,h<- poI ....... _
1lM: l'ULIIa 10 >Ct.
I ItoonIL ~ ....,...h a>cn~ LIw. a llJ)Od ......" kl __
, _-O . Ilh Ihb loJ: b I [IIun:gr toIIICT wIth ~ IrigI:r ...tdL
.,,1 ......
kpI"lI tIM: lUUIa """,1"11 "" )"OU _ _ ~
'KIrI LO r-ion. )"OU OII lum 1. OII and uit... ,.,..
......... ~ driU If)"OU ....,." drill~ a !<Crin oi 10,,10. lIoKh ..
lhc: onl)" m~kcr I <"alo lhlnlt 01 .... 00 m.1<D . ~cII
J>l""'II" ",..nc,..
anIMII

,""n
'rom .......
s.

1'lul1"'. OO..., thr 00""'. 1'Il.LjC In tIM: """ft" aJld


..... 1(1 ......... ' "'"' tIK rouIft" on Ilx- l <mpl,,~ ..Ilh il> "",,Ilic
C-":II,,ntlIOIi 10>\0 lhc: ...... pbtc Ilo'" ~wllm on ,II<"
'01" plu,,, IktIX\ Ilie 1>1. o.od "..,.... ' M """ft" 10 lhe:

""'1<,,

no:>:l hu,,"
Tcdlo.Iu>'

""'"""'r>

Ikot difflcull! ~

[ ....,ndl .. 11 ......... of su,pofl .,I.. 1001" ts UlY. AII


\"OU do il ntposil_.M .empli'e To.1ogro ~ in .eLl
.oon 10 'M II",~~ hoks. In,," 1 bolt ,hlO\>llll
tIM .empLo.e\ ~ndu"'ll hoit Ind Imo tIM LI" pin
_,ed In Ilie workplHe. II stlown .

r:d"!"'~"::~;

A"r pI .. n~ .000t ca .. p.odllC heltol fii tM


p'oper bll.nd Ir"kIt 10 the 'OUl". Ind Jet It.. dfplh
IIOP Ioring eac:h p;n hoIe Is I mlnf' of d.opplnllihe
IlU'M InlO 1 lempllit hole. l urnl!19 Of! tht 'OIIle'. IMn
plu!l9'1Ig Ilie bit In.o Ihe wo.k .

7 . S ..ltch I h" '''''' pll't.. 10 thc back


....... kp~. y"" .hlft 'o ,..., Iu<.... nlw= br li
,Ilo.: I"mplltle and ""lkln!!l....... ntlIO IIK OI"". >ldc
IIK indo!:x pin f""" 'H", ' ..Inch bok '''' t ........ he:r.
fn>c:t "",.Intr. """"In. ,1.......... . aOO tIM: p..~ltlon,,~ ....
ti .... ."...... ,1Ie" s.:tnIC"

Router Duplicator
AJ;I klnd of wooc:lworking Xeros mll(hine,
Iilis d. vk. helps you duplicate shallow

0,..,1"1. ilnd (urved moldin",s, hollowtil


ella l, SUII , iIInd even signs. And 11 does alt
'h l. whU. floiuing on

il

Ihin (ushlon of ill

'hmlla""',

""
~"'II
,hi, ....... k:~ b ..... h<, ...
""... ~1' II 0;, II \on~ ,1Ie ....,....".,. uI 'IOIAT.axll).1t
IS. 'IIo'h;M "''1'> ,.... n f< ...... uxb ls,hI . II "",~."
n28:l ,,.. bn.-iooI ~ ",",..-..:r.l\! II bon', .>fI
..1xdo .... ~ 1, 00) _1111 Oft ........tI, oIiek ....t:aa

II IoIItndy tl.OATII'o(' 0/10 AUI'

OI ('QUI'>C, " " " ,..,.. . , . !')Ur br2an muocd.)' ... UO


__ ou k:nuw ..... ",,,", ,..." .....,.....,. ~ .. TlIc _
.....
... II il. ohop-buiII ruuIft" lIIIpIoc;ut.- I()'OII ho,~. ,t.rn, _~ '*'tn". fora;;llJlplc 5/UIknI' oni"" ,.... ""'"

ro:- 0rI..-. wp)" ............ <biet

Thr dupa .... C'OfI"'-"'~ <>1, ..... "",bon,.1 bnm. Ind


,..., ...,ninl ...... um ......11 joincd.o an 'tr'-rklU'~"" pblCIl
TV uppcr bnm ha> .wylus IDOUn,~'<l al .... frun, ",10.1....
1rItW,"'cight !:Imi...." ,tim...." .. "",.. med In IIM' C","""
>p>ndin_ JXIO'IIion "" 1"" 10,,(, bc:>n, A rrmr. 1col"m ...
risInII: rrom Ilie pl>lcn .00 ;o;nro 10 IM l:M.c~rm 111""'1111
ball.r1nll 1'1>'01', iup por',; "", II ""an" A ..,cond

C<)IU"U', .t1><,l>cd " '1111 1'1"01' 10 .h" rnd. of th<- two


hr~m., kcc(t'o d'rm p. r"1(1 ~~ ' hey "h " p "n<l <I"wn Thc
pb 'en .llow. the <1,<.'1 ,",- to 1>0.' "",,',-..1 'U ."d f... (I\'cr a
o,,>OOO.h, Ih, s" rf.ce
U......, ,"" dupl";.,OO", ,"" unl"'" (Ot' ...... em).:moJ ,Ix!
WU<\1"lI >Iod .'" ...1 up, ""1'41<.-.,,,,. k> . ...:m Cf of.~
0>..... C"'ct)' ...,h "f , 1>0.- '>riII'""h """""" .. " II ,Ix! ... }....... ""
!'OU do ,iii>, tIM.('lOn'iIlIl_' tIupIOc>oc.
Thb .. rw-a ..... ...,."...., ti ... tin'..,., hoId. ,..., otl_
Rnu dilil;an din'l'llj' ' ..... r ,Ix! hI, (t1>r dI.unc-r ,. ~
:odjU!t'bk durinjc ...., ................" ...... p II 00IIIpk1nl. .....
<Il" ,"""" b ft-) nw, >1)"" ..... b;I an ~ .... Id, bul
"...,. <10.) )O ,,*,,,hcr ..1<1 ,....} .I,,'a)" ..nar., ,"" __ :u..

"""C1" ,.. ..

TIu', ,"" """1Ik

""UI'' '

of ,IIe
~1Id<otwnn tkooipI
"", pLo ." .Ik",'. U", dUpOCa' QI"'U ....inIl....,.,.u ..........
,,, :1,.. ,,,,,, .nd "",..,... /In II> ~u""lon of alr bul t h c _
and<o!,unn >lru.,un:
Whi", ,IIe

III;Itnt~ln)

,tte III) ttu4ltt Ulii

</j'n..,,'" .of , ..., ...~ntCI..." .. 11_10:1)' .....

rou';,._

kOUT(R DUPlICATOR PLAN VI[WS


TOPVl(W

.-'">

-.J

-.

,..

510E Vl[W

..

~,..

...,..

19)t

lY>...J

1 9 ~'

\10'

--1,....

,
T _;.

nit."

...

8()nOMVl(W

EI.

.::.-:::
....... . ..

.. I

..11. oi1,..

Cutting Ll st

Put

Qtv

Pivot blh

~.m

sldts

Beam wtbs
Column "du
~

Plllfn 'mGUnl eolumo "du


Pllltn

r~

Plattn

~urf,ct

AUIcnmtnt blcKk

Mounun; 1>0,

"
",
,
,
,

Olmensio n s

Materia l

~W

H. ,dwood

1i')C 2 ' )C

,w,')C 2\o1')C C8'


\I,')C S,w,')C 191t

H.,dwood

"p"""

1I')C2')C 12"

lQ.dwood

,w,')C 2 ' )C 4'

Hlfdwood

'" )C 15 ' )C 20'

PIVWood

~ f')C16' )C21'

PlaStiC I.Im,n.tf

"')C 11i')C 2'

lQ,dwood

\Io')C 114" )C

sit'

ROUTEIl DUPI.ICATOR PLAN VIEWS- COHTIHUED

ILACKVlEW

...

,w

Hardware
a ~ ben...g . W bo/'t x

ao-ring.

0,0,

x ~"Ioog

d~.

dryw~ ~,t"'., ~)<

1 'nlll,

I~"

1"

w.-. 18
x I"W
,18 x 18"

1 th't.d~ rod. ~':18


1 thrNd~ ,od, ~.

4 htx r>uIS, )o!."18


1 11f'd

~r, lji"

X 1" X 5 !t"

1 boii. d.a 10 m.td! roUltt bit, 3- long


1 .... "" nUl. ,in 10 maicII bolt OR 2 lIu nutl, ,Ile 10 I'Nlch bol\
~ IIW , ..tum"

, .... _

plo''''''''''''~1 >I"m~

,,.,., ., 1","" pk(t' '-4' x r

x ]0' ~. IHKnH" lot , .... , ..,


Routt. Oupllu,tor

2I

ROUTER DUPLICATOR EXPLODED ."IEW

P,\IOt block

/ - - P!.ten

I""",,-'[>i<:uou!l I'I'C'llIlIJIuLlr b<uc rrurr "", u;tllj' bc


tlK ,",oM (...:Inatin8 ",n 01 tbc <IuplrAt<lr It dl>trihu.o ~
OI>h"'" 01 lir br:r..'""", tbc i>lI ~"d thc ,;urfacc: , ... , II,
I"''''-cd on. 'in ""II)' dlrrti""';1\1\ oII rrictlon.lbIs .Ik..." ,1 ...
.... nCT;mol il>,.,.'mx-.d ..,-1", tu n.....'C" ...-~h.1K gn:.t~5t of
~-:&>c In a borizo",.1 pilul<" TI..- """ "'" ;" , ... , 'bc .1.
~"U"blon .... II.> origln. In .IK
01 a >hop '.lCUum
,~.u pr.. h;r.1>/r don hlnk 01 )....... ohop , ~ "" .ou..,.,
of "".. '1"<: alt no... lIur 0.11 ,"" alt 1, ",... ... , In Ius to ""
>omcwb~", OO
>Ofl1.CWhc", 1, ....1 Ih~ ah.''''"....
Gonntt"l ,IM: hc:>st
C)lh."" pon , .nd r""
alt
M"",ml.,. om o( it C"nn~c. the r..,., cnd of lhr ~ . "
tl>c pU'en, whkh dlMrihule. 'hc 0.1. ar;;n>SS a suri. ce with
t>r>C .ior hole i><"
Ind! . n.c ai. ~ushl"l1 .h"... gIt
tlK", hob It<os enou'" IOn:c to ni"" th~ pl.len .00
."I1>'c,c, s "'1011"1"" 1. It <Ioc.n', ... 1", It b._DU)W ' ..
<lent, tl>e

tu..,.-

t"',

,,,.I>e

oq""'"

22

loutt. tMQtc

"'n

ndl_l>u' ,h , enouKh 'o m,.,."" It r"""", IC"".' 111.1.


...,...,.h liuri.ce
l l>c: ""plrAtOf i> tbc 1"UU1. ..h col!. bor.ttion br:r .........

FrC<l M L:Idr.,

""""i'",, ma,..,o ..r ,lte Rod..alc Pn:,;o ~

SI><", . OO lIoh Monn IO."OOdworltlnll "'riter anei edItor. '


u'llJ'd f~ 'u ~"Umc: up ... I. h """" duplinlor 'o pru>III">. COPY oimpl~ carvl"5> . neI hoIIow ou, ><">.. fur
.cool. Of d ........ I h;r.d copico 01 phot.... 01 ~ommcl"C"bl
tluplic:u ..... Ind anld",
'''''rtI do. arni "'..,..
",,"c In(ormat"'"
>hop-hulll dupllo.or r""" I

</,"'"

.bou' ........
.bou

1,.I.l-h 1000".

Nal ~ 1 UM:w. F"", b.d pI"Uf"'l"I'C ~


kccp;nlllht
"'hh whlch)"OU .~"C 'bc ~ot ",ucm . OO 'bc
.".11 .... hit .... hlch cu.s"""", ......."'...... II"" 'hc >1)'1'" il!It>ws. In perfr...., ol!snfIl("fll. bulh at......y~ In Ibc" gnl<" uD-

rTOnl ,II<" ""'" ccilillfl.l 11<" k<")'. hc c<plalncd. b

..'1....

I~

,"" ... pcDltUCl"'" from ,""

ttitin8

Building the Duplicator

","""ni. bu'

.-ked Ihor hooizom.:Il "''''''' o( r"" okvic-o-.


II h ' WI"S L.uCT.~ ,,-orI<i~ ptUlOfYpC of ,..., dupliC"~"'..
)"011> "" ... "-as tuI~"g I>ad: ~nd funII tin ~ "",",""nell
\III nnoonW! "'h<~b rhar ....,mnllO "" JIOitlJl In .,
n. 111_ d,lfcn:nl duttolons OI OOCe. E>"<:nlll:III)', lIob
mocml ,hl. p;onlcubt pietUIT a"" ,""",ribu,~d ,lIe idt.....
for IIM- IIK"u>hIon pl~l~n a. , ITpl"""n~n, for ,'''' canoon
...web. lIe 100 eon,ri"",cd Ilie kIc:l of a>6Cmblin~ ,"<"
~ >nd Ilie c()l umru ... itll .IIIT~ rutJs Ind n""
" . . ~mblnl . ,"" ...""N"""U", . . . knockoo ... n uni.
Irotnt do, ..'n Imo hc:>m~ ,mI c"I"mns .nd pL:ouc" . ,11<"
~,or Js far "',"'. 'n
nu_ column nd .... n~

.si,,""

....., on """ In.kk ,h~ h .""n,.


0L0y. )'''U ""l;k', mllIy "'~~ . 1"" ,,11:11 (W"....,kaJ l1OOO Js k'
RopruoJucitlJl can'illjl>. '\'e mcn, joncd. If )'Ou Il"
Ifttt1"4lld-nun",r.1 >1 ... ,,<"11 . you ~",n m.kc .!glt>. \!lU ~.... n
~""'" <.... n ''-"'' an"v"r cun',-"" "KokllllJ(!l. ~'''u ""'n hollo,,"
OUl du" . nd ""nch loCI <5. Ilh:tllu ... 00..-1, . nd the I,b"
,\OfthInJI,Il:I' "",n Ix-" vk."wed as ""-"",I,d c:>.n,ng 1. ~od<kr
for ,hor ""pllc"~'''''
Thc <lk:''''''.ry dcline,; I.... ,..,tld oculplu",l ",bcf in
"'I\kh ,"" Irn;>j=lon ftQm ,h..... urruundln" OURK" ... Iigh.
lIId 110 ""n "f ,"" m'><I<.-k...... ~'"" 1. un<kn:UI " In 1111> "'....""
Ilie .IIKh' " .. >/11< .... .. lI",jlCII tu. CUIlplc of indIa.OO
<hc pmocrip,ton ajl2lrl>l un<kfCllU C2JI onI!' Ix-" riobl<"tI 'u
<!It ~iJIlU<>l <kw"n-" by u .... " haU miU In 1"" '''Uler ond
CIJmStI'''''''ng "riu>.
If ,h;' ,,""'-" ("",Of)' (It ptO~-!0h09 dupllotot
..'ilh fuul' or Ih'<'IlSt''''' pricr 'lIjI. II "'OUkl hr In",,.,,.,,,,,
10 rod .boul Itoo\. il ..'Orb. T1M: ,*"""nl o<,,,.;.c ;,. lhal
Ihis hom<'bulh <luplk..... 'or tIuco1 ...11:.. ,"" commcrrlal
<'QUIpmm1 dono. Indu.b ,"" oopIIIldcaled ,1.<V:>hIoo
~ (yOu """,,', fond
on 'I\oo;c C'On'm<:n:bI modrl
Iu <Ior:on't root ncarty ........ p u _ wplio,or ... IU ..
Thb <iuplinw. t. hulll 01 ron.monptt 1w\lOIo'UOd
Iumhrr and plp.ood. U5C'$ of1~1Ic>obc-1f bori"", ...d hanj..
......... _ ""'1";..,, a >hop ,.,.,.nd" l:tmln:I1 ... ,ri.......,.. n~
oItop ,.,., mll:>l ha,... " """'bIon for conn\lt\jIth< hooc
Ihc ah;oust port. antJ ....... v;>O 00. ' "ou 110,,'/ "',,''' II><'
~ _
JlO"'"CrluI '''''.l'hc LlmUw" ,rimnoct .,. noI
","oppi"" 11"-"'1 pai .... >IO)..a...doJc. RIUl ...... ""', you ..iti
......... k 10 bc. ,.Cf) pr.o<1lcaJ roul .... ....,ful (or.1l ..,.,~ 01
~ routirlfl.
'OII clon', ......."tI O<ldh:t.U. hard ,,~flnd .""',,. Il,,> Ari
~'of ~........oo~ (ur fO"ndn<>600) Iritl.V1Cf<}O\'ct"S ",1

.b<l.

~"ncrr

In Ihl.. "II b nu ...."hl ... k.... ''-"'' tlull ",Inl .. g1 ....


nlO", of lI.and " (ouplc o( Ii,mtded
t('lIctll\-"'. Maf'1")1nll 1:>;111 bori"". . ..ttid\ .....
normali)' .,...
wl,h ""-1.1
I \\'UO!kn
.. ruc'UIT (s '-""~.)' and .. r~4th,ron."rd ""'. ""'I~!oOnM."
and cune .. 1..... YOU n<2)" nor ...., ... )p<"dJ"loJI)'. )'UIJ'I nccd
<lrill bit ,h .. cuI. " d,:.n ""..... 1iii ~ In db""-1er III ......
Ihe "'""..... <>, ,"" ItaII hcarilltlS. and pI"8 Of 1'-""""
..."'". Ih., cu,", u."1M)Il> "",h p;ol":llld Ioidcs (POt .opnn!J '1 ..,..
10<:11 In <li.nw:1cr ,O n, r"" In"'-"1" raeo
.,
lIc"sin I>uikl,<'IJt ,"" <luplio, .... .,. ....1.....1Ie t:>ox bc;um
,1 .., brm ,1", 'OJI and bo"om 0( ..... ~. lnduduljl; ~
The

and .<-"~.
rod; 'k li",

""""wu r".

m,

rei.,,

""""ructlOll>. 'o

"'ti

c"

_.

<

,,,," p;'''01 ~'" Thm m.>.kc .....

lkIt:t"""

coIumns tIw
"""11do .......... 1lIc .11'
~"ll>hiun pLI, .... roma nc<, . l>b1.i .... , .... pbt"" S. lOmpk
""'".,.. o( routinll wid of IIfUO'ft In I pka of JIII...'OO1I.
"I'"l)ing pb<tloo l:tm"ute 0'I'eI" 'hr 111"'''''0.. and drilijng .Iny
"""'" thl'<JU8h ..... lamina,., 1",,, 'hr 1IfUIJ"...., AlIX"tI 1","
(unn

.hor ,,-"1nlI.iniDII skIo

pLI, ....

,o .....

o( """

rouIer >nd 5l)1 ....

panIIdojv......

:and."" duplio'O!" i,>CII b

1IXlUnt

th<."

C'<""pk"~~1

Making Ihe Beam-and-Column Assembly


TI.-

"'titbly b ,1Ie

,"u"',,,,, ,ha, lI"kl>

thc mutCI" and thc Sl}1u<,1<ccpins unc po:rIi."CIly oI.ignc\lln ,..,ta.... ... oM otIM:r. 0c!.pi1<-" .... Iook.>.. it b ,~ .ur')\Ic <O huikl
I')OU tak J....... tim< and.'l<1 up cxh oper..1on an."fully,

1 . Cui Ihc ph...:>t b locks.. I"d 1"t"COD1",,,,kI p"'pulntt


pic o( >1r;tigh'1I"'!ncd ...... k
.1", Ihk~"""".nd
"'idth SpO:<:ified by ,"" C.. ,,1IlS! UsI lOr .lIe plV<)! 1II....' 1u; It
.>bouId br COlII'''' offttt 1on!I. C.........'" ,1"." ho;ortl intu n, ...
pic<:a "'t i""""" k'DII. "T1IC
pic,:... ..-itI . lIu,,"")'OO, III\-"
lu"u.,. o( ruin,"t! on ... wllctt -S<-",""~ up for cunin" '''''

'o

>insle

ex"-"

'eftOfU

OII

th<." ends.

'o

",>-

,~I>i<s-((IrtImOIIpbcc

all_'Nil1 ~c". YOII ,k, n~",-"01

u. . .:.n" ""

for ~"""h iii, )"OlI


)'IIU IPln ""1"<'
rinI. }'OU'1l flnd 1.... ,l"U lI>e _',-""d bll~ OII
Prof<'c1
,"ou" >IMI ,... 1," r:.;rty l:ttgc.;:HlImc" " "" '" ck'" 11.". ,,,-".
- . , ~ corN:>olf ,<> RIUJIh 0'" Im.:., ."d ~ ' -dncr 10
odinr .""",-,, Il....... and c,ch In nil<." o.k. ~ 11
'bu JUSt mighl find ,hc duplb'o' U>dul In ronl""'-'''''''
..1th tund 'ooIs.To "'pn:.><l"'-"" d lr '"--~ ,~, fu. cxtmplc:. )'OU
an It!<" r"" duplic-' lOr n1'>l 10 cuI" >crio o.. jlaul(ln"
JI'OO"e'. Thco )'ou can II"U"", oU. Ilie .".. .. c "'Ih ,"" <lupii ..
~or, ..... ruu~'
'hin~ OUl 'NI,II >(I0I0:01'1.,..... ,.
.. _

>l)11Oj

""""'Il

",,-w.....Ind .b",si'",.

,-"a"'.

./
Thlt pivoi bloc" Iltnon s e tu. wlth. plug {uliu
thutked In .,.ou. ori" pn!". Sotnln9 IflKn.o ReUn!
,he wort.piltcn 1$ ilie pt!nnUJ"9 ""n . ~ tuue.
ItselllNke-s Ilie
fo<mlng ....... k fooIprool

,f""".

Roule. O<tpiKilOl"

II

CII

2 . Form ~ ""....."" 00. ~ 1'1...,.. b klocb. """"""'"

,Iu.. ;,. ~ driI """" """....Ion. ....... IRi..

""'It

;oI

w.k ...." >CI \Il' .1",.

madlinC" Thc
hIoock ha> ... bt- aIiJUM"l ...'I,h ,IM- ni. "f
tht d>oct<. (:hu<1t ~ Jm>,u~ .....~ ..-r hit ')f ~ ...-n'crilljC pin In
"'" liriii """'" l>r.ow di:lIfJ"'IlS ,..,..... ,........-nt.I nf. ('>Im,
bIodr 10 linii , ...... .......u.".. AIqcn ,tu. P"'" bIodr ulMkr 11..
drIlI . .. .. ~ ,...... '1I11OC 10 ttnI.". ,,,,, piec .. pnfeC'Ilt 1bm
cbmp
II", <iri. """"
tu f">dI _
pbcN in ,............. JIOI',<ln.
t-_ ct> ....1o, III".
OI" ' ..
in . hor 0011
ptno..
JtOIIljC
C'"
I"non
n, .hc:
In...". .""'" oi ~ b:dl t..-. rilljC (""d noe I'I~ ' 0 bttntt a ht:lk).
)UU do)n "1<'" ,,, ...... ('>1"11 cun .... 1"'" ..... ~ . .. ~ pb~
l ....Ioc .......,
oi ('>1 ..... CU"", u... pnlllucn
~ ..irh pa ...1d ........ ."..,.... 01 "'" .........,. 1'1.." .enon,
__ ..,.............,..". '<t ,loc <iri. "...... d"'fllh ""'" "" "'"
...... ,.". MA CUI ... In'."11 In.o .hc: ....... ", 1"" bkK .... 1:. . . lC!oO
, ......... , ... II ... "", ... 1",'OCobIooek hLInI< IQ chi: .h.. >CIlirltl

""*

"ne.,. ...

a
M"".. 'l"''"

CUI",,.
10

con ...,

""n nil'''''
"""Kl
10

n .....,..,.JO/W 'n""

\\'ilh lhc ( .........:UoeM of IIM- ..~"p ., ... Ilnnc:d ru,


1"_ " (MI hnl " ~.I<b 01 aU lhc: 101".1<., (lncl~ 1.... ,,">t
bkKk). U II... ", Io ... y l<'lKkn.., M ' hc 1l'adI> ........... or
.. I""'le .. h;"'""" ........" 1II1II .1Ie I.....,..,.damp II.... 10 "'"
,.."".,. Thh. '" MI !'i'o:' fOII ........ het """ ...., prc<'l><"
.......... ,h;u .... MI 1\1 Inco ,loc lIo::wInp lor"."..

3. Trin. Ihc 1'1.-0' bkt<:ko .... hod. fln:o.l ~h;r.pc.


1bi> b "'... donc "," h omooIlI,(, ... ln_ ~ "JM('" bIatIc un
'hc: ... hk ..... lo'ridc . ............ pIn...., ..ith ci", ",il.". III ..... ' 1,
>huukI h:.. o:- an ""dlary b<:ilIIt for ,,... <If'<'r.I'ioa
Ad;u. .hor hUck ~ 10 ' . 1oIdI, or - , _ _
lcf6 (l'ht hbI.k ~ lCIdI 1"" ...........iim ..... bkKk
OII .:tW, .... "'" ...... '"'.. Il .) To '-'''0'' .hc 11100.:1> lOr
,ht-< lfim CUI .. dImp a "Of' hkx~ 10 ,lot mii", .,......
fadnll cno.~1t' 1'. 11I<11G r""", , .... hI.odc: \"l~ ....... tor ... ",

h"'.-l i. "' .... it""'"

'" ,..., -...

,......'". "",.:tlC") '1 .....""

l.......~. Il It

on/J' "'"

hIod." ..W lIe ~ ..hm,..

II" 10 ",'" 'h" ..,."...,.. end ula bIuck


II Ih. plUJI (uII"r , III. a nun ....

lCfUUI'~

aruund Ihr

11>0.: ,rim CUI. IMI ..... ,.., 1~,1r nuIIIIoIm al __


!oU ...... "" JU>nI :lf'OUnd Qlil lC'nllI\ TlInr can IX' ..........
"oIh. dIi....
"~"K1.

le""'''

o.nn.

~. ' ruitaIJ
o.rinp. n.r
CNo.lfIOO IM
. ...1) III<' lnnrr ........ ",.IX' l>o:2tIr1J <"OIIUO> , .... povoI '*'<1
1'hio is impolfl.nl
PIVOT Iloex OETAll

TOPvtEW

m==~
'" :::;::;:t..

,.

Lc::-;,;..-:.~

EIIO vt['N

{;
L

YCTION VlEW

t 1'0"-<1 11.. bar., .." clHp ,


bou .... QUlt' ,~. of bun"!!.

OfI'IIe. llelf "'-Il bu" "!!' .


'fi" ba.e, t l1l" 0 .0 ., " " Iong

Rubbe. O.I"!! ,hlmi be",nglway


I,om .houlder 01 piVOt block.

Trim tllil sllo.ddlln of th. p lvot bloo;k III"O"S OII


tho I.llbll! 1.1"', Wnh ~ nap block ,~m~ 10 , .... mII
Of (utoff bo~ faclng, ..... blOCk, a aUlomatl
cally po,itiontd 10' tht cu ... NOlt Ihal ,he (UI' au
~e ... ith Ilie blocks standlng an tdge .

gauge

,,,o d". bar., It" 119,


P'OVK;U ,lI!a'~rKe 101
I n~. raU 01 blll",,!!

1'111". tub lenon" It


Ion!!. fu ba" of bU,;,,!!

Consul. ,h" d",wl"~ 1'1,." I/In<:. Or,,,I~ You1l 5tt ''''u


,,-ou.1d p,,-,h 'he hc.rin", ali thc "'21' ""'" 'hc
1<tMXb. 'hc OUI~. = 0 "'ould rob on .hc
lru.lod of
1....... flttl)' 1'11<: ><>1"lion tO IhiS probInn io 10 "il' a
~tcr nrin~ on to c.d! 'enon i><"furr ImulUng
dIt bnrinp.n.., ().nntll".,.IIk.. Ih .. nttUnl cI..:...JM.... . ...
"",,'a in Ihc d",willll .
..... cl'li:al"" .I,,,n..
,lIe O-rlntt> b pka of .. OUI
0lt1Oll ronl (ah" ... t ', .. locI! dl;,"..,t~r) ...'eued ,,ltI. sl ....
..."", ~ ""'""00 thc 1>:0,., tii '1 ... t""'lf\. "'" hokI k In Jlb
_'dl dw: bt'<>rirlfl. ,,'hi.., ''''' iti"" drk..

"""*"

jf)'OU

,i,,, '"

s.

l)riU lite n " , ... m lnlt rod I",I~ throllgh thr


P/>OI bloc..". l'hn<' ... I""h hoit'!> ."" tor Ihc th~
rolo INI help Iw.tIoJ tIM' riIt "'11'-"1"'" 1'hc hol<: mUSl hc In thc
ttr'IItT of.hc hIorl. '~ '''''e
noo the L"cntcrpoint. dr:o...
di:lpal1inn:K1U 'hc ph'ot hl",,~ f:>
IU 1'''' dld in ..,"1"11 "1' ,,, eu, 'he 'enon, Iign Ilie
p;.... hlod ,,_, d'iIl
'hen d.hl!' fentt>' 10 tlle
driU plftS bIe-.o bold Ihc bIock ,.,..u"" whne,..... drill
ThC><' fcnca "'ill .1><> ",ne !O pu.i,i"n Ihe "Ihet" bl<>cb
lor drilling."" ~ ..nI}' h ..... ,,, I.y "u, ,,,e cen'e' of
fll'>l bloci,.
UrilI 'h<- hoIc>

1,.

!>i'.

t""

.,'1'.00

6. Cu. che beam p;o.rt.... Thc ...... m~.re lhe


bot."", (""'ICI>Iy hon<oot:il) mo:mI":I~ <!f ti", p;t.~.lId"w.n,
t/tu """1'> ..... 1'OlII .... '" _ ...nh ."" ..1.1 .... 1' ", hc.n. okks
iI<M<: ,.... ' ........ _ ... ,tit"" ...... rin~ . Thc "'d'" "c 'hc
p.oI" of .. de, 'UII<"'II::'. "",.11" tIM- t..-.m.
Ch~ ti ... di .............. "Jl"'dflCd I>y iii<" C"" "'lII.bI for
,10: bc'ltm >i<ll:> .. 00 ",en.. hnnnll ;n mind ,1 .., tIM: tiot 1''''"
)(111) t .... n...1 tltn"'n"""" of 1"""" p;t.n . "'-IIi", , .... "..,'"
ultlm:lIdy "ill hc ~"';nchc; "'-ido:. J9U'U il"I .. no:2la ~'" ir
,fim ,1", ""cbs n"", ..ith
~ 'lfI'" .."",,".bI)'.
lhnriore, Ih I><'l'L"r 1" cuI thc-... 'SI; 'nd"", wldc ~, , hl.
jdnt ",., ";<Ies. un , .... 0100 11>00. ........ loc .;:.lI tu 'hei.
liIW :IilC nu..'

t"'"

roo

7. 80re thc bt;oorl,,1I, ~ 1" ttot ~w.",. 'I1lc.'"


.'" ~<:ppc<I-<:ow"ertto<nl. In dJc... _ ... Ih",.-II
boIolI .... Ix"~finl1llj:hll}' ""I....,.iIk dc-;o",,,,,,, lOr 1"" mne.
noct n... " ule , h., Ik......... tIM: hcarinl1 '" ,'~ i""""" in di:l",.
<In:and \j,. lnd. ok.... p "11:: d"",.....,.. .....~ .. """"">Iri<:: It
10 '. Ind> d .. AK"'n ~nd '", in<'II tkq>.
IIqcln 'he ... ori< hr ' 'lnl1 "Ul .hc c"",Ie,," m , .... 1"'"
lntintI rece .."" th.t n"",t "" 1>0..-.:<1 in ..~h , i!,le 11'e
Ioatlom ''''' ~ho",n In 'he Mu 11.... 01
dr:owmR
b'", /J"fIl1r",,,r I'/m, 11"",... Thc """'" .re een,,,,,-'tI
beI"',"n Ihe edl1~' of ,he ~kkJ . Thi. . . ~..,.,,-cnicnt
1troI_ i. ""'OI" ,h.. ,he fQu, p'ttC':! """ kIcn,lc:olr:o,"",
tIwt "Yrnmctri<":ll Y,," dun', h.'" In ~~." tr.ocll m al""",,,hoH:! .... p:o'1>.
\)nI ,"" ltto.stS on UII:: drill """" UJi~' , '..""...
.......... Foro<n<"r hit CI.mp. k ........ o Ihc- 0011 "",", .. bk
IOpo>iUon 1"'" ",,",pir..-.:UI nd .dlu.. lhe ,It..p'h "'''1' "" 1""
~

'n

t""

"'*" ...m ... C1X'I)' 10 ind, ok.-q> c:lM:dI ."./ ronllnn ,IM:
cIrpIh .op !tr'1111'11 I>y

P~';1lj{

bcJrilljl inlo

(~

hoIc

,,<,,'

,
-:-;;f'-,Y
'i

of

".
.', - -~

"Y-"!

UM . fIlM_ to 10CiU. Ih wotkplecH. aud bonng ~


.. ~ hoIe. for ,IM! l>earl1191 0 0 _ Ni.... Iod! haIH
_ an llot """'" uls. T.k~ I~ 11"""0 ~ ~ ~t ~
........ SO I~ hoIel are ctnltred across I~ beam >idft.
Then drl' an the be ... ing l>oI~s. Aft~r s....ching bils. dnll
d the <J.a.on<t hoIH. ;os .hown M-r~.

,...., bnrinK ~1Id .... n",h "Ith UII::

l ll::"~'"

""'" .. ben k .

fulIy _ n i iA tIM: Iw.>k


MIc. Uri'ltng an IhI. bt."Orlnl1 hol"", ",;,d! biI. and <lriU
,iM: nnc:t"f1la dca",,,,,,, "'-..:n.....,..])On' l """... 1"" Jcnct-: ~
;n thc
putitiun'" J"c)'OU ck-.,..n<... ~
ronccntJic ..ith ,"" """rlnll I>ok:o. U.... ... 'odo Fontnn
hi. y"" "'''' I nn:d 10 ....
of n"'len.1 ""nem"""
J"" "" Ind! b tkq> ...... JU!1I.

'ho' .....

nwn

"""'C. ""

M. A-~"'n>bk: II..: ht.:~",_~. ">...."'blr ~p'un:t ,""


......fi""" and pi>'Ol bIocl:. .... )'OU \\".'" U, 11'" ,IM: unit
"""",,"'II_hlr hcforc .... ~;nll.hb I....""'...... 'k'" pc.....
"'or 'hls ~ I $l1fII!i"'I' )'Ou ''''' A,hle ' hc bel ....
",lth "" .......~ ""1)' Afl.., ti", dlll'lk"O'o, 1> ~"Ompk"c:1y
. >S<"mhlt:d and tNlc:d. hul hcforc ro" put It 10 h""l' """.
~I"" . hc ....1.00 ,nm l""m.Ta do ,h~. "'nlO"" "ne .... t:b
.. ~ Ih..,;, . pp/j' .......... . 00 rcdri,.., ,,,,,. ;c"'....~ In ''''' "''''''
h~ Thi~ c:nStan:$ th:>' Ihc .. ch i< ""'inl! rcturn~-.l ,n il>
",,;oct . ,e"cd<lnd-f>ro'\",n positiun. MIc, .11 ,""
th,., I"'rtn.ncntly lixcd. ""'" '","er " 'jlh flII'h-1rin,mllIII
hl' '0 ........ tIM: wri n'C'll ",';'h tbc >kk> (Y'''' CII' t""
1111'" "' kk. "",,,,mba')
IlUI I'm 11'1"1III'1w..-.I uf ""
OeWn .It........ n'hIj ... ,><iI: h) f>"t'I!'I"" Iw..-.nn" fI,lIy
InlO """h ~ In 1.... lInm""'" M .~e......, lh..')'~ .... nu,.,
.. I.h tit .. ,"rfat', .M,hI. ...... m lii<ItcI '00 Ih,1 Ibc In"", r. C<1I
'recly
Now InS1~1I Ihc f',-oe 1>Io)d, Cha.1< tl>:o, )'OUr o.ri,,!!,
{'" 1tl'''',I-<-~JRl "'" ...., "., in pb (lf\ ,h(' ,~. \Vilh OI ...
u( ,IM: "'-le,
fl:tt un tIM: hcnd! rop, iruorn pi\'01 bloci<
In'o <'2<h of 1.. h""rinjo:>_Sel ."'"...,.. ><k 'n [lba. "".1i1lJ1

,,,..n,

""'Ilo .""

....,hs.

'urn

,.,<1

CII

.-"i!:
~

;II " " ' ' ' ' doun't ,ull.,. requ,'e Ih'" O'
ro". ".nd . LI.,.. Jide On Ihe wOIkbornc:h . nd in_eri

An'.... bll"l1

bunl'l9s In I"e ~ctsse._ p~ss a P'VOI block InlO tadl


burtng. fII a'Hond .Ide. W'uh i.s bu,lngsln pun.
_o Ihe pivot bloch. IUghllht lnembl.,., and lpp/V 1
<lamp Qver tacll ",VOI bhxk. as skown htn. 10 l>oId
Ihe .uemlll'!' whl ~ VOu .crtw ItIt wtbs In place.
thisoilk' bn .. nj' ",n OM ~
bloc .... ,\t.~c SUR' tM.""""", 11'1 _II th.:

."n"n. "" IIK' pi_

""y ".." ,..., In..",


r....,. of ,"" ~ .... IIM: o-rinWO ~vnlXt hol"
,e"o"
oJlOIlkkn:tnd ,I'H: """rlJljllnllt'r r.>Ccs.
~, .1Ie ,..".,..,hly,and 1iP>'1t' dunp .he si<l~. '.,.,nhtt,
~ ."e " b m"" dlm:tly """'1" IIK' b,.. rillg. 'TlIi'I ..iU
cruun: IMI .here '" abo<>lOldy "O
pby. 1'bcr \wO
oi th<: wdJs OI> ' Ik .....,ml'>ly.,.,. "''''''_" In II'" SkItII1",,', and
"'1t'W Ibm> In pbct' U,.. l.mm ~......"I
Turn OM

t''''

.kk-I..........,
.,:r',"',.

n,..,... anII "",",' tir orhtt ,,.'" wdl!o In pUa .Tbc


pn"Ol hl...,k, 51>01,1<.1 turn
In the hn~ ..1><:n """
an: don., onod ha,,, """"..w Ilie d.mfl'-. (lf,tK-1' <Ion t, db,...'.:mbk "'" bc2m OI .... II)' "1I"In. 1111> II "'hy )"" dOn ', gI""
~

,""'It'

"", ..m. In pbcc,)

M.$nI.bk .1><: SttOnd bean' In .h.:

"'u,'" ,""2)'

Lar Iloa bl!a m ~ and <ol.. m .. ~ .... Ihe. wo(I<IM .. .,1o 10


... ~mble th~m. Li", up t"".~ subuiemblies. Inun
Ihe Ihruded rods. an(! Ilgh'e" Ih~ nuts r.~"'lghl.
Af.~, lhus lying t.ht! parti '''II''lh~ .
ahgn
men, of ''''' pans aS nKes~ty. I""n d.1ve scrtws
th... ugh .1110 plvo. bkxks Im.. t.ht! eolu mns.

",n",.""

<,III" .hc p;rca IO\oI<1ha. '"",,ing a "'''IIk 1H..ioa


",>lun," Thc: dn ..in~ O""',,,, ~ I)rtltll <thowJ llot
~""'lIJII"IK"n, o( the
1f)"OO, fioo it ""'"' """,m""" .n ~ .1><: p><tI
.~I><:r ,' .. n '0 cbmp .""'" " 'hlle: tM fii"" <Irio. nul:<
.......... 1><: K~ ",,,,.Iie In.hc pUh oI.hc ~ ..... )'Ol,'l1 mUt
In .hc .."'.. ""1'

p'''''.

10. Cu"he <."01 .. nuL' '0 ."ogl1l. When tM""" il

,,<}'. Iri", <MIC" nod oi."" lo,"~ <"Ultlmn ......."'. thm ..... ~
i..ro '''-0 l-tndl1onjI [>It:S &nd '''''' 4<o<1t.k>n1l rti~
"'ti.:" m.>~ 'hoc cu'>. maIo:..,......, )UU( bUck il fXf'
pmoJ;';lIbr ta '11" '"" ...;obk and ,11" Y''''' mba ""..., rmc.
l< petp<ookulu'o .lte "'tlc( pUII" har, bttoux yuu ....'"
.t", ctrui to hc Oi "'1""'" '0 .It<" ni> o( II.... """'n.n :Il YOU
QIl

lI<"t Ihcnt.

9. M..u a .,olunu. bl;o"k. ...... ~, ,hen::lA: Ih"",


MIi."t'<11' coItlmn.' In IIM.' ~"""".bIy.1t .. ,"lbint II, 111 .... UfI Of><:
kIn3 coI"mn. ,l><:n Cn"""'" it inlu tI><: .ltn,".: Plt.-.;a: ntttktl.
Ik:lIln lty milhlljC ..... rippiflJj ti."", p;n.'D of .. r.olp".
ll"Iin~ol IuonJ .... ><>tl .. ock .<> .It<" ,hi<;~1><:S5 ,,00 ... id.1I
,pct;il""'" by lhe Cu."n~ 1.1> . E:odI ,,(,Itt:$ 1'............" .h<>ukI hc
~ ", j(l.lnd. ""'Il.It.
26

Rotile, M.1I1K

II . A.o;,;entbk thc:

bc-~rn.' ~ nd

WJU"IIl5. ASsum'lIjI

tiu, J">u bc:Jugh j6.!nch lc"IPtI o( ,h ....:-aokd rod ... w ~


in.o OM .,.,.,., ,", IncI>t... k>nIl &nd '''''' III loc""" .....
AefIIbIc .lte ho.o; 1>0..,...... coItlmn.'. '00 ,lt,,-..kd rods.
:thQwn In '"e KOtll,." IJuplkatOf" F..~plodnI l """ ,

You II ha""

II> m.>~c "n~

dePlIn ..", rrum " '11.'

}"OII

tOLUMH AS$EMILY DETAI L

$_.

PiVOI bIoc:k

OI

III

PivOI bloc:k w llll

bu,lnO OtIlenOn

..., in I h~ E.~pI""kfJ 1 1~,," 11><: kJnllt"' rod c~n ' l K",w


iIIo!b< Tn"l un ..., pl ~ n hn"... "",, lO" h "'~" ' 1 m ~ d~
iIIooor pan~ ~ J.... Ih,n" ~n ",UrA nu. ""'''' Ihe ru<I fu,
dIt Ilme be,nl.
.-lth ."" n .... <In ."" ,h ..... dc.J ru<I ~nu~ al"'ln" Ih ..
p/1'I)I bloc ... bul noi ....'crly U!lhl. "r .he """mhlf on 1..
..., on. Ilo' ... rbc ... likc ,.ou, _ I~hlc . Now nWII".rnJ
"'C) ,IN; ~ .. m... In,,, <'li"'" 1><""'IoeI. nit""" On ,ht
pIY01 bIocl<J """ noi I"""hlnll
bo~ br.on" Wllcn yuu
lu>T IlN;m IUSI riJl/Il. Ilt,hten 1"'" nut:; tO l>oIIJ IlIem
JK\IIdy In 1'11. ,""" liriII pilo1 boks Ind K",'" Ihe
pinii bIocb 10 Ihe roIulIIm lM !I{'ft'\\ will kl'('[) 1111'
IIum ... (rom ''''i>l11lA an Ihe 1'1..... bIoeb. thll> "",In

t"'"

"JnIIl1l t lle .cc" .....,.. o( Ihe III. ...lIi.., Ilie I....... okd rod
w,lI kccp the ,;,:",w5 (rom lN;;ng pullcd oul o(
~ nd
1I",ln oI Ihe column .
)'<It, .In """ IJI"" and Ios Iuru....", if }'uu 1iI<~ . bul Ibcn
j'Q\' w(>n' , I>C' ahle to dL.......,mhle , ..... d"pllc:ltor for .. on~.

t"'"

Making the Platen


YtIu . ", . h< .... , t" CQflSlI'\lCl Ih.1 magi<" C;1O."... upon "'hch
Ihe IIUpliC;1O'or Jlo;al$,TlIJ5 l!i n::ally tllc m,,,,, rrugic::>lpa" o(
Ihi> lill. IJke m"'l 'ppa"uus ~ bJ' m>.glcbru. it .. ci...
II"nlly "mpi<:
In llll' COltfW o(ju.~ few 1IICfl5. )'OIJ lransform I p;ea
, o( .....Iru.ry pIp\'OQd in,,, In'i,",i"" d<:>ia: by "",'ing
R"ut~r

Duplluto,

27

PLATEN DETAIL

,.

AI. supply port

1. After bo.lng

lh~

al ,

~upply

POM a"l ~"wid". Y,"d~ep

2. ROUl Ho" wlde. Wdeep


!I'DOV~~.

9'<>O\IU bi'~Cll n9 the port


Ind ~.all~lIng the platen',
edgeo .

11"""."" in it. "",-.:ri~ thc fOO\"" "ith

plasll" bntln., ...


tMn rlddliJts: th .. I.min ........ Ith hol.".. You ha"c to Ix >..>I<lng
)'Qu,.,.,lf. <Ioa somtthln!,l thi._ simple =lIy ,,"OrI<1
' c s. it <Jocs. JUSt)"OO.> ",..it ...

1. Cut thc pblCn bbnk. As 1 ..id. Iloc pbl .. tl I!;


pl<-cr of t. ~tlch plyw<>od. TO ......,rI< Pf'OP"rll. tM pbten must
Ix <kad nal. $O ~"'ct )'OUt plJ-....ood .,.. ....ofully. CUI II '" Ihc
din,e,,~\S 'pedfk-d by Ihc Cuttitlj! IlsI.
2. Hore the air ~upply poM. TI-.e al. il! :rupplic<J b)'
)'QUI.hop '"K"Uum. I'or th" .1. to ~ InlO Ihc pa>."""'" l!\:ol
)'Qu will "" rotlllng inlO lh .. pl.l<"n in Ih<: n= )ter. )'Ou
ha'.., 10 bot<" I hole in Ihc pl.OI"n th.,., big enoug.h for Ihc
;hop , .. ,,', hose. &..........., the ""n"""lor a" CXI"OO onl}'
}j, In"h i",o thc pl.,en.ll '. impon"m Ih:ollhc port d<>!;e1J'
m,,,ch tM "omlccIOl"". d i.:l.meu:r.
I\c"jr.in b)' <ktennining huw blg Ihe hole muM IX"
M... ,u", thc uUI<ldc dlan-.elc, of Ihc ronnCCt<:>, on Ihc
It"'" " '1111 p. i. of c;oliper5. 8(1", a te>! hole "" ith a
fOr5lnc. Of multl. pur bit ""' do~ as I"'... ibk 10 Ihc n,ca
sun:d .i>.c or Ilie "onncelor. A 1. 1"JIC' Imsc mjtltI fCquin;
Ih., IU" US<c a holc """'.
II Ihe hOle I~ ~ligt"lf tDO .m" I, IUU on Ilie III.",,,.
,,ith. b.lfround .... p . l f It '5 ' 00 1.'1I<'. )'QU ""n wr. p I'pe
28

Rout~r

Magic

3. t.ay aulth! al. holu on Ih!


plUlic lamlnate. a rfanglng
th!m an. 1" 9"d. O.illihe
hal~s wltlt a hI" bit. Apply
th! plaslic I,minate ta Ih!
plat ~ n .0 th~ hol~s line up
ove. Iht g'oovts.

.rounoj Ihc cnd nf Ibc cu nnceCO,. n,., h<>.se "'''SI fii rc-...
"","'tblr aiNlgl".
Ah", )'Q""'" dt.-.::ld"d on th, hil 1'",,11 USC. 1.) DUII ....
cenh" of Ih.c al, ""ppl)' pon . f<>!ln"'itlj! Ihc dr:twing Pliltfl/
DeI"II. l1>en bon: the ron. \ 'ou .,..0 00'" rompl<t...,.
thtoug.h th~ pl'len .
3. lay out a nd roUI t"e alr pas,;all""'. Thc alr Is dUP"~ aC"fO:S:i Ihc p-I'M' Ihruutch gr;.J of ll""D''''' I"OU!N
InIO Ilte pl"",, ', bonom.ll", Ii.."'ing Plale" De/aII shrn>1
Ihc:sc al. p.,..,gt:<. Note 111:>1 tM'" II hincb"~ ~

IU""''''

\'Hnch-d.,.,p per\n,e,,,,
.00 " .lmll .ty .sizcd ono
CXt<:nJ.ing from .I<k 10 . I<k thnlll)(h ,he ai< ... pplJ poli
Complctltlj! Ihc !!rid . '" a 007.en ,-"inchwide)( )j,.;nch-dcql
gnx "'cs ""'h:d rrom cnd ' o cod. NO/k o( tl~ gro<lV"".aI
Ct>u",",. """'ks IIt~ Ihc eJl!" of Ihe pbte".
11"", )"Ou produce Ihc groO\"CS ma)" tu,.., a bearinK OII
how )'0" b )' lhcm O", . It b ..,;dul. late. on , tO know who:ot
the gro",'CS ""'.SO )"Ou <10 .....", m. rI< Ihc 1!f1>O''' """Icrti....
on .he pblc" cdJlC!l. Roul thc WOO''CS wilh plllllllC 1"O\Itcr
cquippcd ",ilh an cdgo: gui<k. Of ,>Il ,hc rou,,,. ",bie.
Rnu, the bl)tC al. culumRll fir><. U... a *-incit strupI
hil.Adlusl the <kp1h Slop ro. a \oHncb-d .... p CUI. Scllhc cd!Ie
g"Idc "" Ihe ""nl<"11",e of tlte CUI '" 1 incit (romllte SlQCltl
cdJ\c, Roul ' he perimL~C1" oi, paso;:I!I<'. l>on1 {orgct ltul thc

opcn up ""'" pon. S..i,dI 'o I ch:unkring bil :and


rrW:e anoth<"I" pa'lO :around ..... pcrunn""
pla'cn. """'"

0i0)"OU C2JI

01.""

1...11ng ..... otwp lamilWc cdw

5. DriII the air bokt; In the p ..... lk 1:un1""'1". TIM:


nwoy hok:s in IM pLun>'. pl.a>l:ic 1amI.... ~ b"u"", n' .... be
driIIcd ~ il I ~PPIiCd. If ,.,.. liriii lIM:m ~ft"" II It
Ipptinl aii tIM: dUSI and d>ip> C""~lcd ,..W coU\ In .1"><: l i.
""........ :and Ibry rmy 101",,1 alt """"
N<n!.' ! know ,"" uouaI ~pp"""'" tu bmln.!~ "''"' 1, 1"
CUt .hc bmln>: ~ .nd "pply Il to 'hc sublil ..... c whh .,"""'" ..."riwlg "rotind allibor etI)IClJ. In Ihl' n>l' Ullply . ,
pbn 10 ~~ OM etlge of 1"" I.ml...lc fl,~'iIl ,,, ti.., >u",",r:.. c C
W8C. """ ha," .he OII<:riwlg onlr
",he,
cd/lct.
CuI ,1"><: plWlc lam!mllC 10 tII~ dlmcn.wn. ~ by Ilie . .
Culll"ll USI 11tcsc dimcrui0n5 provklc ..,.,..... ,. lOr fOI' 10
Irlm Il Oosj. aher II It lI1<:n.oo In place
GI"cn Ihe .ppllcltlon .pproodI. )'OU Ilmply h...... 0 Iay
oUl II.., hok:s. ,,-MnII from ..... "O\dJt " cdw A. tl><:.n..-w.,
P"kHe" J)ellIl/ sJ>crn- . IM: ai, """'" .... drilltd OII !!rid of 1
Ind!
tind.hc ttnle' midpoIn. ~ "'" fl .... cdjIt,
and Iar oul 1"" grid fn:m Uw poinI. u.., pcncil :and li
(nmutjl St!""'" 10 atenti ~oct
.1><: bm"",.c TIM:n
, .. m .1><: lam;.... e 90 dqjttt:JI:and pn>dIIllnn rrom lIi<k" 'o
>kIc. IOrmI. . ~ grid " ,II! Ih "'luara. AI ndI iV>d Inl.".
>caion, )"OU m ..... driU hoIc ~ tIM: bml"'I<:
lIodt lip lhc iamin:"" ..ith .. c:Ic-:In. ><>Jid pic<:e 01
ocnp-pI)......oo OI" mcdIum-dcn.si.y tlbcrboani. Orill Ihor
~. ~,...Ioch l,,"ilil-<lrlU bil in .. po ..... bk tlrlll. 1"hc
don'l nd 10 hc loOI.etI "'llh absolUl~ p""'Won. 1.
bon<1 hani.!IIM IcdiolD..

OII .""

ii"

1"=

11<1"'' '

UH a hand h.ld roul. , will. a n IMIII. IIllide. 10 (UI


~ l irpu,"!f" II""""". ~I Ihe edjje lIuide 10 roul Ihe
peflmder grooves fir.1. Don~ ru" wilh .IOP bkxb: JU.I
III' 0111 the In.H:lt cornt" of Ih~.e 11_", Ihen roul
flllm n"II, k 10 mllrl<. To .11In: Ilie (UI. lip Ilie roule o
Ilie bit 1. clelr or the work. liS .hown hfo~. TMn ~1I,n
advMIC1nlllhe fOlII~r II VOI' Iow"," il lnlo the WO<tc Ihe~
I IIm pull l"ll lhe fOule, IOWlltd me).

'"Of! >han of u.. ~ of ""'" ..od:. l"oll1l flnd k


mioI 10 I"0Il1 Ihc:x 1IfOO'""O In Ih= or mon: p<tS6CS 01
~

~dq)lh .

Rc;jn thc alti< JIlMk, :and ...,.. ""'" aii" ~ !ha.


bo.b' thc alt" ... ppIy pori lIout ..,...... 1"" "illlh of ./lr
piltai. frOCIIlhc: pcrilnctcr JIfUO''' ~ <:>ne "'-k ' 0 Ihc: OM
....... othtrokk
Sow fOIII ."" ~ zif (O/umns. S"'i.ch '0 ~ \j.lneh
Anrf&hl bIt. and ma Ilie tlq>lh .. Of! 10 pmduc~ ~ *'"lnch
dtq) f\II. Sc:t .IIe cdp= lukk ~. Ion 10 rou. Ihc lwo
1'9<1'"'" d.,..,.. \Q II.., pl:u~n ooli!n- Wh.:II
do 1. mullwo

,'OU

IfOO'"d.OM rden:ndngnch ' . "r.hc pbtcn.Thcn rt:Scl


thI/
Ind ""'1 IW" moIT
Kttp rnttlin8
lIId fOU1I"i .. "UI an ti.., gn)O>'''' h.." httn cut.
./U>< .."....",ba: OON"r bIT.k Ihrough 1"" cdgcs. You

""ido::

WQO""'.

.."iJl1 :tir e"""pinll .....Iy IhnlUJIh Ihe Un)' hok:s )"OU "iU bc
driIlin~

Ihrough . he Ilh>< k "'mhu .,)'OU wiU bc .Pf'I!inll

4. Apply I I", pl:.l$'lk l",mlmOiC to Ihc pl:llc n '"


IOp. A) 1 m<:nIM"...:d , tI.., plalen m ..... bc !loIIO wort. and it
,.,., "",..... ,,"Iy Ilie boII_ ",rt.tt:.: ..itll Ioml""~ , tlM- pbtcn
il:dmolt ttr1:lJf1 ' 0 rup. S<> "'" ...., J'ia of lamiru.c 10
thI/ <Iin>m>I<>n> .".,.,11kd by Ihc: C"I1~ u.... ~ OM

no. ""1>-

lor oM
AppIy "O,It:>Ct ttmcnt .0 ,1Ie 1am1n>le """ 10 thc '011 01
\bC plai"". WhaI .1><: ccntonI, 10 dry. oppIy ""'" lamln:"" 10

.... ploI"". IJ""nh

and flu:!olHrlmmlnjl bit. trlm Ilie


.........., ..."CIh>ng. onu li hoIc: Ihl'\.>llllh Ilie 1am1 ...IC """"
.,.q ti>< zIf ... ppty pun. and 1....," .1><: 1>1, .hruugh tii., hale
li " " "....

"""'*'

"'*"
"'*"

6. Ap p ly Ih ., p las tic laminate 10 I hc OOllonL


Dnpilc Ilie lII"OO'"d 50bsu.,c and IIM: po.."tforalcd bml... IC.
.hb '" ....... 11y a IiIr~18h'forw. ni job. Set up tint. Umlp
r...Igh'nlgc .h.t"J .hkk""
.hc pLltcn .0 oM ,,'OrI<
beneh ""'''"Cen you .nd IIl<: pbl"". Pull IM plalen 1'8l"
ag:.olrm 1. ntl .....rt Ihc: cealcr 01 """ OI" ......... oir ~ an
.Ilc 1..,.., of ti.., fcncr. l"oll .... POIII'O ...... tho<: nur10i 'o
alipt tIIc t.mlmuc. and }'OU .... lJOing 10 .... Il>c lami... lc.
O\dJt edW: ,,I.h .his fcn, ......... c ~ JOU tu", .....
pt..en tJr1cn'cd apptt>pna.tlt
Sow .ppIy Ihc: Ct>nIXI mcnl Ao JOU >prnd l un Ihc
~ pl:I\"". II,. 10 .-00 lIC"inJ 100 m""" <100>.... In 1110:
~,..het<- It mJW" uIt~ .....
ol:alt. llIbl!;n',
dlll'1.:..II. What b tric.y if .wIt"inll thc .........1 to Ihc I:Im~
""e, You tu.... 10 ltifMI of paill! >!ripa; of oM m<:n'
""',,""" ,"" h.oka. y"" \Ion ', """" ~ film oi ccmcn. j!.um
mi. . up Il>c ... I>0I0. 1 found IMI. dJ:opos;lbk briOlk: bru."J,
..."OI"b:d juIlllnc: b" applylnljl"" cemenl in tIIis ""nicub.
si .... llon . Allow."" ccmcn o dry ) uffldcn,ly.
.......... appl)' ti.., !;anli... ,., 'o ,III." plolen. Stand i fl"""
cdgc: on 1110: pili"". IWtI all"in'l Ihe rence, an'" rrW:c 6Un:
lhc appropna.e OIr1np oi "Ir h.,lc~ ..... ligncd "itll )'OUl"
. Iill',meol m"rb on l/lr r"nec. fior 1110: Iamin ., "" II
. 00 gnd... Uy Iar It OntO Ihe plllcn ""m"'" II do ...n ",lh
JroUer ot Ihc: hed of y.,.,r hand
Sel up )'OIIr I>ml ... 'e Irlmn .......... roti."" ..ilh li fi""'-

.haJ,

now

bo\O".

hkM:k ... ill'l gmo'

ttII,,,,

;" "'"

~.

...n:aa.

Mut< .Ioc
01 thc pl>len
f'tug th<: :oIr "'Inlu the
)UPP/)' port New pbtt thc ~1n3 +ir>dI
!lC<.'l1on o( colu","
'he .rudttncnt bk>d:. :md .....
'Ion ,1>0: tw<) OI Of " " ' " thc ccn,l:1"tI1afk. Thc face 01 thc

.1.
hIock ",1,1'1 t""

:uouoo

'f.nut >hooW hc dawn.

ttII,....

AdjllM ti", coIum" ~nd bIock """"'1 ""'" thc


01
the p";nen. it~. '" cn,,,.n: 1""1 ,he :aIr " ' - """"1
Inl~rfc~ ,,111t thc """",,,,,,nt of tIK """rM.AS )'OU ati II
from 'hc f'rom l1ew 01 thc: Nou',,," lh<pllc"",~ 1'/"" 1.,....."
Ilie colllmn shollkl hc OI k:-_ I ~ Ind,.,. a"..y fl'Oll' 1","
1""" cunnn1or. Whc:n )........, happy wllh ,hc Io<."allon.
"",ti< II. Thcn l!l"" .nd "'t"C'W Ihe ot1,..,hm~nt blnck 'li
pl>1o:n " c""ple of 1lnch dryw:dl ","1:W, .., >u(OcIt,u.
Iongcr """-....s u... """ )'tiu'", qulle ccn.ln thcy """,'t
"" pcnctt:lUIIJI "" ai. """""8" In th~ pbtcn.'lw.' roIlI"'n li11on. b)' ,IK ...... y. ",mains Wl>1t,..,hcd.

t""

"'"OioJ

Assembling the Duplicator


Adnncil plannlng 15 11'111 ker 10 s",un,,,I..,. ~I.
n~ling Ihe pIolen. TlM! gricl o, ... hol.s m"SI be laICI
out '.om ~ """sh' edte. lhen dnlled Ih~ Ilie liml
""le. TlM! cdll" of lhe plalen cor~spond'ng 10 lhe
'lIush' ed\le of Illt Iaml""le muSl be buUed igilnst i
'cocc. Align ..... nl m;I,ks muSl be serlbed OII the ftnee
n<t tlle !.iml""le (on the m"klng tlpt:). The l.imlniltt
Cin Ihen be "rolred'" do ... n 0f110 Itle plllen. IS sl\oWn.
... ith tne I.ml .... \e~
hoIel .lIgned ove'lht plllen~
il. pa.ss.gu.

.1.

I<,,,,,,,lnll bOI. and "'''' ,h" I~mln",<: <'Olgo filM ...;,h tM


plon"n <"<l~"" Swltcl, hll.> anJ ruut a n:01'TOW tx....1 aruunJ
th" a41<-'" to nnl>!, otTth~ joi)

Thb 1> ........ tIK llllIIl1trtc mIII' con'IC$ t""""her. 11:>_


IM major ""I. thc: lx:>m-an<koIumn asscmblJ'. hu ~
beat """""""ro.)'OU 11>,,, >eru<: 01 ",h.at thc dupllc:otl)l'
b 1!OJI"8 III Iouk Ilke OUl now )..... arc 110"'11 to ",..unt It ' ..
Ille pbt"". MQII thc
and thc ..1.1.... and rndy ~ lOr
ils "",ioJcn ,~ ""..- )"0'" workbcnctt .

I'UIJ'' '

1. Join t.he beli.....and-eolunt" ~mbly 10 ~


pl;il" .... Thc5c tot", lIUf<>< cIcmcnb; ...., dnd1coJ
...IIh thc ~ ruoJ tiu, =cndo 'hntuWt thc "",In
coIumn .

'.'''t.

7. T~kc ~ t.,,;\ drlve wlth )'011' pl .. l" n . Thl. 1. a


d<.'\iarKlfl front P"'P'" &I~p-I)y...ccp oJc.:on,m, I admit. Ilu'
th", b "" cool !"'" nd ro rry 1
. 'IU' rll!il' .w.y. Aud nu ...
,"". 1"" tp,c 111<: ai. h<Jk:) drilkU.'..... ~"aJ111<'1 lt:aJlo>t OII a
CU>hIoo 0/ .Ir.
So >l1ck un" <:...:1 ofltl(" hoK In .he
,~ ' . Cl\h.lJ!it
p<><t. 111<: 00>er Ut thc: . It )Uppty p<><t "" ,hc III.i'cn. Thm ""
,..., ,~ .00 """ _
nk...,ty Ihor puten floal ... PiIr """''' '''0(,
on il .nd >C<' how it I"C'KIII. CoJI the "mity '.'hc:r;L/ld
..00..' It nil" it"J.~, tri<:k.
Obr. brnI< . <M:f. lIact< ,n .."0<1<

.tu..,

8 . Malle aod

."S"'".. lhc a Hacl"""" 1 block. Cut

'o "_n......

'hor hIock
'hor
opcdflctl bf 'hc: CUIlInft u.t
Wry UII' ,h<: ....... for Ihc moci...... rod N<X~. In th<:
d....1njj C.llum .. ~ 0rI,,1I. tlle w:ncrolloc:otlon of
tl'lb hok. 1. S ~uidt!un, r...... thc cn<h anii I Iocl'l bacil:
OM nIfIP=. ". 'h:M .,.... . driU rou"l .......... jUSi deq>

rrom

~-nough

lu =<' ,h<: ~ on T-nut 1"I",n bon: 'hnJUg/>


'h<: lJIod< for tlle body of lho: l:"u' 1101' thc T.... on iruo thc
hok. and chcck 1" m.>kc ,...., 111>1 no pati 01;1 Pf"''<"<'\'
01>0\'" 1"" (..,., o( ,h<: bIod:
Thm ltu- pUten O>"tt (50 tlle oidc: " 'i'h the b"'Uwe
Is down) nd ,,'UI'It <><11 'he bnI ........,10<1 ror ,~ .nxl>n",n, I>Iock '11" kK.. . 'k>n 1.0 In.pon.nl , bul po>illonlllJl,h<:
30

~oule. ~ .glc

To mounl ,h .. bu.mand..:olwmn w.. h On the pl.il~n.


VOU ",uSi .e..-e t"'" botlom "III ..... ,''''' etnte'
coIu",n's th.ndtd 'od. (The sere ... s w,1I hoId ,"'" unit
t~the. when you do thls.) Torn IIIe.od Into Itle
~ttIChmenl block on tlle p1i,en IS fi' U It wlllllO
Holdlng tht rod wlth Iocklng-g.ip pll~fS." 5hown.
tlghl~n Itle tOll ... 111'0 secu~ lhe Iswmbly.

1bc ~l'SIlhini' It, 00 i< '" pl:K:e ltu, .110n coIlIIlln >tlon bl<1: 2ruUJllllhe ."""hmel1l block on Ihe pblro. Oon 1
gI.. l' lt"",-dofl'l f. >len il in anr "7Y.
Ncxt. 1'CI1IQ'" 'IM: 1>0"0"""'00 nu' frum 'he 1/1.ln<:h
Ihn:>dr:tl fUd, Thm ,11~ lop.cno.! nu, OUl ne .. Ihe eno.! of lltc
roxL Ili8hI ,Itc bnlD<lrnkolumn ~mblr. ano.! st."o.! il On
Ihc ,hor. column 'han un ,h~ pU'''''.Th n:1<l ,IM: n>tl
.uo IIIe:Toflu, In ,IM: . u. ehme" , blo.:k.
ro 'igh'en lip ,he __ ",bly. )'O" tu,,,, 10 Ilghl<"1\ Ihe "'"
OII ,1Ie: rod', 10f' eno.! down ag,oinSl Ihe oppcr pi,ve hlOl'k.
Ikfon' doi"ll 'hi~. d""'-"k ,11 .. 'he .hon <'Ulumn ., ,~" pl'l1<:n
Il ,-"e,.ncm! on 'he lower pIvot blod: ano.!lh~1 lltc btam ... "'"
roIunul ....,mbIy worl:s f=I)' When . 1I ~ oliW>e<l. tlgh'<"1\
tht nUl "" Ilie: '''Il of 'IM: ,h",o<l.:d rod, cla"'pln!! !Ilo: tKc~111
""'-""""'! 'o ,IM: pl.'en. You m. )" n~ 10 hoId Ihe rod ",llh
pIkn ")\lU 'i8hlcn ,he nul.

""'li

2. Mak" Ihe roule r moumlnlt pla le .

II<lled al
tlJdqiDninK of thi:! etllplcr, Ilie bal rolll", for I~ jl)! iSl
laminale llimm",. In fact . bccaus.; Ihe [UUt<:r ;s mountetl
t>m<..,.." Ihc bnm .>i<k:s.)"Otl ""n', """ an)"lhing hu UI11I
""te: IrUrmer bccousc 1. w",,'1 Ill.
To nH)Un1 lloe trim",er. )"" ",.k ... hal anl<>UmS to .n
.,...,r>izcd bascpl.te and S<!n"',, t'UI 10 'he bouom etil!'-"" of
tht bt2n sid<:s. M.ke ,lIe n\Oltmi"S plat" rrom. se,..p of
\l.inch po'p"uod. Cut II to the dimensions speclfoed br tbc
Cultlng Ust.
Rem", Ihc bctor}' 1u"--pl.:tIC {n,m tI><: !:uni,...,e 1<ll11nl<:1",
:md bond II. 'o IIM: moontlng pble bbnk usinJl ""rpc1 I>pc'.
.\bk "'UJ' dTon 10 lli(tl1 tIM: b:l>epb,~ '1 bil opening","Cr 'hc
ttnlapoint o( II'" moun'lnJI p"',e. Lf)'Oll \IonI. )'OllU tu,.... a
ll1fII lIt>< :aLignlng "'" bil In Ihe n~"cr dl ...:ctly undcr ti",
..,...... Yw an ftoo II".. for wng Ihi< in Ihe duplCf "l1M::
Gmmc II>s<pl1tc" un P"g<! 6}. U.., d'e ba<o:pLa'~ au gui<k in
driIIiJlg moun,;ng-.crew hok...
a bll 01',:ni"8.

c.x""",

\\"iU ,,;n'ply projecl oI' from lhe mowlIinll l:r.

5 . Make Ihe ~Irlu.~. Sun 111' ,,","'ing 'he he'.uJ 0,1",


hol, \\"i. h a hacb:lw.
Noa. chllck ,'''' Ih,..,adcd cod of Ihe boiI in )'Oll' dnll
~ . Sine.: )'()u 'lI nced 'o run nut< <Iown tl1Csc 'h ..:,b
wIM:n )'''u J""all Il'" >I)lus. you wa n. 10 .."Oid o.!;"'ortll1!l ti..,
thmttls "'1l h accsM'''' lightC!llng of Ihe cbw:k. /\ eollple of
bJ"C1"S of m>sklfll!
O<l III< 'h,,-"OtJ!; p"",itI<: SOtl1C In"",,
.nee o.g:Iil1Sl ti;",,, ..,,,,,.
Now file II><: md of,hc boiI 'o Ihc $luI'" of)"tIlI' roulcr
bil. nu. il;. ";mple. il 5OmC""<>"tul tetlious. 1>Sl. St.~ tIM: llrill . ,
pn.:ss -"f>CCd quite sJow. ~wJ"I! II><: I:IhIc ou. of tlle wal. :uwJ
rtlc
,1.., roI.:Illon of II.., boiI will Ilat n,W me \1'hilc
)"Ou'", oot hand-tooling P"" 10 5pacc-ajIC lolcr.onec:!l. ~ In G
mind ttut ,1><: mOIt-" "'---cw-. tclj)"" "-1>">tI""e II.., ,,,,,'er bit'.
p,,,file.
mute :occur~lely )'OIl' dupliC"O.lOI" w!ll dupllc,,,,,.

1:1""

<
:i'

"Pi''''

,1..,

As

6. Mak", thc ~ty lWl mOllntlng bar. lltis Iw l.. a , Ii.


1ncJ>.long >lrlp of .. ",,1 wilh a hole drilk:d llIrough II fOr Ilie
.. )' .... The ",idlh of lhe h>.r i>"01 cti'kal: .n)1hi~ :. inch
Of mort: in wkllh will do fine. tiut 1.,. 10 ~nd o pkcc " k_
Ilo inch thick. /\ ",,,unling bOf IIU! fk:>:c:!I wil1 gI,." )'Ou o.!i>,
Inn<-d dUplle,,,C5, ",hieb ls C5pCCblly '"CXinjr; if )"OU'"" 1'1';11JI
10 n:produce fon<" dc:1~il.
Cut tI><: .. rip \O 'he .ppropriate Iength. III<"n 1:01' OUl """
liriII Ihe hoIe for II.., >1)'1.... Ek-gin ",ith \to-Inch-<liamc-tcr
pil'" hllle . !hm m)~flIC!Ile !Ic ""illt Ilie 'Pl'roprialc-sl =l
l\\"isl-driU bit. 1lc
10 cb.mp 'he b:., 10 tIM: liriII P"'OS l:lblt::
whllc 1Ir1l1ln~." ,he drill bII """"1 )"Onk 1, "''' of)"", h:>nd .
Whil<" )'Oll .'" ., 'he liriII [>"' .... ia)' Oul ~nd tlrlil Ihe t",."

s",..,

",,"Il"UM

",Ill

3. InslaU Ihe m Olan,;"" plaI". Scn:w II'" pia'" \O


tht !>ollem <:dges of,he beam sides. os ,"""wn in III< I?orller
/}u!Ifrntrw 1IxpIode</ l'k'u' Scn:wlns. but ...,. gluinl!,. Ilie
plat~ In piace .Uo\\". )...... II.., Option of ",me>'in!!. Of
rrpbcing 1, OI a futu,.., tinle. Gluin!: 1111(1hl makl' Ih~
onounl~ a.....,., bil m"", ligld. bUl 11 1.n, CMcnlial.
4. 0>0:>06/: a stylUII conflguratlon . Qnc of Ihc: kq-s
10 '('cur.,, ~ duplin,ion '" 'o ~ ")'Ios of Ih<' .. mc .Ize
aod -!IlaI'" .... ,'''' ro,,'~r bi . Thc 001 roule" hi, 10 """
~ o n whe'h(' }'Ou''''' ",""",,'ing "'rgc .n"",n1S of
>IOd< OI" ICprodudn~ fUte d<UII. A ~nch """,-hox bI . ..........
goOO joi:> of """,,,i ng ..... SlC .... hilc a ,"Cinlng. V1!""",ing .
... >lg<H!l.klng bit ""ill dupli""'e fine' & .. il. [f J"OUr wori:
~rt:t:,.xh "",emi,,,, w)Ck 1'Cn1O\":ll .nd nn~ delan. ]'OU '!I
\\02111 '" "'" boI:h kloos ofbil and ",ill n.'.'<.I. "'-"P"""c >!rlu.
:md """,ntlng l:' for cad' bi, .
f.ach SI)lus ;, .....de fro." a bol . C""""" <>ne wl,h an
~ $lunk dianu" er OI lcasl .. )ll'C"AI aS t~ ",ax
Imum cu:tlng <li;IIn<"l<"r "nI><: bll.111e ICIIgth OI Ihc boiI. nor
indudin~ ,Ile hcad ho uld bc., le .... os ~I O!i ,11C ()\"Cr. 1I
Icng!h ollh" rou,e, bi,.
Ieng'b 1. n", a prohl<m - Ihc

Ex,,..

Sha .... Ihe st'l'lu~ bv fil i "!lth~ ~nd of a boiI whilt lne
0011 lurnS in tlle drlll P<l!SS. Hold tht! mI! 19a1nSllne bolt
I!nd. lnd ~ It l round aS ree~ssary 10 shape tht! 0011
end 10 malrn tht! "companion"
bit~ CO\1\Ou'.

""" t,

Rout!!,Ouplieato,

31

A 5tock-andPattern Table
Thl~ Iwo-tlered liule ,,,bie I~;I liery ImpOttall,
"djunct to t~ ...,uter dupiluIOI_ II hold~ both the
partem (lI,c ObjKI belllg copledl and Ine workpltct
(I~ woocl InlO .... hlch the !amlnale Itlmmet i~ Cu,
ling). U~e of Ine table makes II qui<;k and UIY 10
po.ltlon and IJign , hele Iwo pIetei," nOI Incon .. d.,
Ibli! .. ch't\feme~l.
TIte Ih,"9 i, ,hl' for ItIt "upllutor ta do Iti .... ork.
both the p;itlerll tO be dllpllCated Ind ttlt stQ(:k 10 I>e
rou ,~ mus, I>e held rig.dly. Nli , her mus, IM able 10
wlgglt Of
Tht IIPpe. I~ff.. cu of tlle two mUII IM
12~ inche. aput. "nd the p;itlem mu," IM dlrectly
lbow: Ihe stock. MO.-i!'OV<!r. lhe "ztll~d Ihlpe, 0 1 the
workP'KU .," unc!oubledly liVV ~rtil ly from proJee!
to PI'Ojt'Ct
TII" .tock.nd lli\uun ,~t deslgned b~ F"d
Ml, lilck Ind Bob Mo . ..n ,. il .,mp~ "lpoMe to tlle
need_ 8euuse Ilie cIt,lg., Is 10 "mpJoe, It '. "d"ptable
10. liantly of 'peClflC Mtd . Th, d"'.,ng S' ad:"nd
I'iIrrurI roble PlllrlS ~how. Ilie de'II!. of IM I.. ble_
Notlu Ihlt t"'o dllft"nt leg ;ar"ngementt ." shawn.

."'fI.

STOCKAHO PArrERH TABU


Cuttlnl Ust

dog./Wtd~tI

Wxl"xI4'

..,..,.,
..,.""
..,..,.,

Do_ls

li' dli_ x lW

Hlfdwood

""

QI)'.

~"x

TlIbltlop.

.~.'

Leg

SI ~llIhl dog.
TlIpe.

Dl menslons

~-

16" x 20"

2~'

Mllllr'.'

x 13W IW<lwood

Wx IWx 14"

Hardware
drywilll wewl,, x 1~"

'IN ,....

'TII, It:..,,!t l,..ti{l.i/ 1,


1'-1'1ewU
",bit: 'Of" ,/te 1oftg-It:Hd "''''''''. _ .

.,.",,'" "'tit.

".. It:, lida rs ""'Ilo' Ionf.

(C'''''''''M,II

TIM stodNlnd,.nvlI
and eaw to use .

32

MOUltr MagIC

~bl.

1.

il

good way 10 hoId boIh Iht palle,n ind t!'le WO<\ng s,ock. (1. tiI.y tO

mak~

STOCK,ANDPATTERN TABlE PLAN5

ENOVIEW

FRONTVIEW

:J 2"'"r

,.L

,'

TI...

I .

'_~~=WL,Jl

'

'.~

__ ._i

' ____ 1 $

TOPVlEW

1- Iyp.

r -t--j'

,.

1
..-

000

Roule, Dupllcllor

33

A Stoc.k-andPattern Table--Continued
DOG-AND-WEOGE DETAIL
~WlNG

TDPVlEW

-t"iIII

.-c~

,..

"

1. StieI< ono plece 10 Ihe ollle,


".lItll double . ld.d I.pe, U
hown IIt.t . 10 s.w Iht fi ..1
dog .nd wtd<)e.

newlV Cut wod<)e 10 the Hloe


01 lh. uncul plolo YW Ih

second dov .nd

- *. ")

L.~-,'
t'" ."
3"-

5.iw hett wilh IlIls NIIe


g.in>l tlle tablt .. w fen" .

5.iw Ile.e wlth thl. Hlg.


"o.ln<1 Ih. 1;Ibl. I-IW fene .

Oowel nd hain
In I.ble angl. 1:6.

Tht sho.\-1099td ~rsion Iccommodalts Illlclte. stock


.nd palltrns Ind 1. usier 10 el.mp 10' lable o.
wof ltbtnch_ The long-I~Otd "."ion .110",. you tO
.ep.oduce sh.llow
wltll mo ... prlSlOn
bec.u.., Ihl Mim. 01 the dupl".lo. "'dJ rem;"n mort
nu.rty pa"lIel 10 Ilie .urfact. Dt lhe 1N111.n.nd lhe
Slock. \1 rou .nII(IINI neHl for bcKII " ..slOl"l .
m.lk. Ilie ,hon. OM Ind. ",hen you <!eHI Ih. 1.11
.......Ion. block II up off lhe wQ.kbn<h
n.. d w,ng o.o.,,md WMgc Ofr<lll show. on"
muns 01 ellmplng tlle pan_rn .nd Ine "ocl< 10 Ih.
I.bles. lI<I!uust II doesn' proJI'bovt 1he SU.tlU 0 1

C''''''no.

J"

2. Thtn Slk:k th. edOt of Ilie

,.

ENO V1EW

THf WEOGES

Roul" "'91(:

Ih 10(1t. Ihl~ clamp'ng .y.tem dot.n~ Inle~ "',Ih


III. duphcilOI. II your :uoc~ Ind p.>llern Ifl' .'Onl[o
unlly ilI~t l/wIn Ilie 'CI~ u ...... d nu, you Un uS<!
Just .bou!.ny <1.mp."f"Iu w.nt. AneI ,f rou'rejuSI
.nxlOllS 10 .un tllt dupllalOllhrovgh 'IS pac
","hout I.klng Ilie lImt 10 m.lte you. OWn (I.mping
~"" stitI< III. p.n n and SIOCIt tO Iholr fl'.ptW~
(.blu wlIII doublt-"ded 1;Ipe_

1. Cut th. U1blf! pans. Tht I.bletops. dogs.


wMgtl'" plywood; Ihelegs. h.lifdwood CUI thest
paru 10 lhe d,,-nensoons SPt<lfIed bv lhe CU1I'ng li$L

Ind

2. Assemble the le9!J;. Clue anei n.~ O< Krt ..


thf ''ilhi leg plKes InlO fou. leg" ~. shown ,n t ....
dr .... ,ng S,t...,ndPanun rabie P/4O".,
3. Lay out .nd chiU the dog holu. Tht
IOU."OIU ~rt shown in t .... d ...... ,"9 Sroct"ndl'" nu"
,..... Itf_ 'fO" elmt the IIole . ho ... e"er. naliee In
lfot
Oot/'QfId'WUQt ()fftlil Imi Ilie 1Io~~ enltr
N . Ioclt lI.n Inglt Ind Imi 1.... se' of hole. an one
j.iIIf mu" angle in Gnt d " Kllon ... h,le the 1I0in an
lfot OI""" lICIt lIl9l' in th' oppome dlflcllon. Thui
il'9t1 ,nlUrt thiot tlle cIovs Il'mlJn down liglll agl,nSl
tM ub~ ....... n tlle ... edlle i. IIpped In to place and
thlt t"'" ... on, crup up ... lIHe you'tt rouu ng .. cnpy
,nw some .... ,..,. t ~ ptns ..... Slock.
n.. ;a(tual,n91~ of tlle 1101" is nOI ""ieal. The
1,6 .ptC,flC'''on ,. Ihere onlr 10 liNe vou In idu 01
roughly ho ... mucll ,nglt is approprlltt In USI YOU
,~) ' ,m, I,,, ... Ith wo.k .... ncll <log., It js Imponlnt
thil ali t .... 1101,. III .... Ihe ume lIngle ind lhiol 1....
do ... t t halu In tlle dogs IlIemstMtS hllve III,. 1.1_
"'IlIe, It 1. I lso Importlnt thit th' ho~1 ,n e;Kh Pili'
!It ,qu ldlstant,
'OIe Wily la dntl theM ho~s IS nOI .. uh .. dflll
prus but w,tll ~ hiondlleld dtill . \'ou U,"," SImple jog
ta!ll'ldt t.... b't and pos+uon tlle h61ts,
MIl<I you'sell III" J'g gu,~ tiv dflll,1'III two hoIts
Ihrough.2 ,""' . q .... '" p'Ke 01 hio,dwood. Tht hoIes
must tie 1 iMhu IIp.l1n. Thtn btvtl.n edg;e of the
llirdwood SIIlP ... ,tll 1.... table 1.1.... bI.eIe IIlted la Il
<legrttS W,th the bevelfll fKe ",,"ng on t ....... ort..
poete. tlle Jog .... '" nit tht onll bit tO Ilie prope. lInglt
Ion"'" hoIts you .. ,n\ to bOte. """ I""Jog w,ll ,n,u"
tIwollll
hoit. ,n eKh p.lIlr w,1I be equ,dlSllnt.

.'''''l'1li

t"blt ind legI UP"lIhl on the bench wilh tlle lells


.t."delllng tlle "cond ta ble, Chetk thal tlle dlnaMe
Irwn OM t.bltlop 10 the othtt Is 12" Inclles. lhen
gllli ond screw the SKond flblt In plin.

5. Make the dogs and wfilgn. Tht IOIlIt


01 tlle weoge. nH6s to mllt ll the Inglt 01 Ilie llpelld
dOg' ~ultf 'C<II"lely. To .chit'" tllis .. ,tIlOllt undue
lun tl<1 .. ,tI! twO P'Uts of stock 1 'Mile, ... ,oe fo<
botl! the wtdges ono tlle I.pelld oOgs /Ind lWO p,ec"
1111/ th'l wlelth for ttle IInlipereel de>gl. lIIy OIIt Ind
bore tlle 1I0ies fa .
dowi!ls l/lt Si"" ,,'y you bOtecl
the 00g 1I0lei ,n tlle "'blts.
Now n p the l,nd! ..1de plKfS Into .. ~. Ind
dog. wnh . lipering jog an tlle tlblf: Uw ti VOtI clon'
hi .... I tapenng j'g. StK~ _
plKe tO tlle othtf IIlKe
..,th u.pet tlpot'.
shgv,n ,n tlle d ...... '''!1 Oot/ ... ,...
wu,. ()ft",', TMn mUt the (UIS
Clut Ilie dowel. ,nto tlle hoit. In Ilie cIog 'nd
you.e dant
Wtll. .,......1 doM, VOI/'U prOb.Ibly flnd thiot the
dawtls MflII b'l of slU~'1'III ,n onIt. 10 fii UI'1y InlO
Ilie 60g I>oIts in Ilie lobi".

1"""

1,

1"'"

4 . CI..... nd !J;cre. Ih. Uoblu to the leg!J;.


hlI~n) Itepl 1f;K1t oI ..II,(h ,"rf;K~' 01 Ilie
W>lts 1'1 1'" tOpS, ml.k I""m I\Ow, TIIe tOPI Ire Ilie

II 'f"OI.'

1""

wrf~es """'re
two ,nM.mOSI p.lIIIS of holu .re
dow.t '09tt .... r; lhiol
t!>te hoIts fI,re o~t It t"'"
bonom hh t .... leg. al samt I.blei,
"""ce Gnt of Ilie IIbles 10pOown on your .. o, k
bendI.11!d S1.1ld !he leg. on end It tht /OU. CO.M" .
Pl>'illOntd .. shawn tn tlle o,awlngl. Note that Ilie
nIe sode. of tlle leII! \10 On th, tnd! 01 tht I. blt
... ",re!hot nulOW sld,l 01 Ilie legs go an the f.onl and
blck. TIII, g''''. the lower belm oI tlle duplKltO. tII'
,rw " mum,sl l ' o wlndow 10 .. o.k III.ough. Clut Ino
serew the !tII' In pl. ".
NQW pla<e!he re""' ,n,ng table tOP'IIP on VOtIr
... orkbtnch, II you've mllele Iht lellilo the Iong eltmen
SIOn shawn. p.op tlle table liP I Y" ,ncllu on. tOllPIt
Ihlcknt"" 01 j(,lnclltll,ck .tlt, PI.ce tlle lInemblld

,s.

_ ' 5 IIM HlIIP for drlllhti 111I91ec1 60tI holll .


Tlle workpiKe 1. 1I11I"!1 an I K"P plKe of pIy.
.. DOd . T"" hlrdwood dnll gl/iele is climped.1 Gnt
tno. Ilelo r.rmly IIt the o!het. Tht m Iu"!1tlpe fll!1
an t .... dnll bit ii' deplh g.1Igt limed II p"'V<!ntl"9
dlmoge la Ilie btnch tap. Whtn Ilie flig ''''"''PlIIIe
surflCe of the guode . Ilie b,1 hio. pot'Mlflted the
... orkpiKt (but noi Ilie K"'" beMath it).

Iloultr Dupllc.IO<

35

..

STYLU~

Using the Duplicator

AND MOUNTINC BAR DETAI L

\Vln;nlltto

,c'

~
____...

fii bo lt

' Oul duplica'u, b buil . n", btt,j","c lrin,n".. 1; mow1IN


" Ihe ~nd of ,1><- Io",tt beam. ,'ou',~ 110' a bos-rdkf """1n8
j-UU " ... nl 'o ""py, And n"",)'Ou p>.usc.
Lool: ., II. It ce".inly luoks ,.. gawky ., IclbotJ
C" m" .11 dbo", nd knce . 15 ,hi. sucke, re,ll)" goruu
",,,ri<1 )"U uk )'Oursdf, "ou"" gO' tim ... and moncy lkt1
"1" In It,"" il betie .
I lhink i, "ill. 1t did for Fre<J . od Ilob.And It did for me.
Wh.t)'Ou h .." \<.> do i. llle s:>mc 'hi"l! )"t)\I (O ,,ith:ll!
'ht."St: m.jj.Ic:Il. (1)">tic:oJ ",u'ing ",,"chlno: Experimen,.
,"ou
10 I.... m Ihrough upcnencc: ",h.. i, !li like 10
"""",,u'-c. lhi5 un!!"inl)" <lcvice. ,"ou h .." 'o
Ihis ."OOd
",i. h 111>1 lht: '"'l lus, and ,. . d 'h" ,uS:ltld
,N
b)ltltc ..-....Ie.-. ctlergy ."d 'Ile forec of l he spinnlnll-C1JllinJ!
bi,. StI", it's ""lII". ...erul, bu, 11 iS Ulcr.dly FLOATISG ON AlR~
The I S. ." 2\).p.mnd dt....u )"Qu lifl un'" 'hc "",rt.hcndt
.lteds:tll ,h., ""ighl ... soon .... )'Ou nici: on the ,hop.-ac.
whopplng good lrick l
Su now )"" ""'u, 'o go 'o wo rt.. llcre'$ how lU SCt up
aod ""',. copy ofa bos-",Iic( .........'ing.

h.,"

!
Ma~e Sty1I1S

from bolt of same

,hank di~me te , a, ,oute, bi!',


cutt,n; diamete'.

moumIJl'scn:w

holc:i. os .hown In the <,I ... wlng ~)"I"s ,,,,d

MQ,mll"g &" l klull.

If)'OU wan . if}'o" .hln!.: it wiU n' ...." It ..,,1.,.. ro usc.)'OU


.-an tol' ,II<- SI}'llI' hoIc. 11w ''""o)" )"OU .-an simply ,"m ,he
"liUS ilS<:lf '" :uJj"'" ;l~ 1cn!!lh ro m:uch 'hc ..,.ner bil sc"ing.
1"0 Jock

in positlon.)'OU

;am ~ wing nm ,h.,s~n IlJJ"I"Inl

om" II>< >1)1u" ~g:linst lhc ,""unllng bar. , 'ou <In IIO!. how
",cr. h.:t'" tu "'p thc hok. IItSICld.)'OU ("JJl <lriU ,il<: m"""tl"l!
bAr ,,> ti>< "" ..... ~ iliiul ........ ofth" 0<)'1'" and """,nI ,"" ")"1 ...
wi.h ,wo n u... 0It~
,h~ Mr.nd """ bdow.
In cithe.
"""em"", , ..... )"U mII>' . 1",,)... m.!"h
'he Str'''' ""I"n>ion 'o 'hc """er bit ""Ie~ . Rcm~n~r
. ISI)
)'OU n""'" a <li/k",n, mounlin~ N' for <"Vcl"}' <lif
f""'nI dbm<"lC' of OI)'lu" )"Qu ust:.

C""".

.00-."

,1,

7, IruIt:tIJ ilie m""ntlng ba. an<l st}'Jus. M lonJt


)'OUr ",ou" 1, oeeu,,"!"1y ""'un" .... In 'he <..,nte, of lhc
maun'ing pl:.i'c. :as .......u In 'hc dr.t.winAA 'he "li",
nlOun'ing bM', <Vf"I"CCt nlOun,IOJ! P""itlon .. 1 lneh ..." from
II><- ,,cl>..,. .huwn In ,ho: SI"" 11<~1I d,.~wi"l! . If fu, >Om<"
,..,.".,., )Oll\'e <,Iunc IhingS <lifJc~ntly. IfI.1kc SII'" 1"'" II><
"'llU$ I1.ounl$ dittt'l)" ~ ,lIe mu'e' bit. Se"", Ilie
moumlng bol 'o ,lte lItt<krskk- o( ,1>< hoox Il,,:am stdes. If)'Ou
.ntlelp>'" f"'"<l, ... n' l} ch,nging .h" """'"""11 h,. ,n '~C '~
nlO.!>,e , "llllS of a dilkrenl d i.>m ... ,e' ,consldcr lISing sn,:ill
hJ."fI<" balos . lId wi~ nuos Ins, ... :Kl of serew .
You, duplica' "" is now cumplc..:. Why
)"u h~
1, up 1<, ~'" !-hOl" ' ''c and l:aI<e i,
'pin up:ltld do",n Ilie
",o!1<l>Cr.chl

f"".

tIun,

"te,."

""'' t2nCc ". . .

It', .

1. Chousc }'U... " 'o rk s u rfatt, lhc dupl;c;,tOl'


"",ui"", SOlouth, fLt,. Ic\..... .\iWfR"C; """-,,,,h and ru, >O ti><
pl,""n n"",e; .!>oul frn:ly " 'm",u, h:onglnl! up Olt irrq,;uw.
'lies In lh .. surf.ce. I.. ,-cl SI) il doesn', Ictld 10 "Ildt otr
oo",nhiJl, ( lIc01cmbcr. ,1><", Is 'inu,ll)' nO ftictiOll t>cl"'ttn
'he pl.len ond thc SUrf'L" It, "<ling un l>fK" y"" 'utn ...
,hc .Ir.) II ",dl"",Jm:dned '.mrt.i>cnch "",k ..., . good w<>ri;
surf:><:e. A fl.>1 m. ofpl)'wQOd Ot~. Iousy wol"ti>cnch OI'
"bI....1so wun:" fine.
2 . Ikdd ... bow 10 s tage Ih c work p ieces. Wht"tl
Ilie dupli""''''', )"OU It,,,,-c ,wo -""OI."\;p;"",,,- )"OU :att
:Kl<Jrcs.";IltI ."nmiran."'usly. On~ is
patl~m.
oche,;'
Ihe ~ock bdng ""'Ied.
,\ In ,emp"',e-...,..'Hti\ o~ . l"n,. '''''y pa<ticulat "''''
'ion"'ip mUSl ..... m.ln,.ln."<I i>c,,,..,.,n 'he p."~m . nd ,I>c
wuri<l"l! ,",,,,,k. IJuI unlikc Ihc lCl1lpblC "",,"'l<><l. "'here ,I>c
ICII'P"'IC and ,lIe "ock ~ .... _d,,"lched 'QIIt1het; ,1Ie ''''0
wort.-plcccs must hc ..,p.... ,ed lOr ,1Ie dupllanor, Worklng
oul. , idr ""1' oI!"",i'i"n,ng an<J """utn~ Ihc !"Item ond
Ihc wort<ing s'ocl <:an Ix ""';or chltlIe"S'-", An<! tIIiS i:!t ,ruc
when usinll an)' "'u"'. duplicalO'. IlO! JU:il ,hl. unt.
Wlth Ihl; dupli""''''', ,hc ch.lkngc 1" .... mp<lUntied by
Ihe !:te'
'hc 1"'"<"1"11 n'"" Ix ....peodC<l d iJ"Cet1)" aba<..
Ihc Stod: lO bc ",m,-"d. Th,-" <lW.ncc I:>c'''.....,n ,"" ,wo
" 'uri<l ng ,u!fac"", mllM bc 12'1 ine""'"
Ona: In whiic. Ihc w orkpictt!i Icnd 'h"'...... I,' c 10
soroc ~ $1"-!ting tiu. ("JJl bc cobblcd up "' .... ppon
lhe ""Ul11l ~oo-.~' ,"" wurkl"l! swck. lIu! """" oft .... lhan
"'~ . ~ . ;'Iy .,,<1 ~Ihk , ,,,,,.I~,-.-I '''t>lr ;. ..-h>t }"" 0....-.1 I ..,.....
orun""'" tlUI )'Ou spend 'hc "me righl now,lxfon, )"OU rc:illy
do any puf"Jl"lSdul dupllal'lnll ,,"OI."\;, tu bulld thc auxill:r.'1'
projcct. ' II Slock"""d-I'"~n..,." lloblt:: prcscntl-d Olt p>.gc 32.
Ilob ""d Frcd <:nlllhoo .... led on 11$ design. and It Ju work<'tl
weH for ' hc job\. 'h., '"1.-c ,.cldC<l willl thc dUplica"".
)"OU lIS<:

,h"

,1.

1""

TIte dogl nd .... edg. Uh'P rnlIke. II en,/, 10 clamp


bolh Ihe p;>lle.n an<! the wo.k 10 tM table. Lay the
potlern on Ihe uppe' tablelop. tlght 19a1ns\ ,he
lu,lght dog. Set It.. lape",d dog into set of hole.
dose 10 1..... workp,e"s edgt. 1hen tap Ihe w'dO' InlO
t/Ie tAP ~ween Ihe dog and "'" worlc.

""'" 1"" 'ahle ,," ,il<" """'bo:-ndl. bu' <It",., cbmi' "'lf"

.... jos }"ft.n,~ ..,IUP ""lui"" a Ilnl~ , rW :u>d cm>I". """


~ an fICt jiule ru..y To ......1<)n It ... ,..<.>tI<. 1..... nenJ In
h;t..-

th<o '"'uplintOf" ..... up ..ith ,t ... bit .nd

st).,.... ",,;ng

Ihal.}'OUU bc .bIe ...,.,U"" .nd ,,"Ctl(lll" 1"" p"ucrn ,,><1

tIt< ..-ortt 'o ,IM: """" Thrn

}"OU

can run ,hruuwt tlte Il",i..

.... """""",ni 111:1, ..UI t.. n~. :and """ 1t)'OU n ro<tlpk"I~ "'" n>uI~"1I ,,[><r.t1C)l"1 .."ith IIM: I>1lI." In ''''''
p..,.;tloo.So...

3. 1'Ic.k ro'" bll (and com pie n"."nla..,. ~trl .... ).


TIU. JOOd . long.ludgmnll,,1 looIt "1 Ihc p;tllcm n~e Ihc
bitJ lIId Mflu ....""
p.l1I"""'. and """ ..hieh I>it. h 1>0,,,,
.. '""" 'u cupy II'" I""<"n1. If)"OU 11>.'c a (c)I 01 nl~l~rbJ (4)
boJ "-ay. (Ib'iOU>ly 1"tJU ...... n' 10 ..an "';,h " 1>111 hit. To
tn<"t Ihe delal1>. )"OU nd " ,,,,,,lkI"'nlC1Cr hil n,.)", .

'u ,""

~OfaV1POO' CT

Ib,lng ",Itffi tIM: 1I1t. chud< II In III< ~.ml" 'I~


mmlMf". R........" It.... molor rrom ,t.... ba....,. IItch'en Ihe bil
iti ,(,., <.'OIlet. and ",",um 'he n""OI" Iu Ihc ~ .

,h.,

.\IoUn' " .. "')111>


gocs .. ~h."" ~h<"",,, loiI"" 'IM:
duplic:u.", Thb Ukdr nlcans 1..... _
"""'... a nllMl .... ln(t
. . .ith ,il<" approprtll" .. )'111> 10 ,"" uppcr "'~m
4. Go .. nCCf Ihc alr !iUpp1r."'e .Ir '":11 fIoab 1"'-"
dttpIIntor como fn>m Y""r >hop ,. c . ... 1\" ""'" re....,..'
Ntr y"" .... ,'~ tu h:n.., a '"K ' ....1 h.) an ""....... port ln10
wbidt 1"'-" ~ CM1 M in5ct1~-d_ .\1""1 <lo ~ nul ,11.
Plug In Ihc 1"K and po;.I, .... , 1, IIOIok ,,,,-" .......... "'''''-h.
"""'Sh 00' 01 "'" .....,. 01 )'Ul1r n""""..1\I. . . much ..' ",...
-'1'IU1!1 """ cRlI n{ 'il<" ,,.,..,. ,n." "'" aru.U>I pun. "'"
0lh<T inlO ..... dupl""'I.,... al.
pun . It .hol1kJ ...-A

"'pp!)

Adj 'UI Ihe bl, and s "llI s senlngs u.lng Ilie SI<Kk
Ind IM p;luem Ilie. IheyVe bun dooged 10 , .....
Ublt. AdjuS\ Ihe bit, Ind po.lllon
dupl'Qlor.o
, ..... bit ",SIs on 1"" Slock. U I hown. The devtce~ luil
anet Is wclI thalit wih seule onlO Ih, b~: yOIJ don,
kavt 10 hold II. Then IdjuSI Ilie Stylu. so II 1. In con
laCI wlth IlIt UPI)t' ublelop.

'II,

'ltth,1y ..i,bout n!1~ritlJl Ihe pun more lhan ';. Inch "
,urn ur 1..... or m;ISl<l"lI ta"" """""" 'hc cun""","" >ItoouId
'1W"n! ~ lip If It g<>cs in ' '''' far.
I"*' OII 10 Ilie d upiicalOf" ,,-,'II ~ .... nd, ..tlile 1"OU
,um OII .hc .-..;, If CH')"I1Dr11: io "",",1"tI ... 1, -IhouId. 1hc
0111) "",,,",,".blc ~"'.,..,.. 10 It.... ii!!. >llditljlaround .UI bc
It.... dr~g&inp. ""d fIo<ing of "'" ,-acuUOl hoJt If)"nU tJD.
C(J>'CT. ,,lI<:n )"tIU >,.."ch "" II",
lha, Ihc ,",uplicatur It
>Udo.k:nly .. ud< 1oOIidI). 10 ,hc; wm" ....-btt. Y"" .... ~un
I'Ilnl It 'O 1.... '"K"s otK"tl"" """.

,-ac.

5. llootIlM p,n",,, anei Sloc:k In p""'"'. Wh~n<"'"


fl"'S>lbk. ma~e """,p 0.'1 hr makll1ll "'" >locIt ,'''' """'"
>i~ .. It.... p.I'fC1n ,.11:1, "OI)", Y"" c-an ~ ,hc p"ttern ""
i" 13bk. 11Im ..... Ihe d uplicalOf" Itl<df Iu pOOl'lon 'Ile ..ud:
OII ,hc .. oxk tabk.
l 'siOjl [hl. ll"chniq"'" 10 p<HJllon Ihc ..<.>tI<pies
dodn I rommil)<>U 10 ""'~ 'hc ..lIIc In. ~Ion
'100 You a.., aIi~ ,t.. p""cm . nd .. od " "h """
,noe""r. ... lIich il> CO&nllioJ. ~ tl>c)' 21"1" aIignnI a""
",'~'<IgnI 'o Iii<" tabk, '''''r a.., ..,1. \"00 can da. ,"" I.III~
rrom ,'''' "'-orkbmdI .nd cJo oomcthin c:umpklCIy tIIf
re"'nI ..
bo.ck Iu Ihc bench , ..... "'"ttb b.le . IJld
,to<: )'II .. ut bc propCTIy .IJwlCd ,,I,h """ :anuth~r.
So hcn:-"s 00... 10
It. Wilh It.... l'OOJ'(1" 'umnl olt, """'"

\i"'" ,,,,,,"

"'li

,Ion ,,,,-" >Iod! .... 'bc roUICT bit oJldn .1ona1""0 of I~ edgco
",hll<- It.... "'ylu. ls olidilljt ........"" ("or"",~
nIjlD of , .... p.,,~m . Thc:n cbmp ,he >Iod In ....,.,. ,"ou
clonl nn-d 10 ""
pruiK in ,h;" ",,,,'lonil1J-nobody
i likdy 'o nOIi<..., If.IM: potition oI a <.. ~ In ' hc ... od 1.
uIT by "",.u f~tI"" of .." I". h.

,,,'U

0\..,""

Now Ihe " ........ pi"'....,~,


ROUle. o..pltUlot

)1

7 . C lamp the s lock.and.paltcnl lable. Il1rh


>hop ''X runnll8 and II><' dupllc:otor Ihl .. mobile. bul 'It
Ihc "'.".... SOT ",nnln.,.. 1r.>C<' ~round Ihe pauem 10
how hal \O oritn he stud, .. nd-plllcm ubk. You do,,..
ntttI .0 il<:
~"" , .Incc )'tIU an """.., thc ulok
willooul ne,,(Iinll'" ,.,..Ii .... II>< bli and Ol)'l ... onllllJlf antl
wll"'"" .K"Cdlrljl 1" rcalign Iil<: p;luctn ..... Ihc >tudt, 1Iut
Ulll" otperl_"u"tI now ~ ""'" ~
ar.

,0<,

sItifu;

8.
b

Here'" the o\/e 11 utup.

Th~

noxk and'p;altfffllllbie

IS clamped allhf fGQf o I IIM! wO(kbMcll. an IIM! far


sld~ Ollhf IlIblt. oxc"O'fIng IIM! Ctnt" of IlIt worlt
btlKh, i. IIM! d"plicaIO(. TM shop \/ac,,"m b 10 IIM!
s~ . TM """fiilo(. SUII~ 0111 wilh tar muffs. ultlY
!I"SSfS. ~ .. uisanc:t dust muk. Is Hattd by IIM! work,

6. AdJus l eJ<le"slo n of tlte bit and 1' ''' j;1)lus. II


boIh II><' p;lllem ..111111<: """,pic:<:e ~re IIK .,.,.., Ihickr>C55.
)'1"100 m.kc lhis >dlllSlnlCfll .... "lC d", 1abIct"P' t i

"*"

coCe lJ("n,s. 1Iu, .il<: bnl """) .0 du i. i< aiic. "",\e ~


IK p;lLtcm :&IId .."Or1tp;tto: '0 tbctr resprt"tl':( .ablnopo.
Elcl~"" Ihc bit u far .. II all 1><' ""lcndcd. lhcll ",,;t It
"" Ilie ..."Or1tpi""", l'o ....... ll>O>'c 1"" duplk-.olo ' arou"d 50
lhc >l)'lus IUSi '()\ICI><:> II><.' hlllh<~ pot. un 'he p;ltttt1L
Adi"'" .tt.c .. )'luS ""."nslu" .... tha. ,
1"" ")'Iu.. i<
touchin" ti!>. hl~h painl . hc hil b rnt~ " " 1"" ,,"Or1t.
plcce ,1"0 :IOO,pJI>h Ihl>. II ....Y hc M'C~ ' 1<> "",,IU"
Ih,,!)il ulcn>ion .

"he"

'''''0

aRc. )'OU JId ..""ni.


R OUL

Anual otp<:ricn~" It b)' f.r Ihe bc5t

1'''''. 1

Uing Ilti> tJj(. Slncc 'II<' jig m.. ln,.In. ,1><' """liaI n;WJon.

>1111' 1I,,,,,..,.,n II ....1)'1 ... an<! Ilie ""'I~. bit. )'OU an 8u1do
Ilie cui. by hokllllJlllIe SI)'lu ...... 11>0'11,. it ar b)' 1ddq
Ihe <outCl" .,111 "",,'!nit k .vIU'" ""Ichintt ..'hen: 1.... l1)ill>
Is goIng.
"", IoltCl" .~ J'fO"Ido much boi' tr ("nlrul ,
li.., both ha ...... Grip Ihe dupl;",,,o. On d'hcr .Ide of 1""
bmhul~ lrimmcr,bui ..",.cIt Ilie '1)'llIs,GuiIk II by mO>~
. hc ""'Ief. Don 't ru.lI, ~~ )"(Jur ,1.,.., YOII ...-.on, .0 ,rIm
'''':1)' Ih~ wood 1111'" OI ti ..... , I':>.1hc:. lhan bu .......lac
Int!> II GI.ndns .11"" .Iock ocasionall)' ..-ilI moS5Un:)'OU
lha' .heduplk-..llooo iii P~"3:>S nlcnd<:d, It ponb:ohly
wlll ....,n] rrom ti.,..,.o .inx tiu. )'OU"" mltd O" .m_
JU>I kttp .1 It un.il Ih~ .. )iu. ~ " .... ~d aII
In:! .00
<l<Ib
.il<: .... ltem
"", <luic~e'l et",'inllS '" dupliet'e are lhuo;c IIUI
n:.aln ,he "'''''cr' ~ urllllrulll<>"JlO' mOrb. IIt' 1$1ljI' N' .....
"')'Iu_ Ih. 1 cl".dy m:uch II><' cu",.., 01"11><' a"''''''1 fIOUlII'
)"u an fullow rigIIl ..".'n Ihe CUl~S MrokN ...-ilh lhoc
>tIlu . n:ptOdueng D<:h of 1"" oriJtinaI SOUII<: n rb in
" ...... duplln.e,
Il". CUl'I"l! has bttn ",.KkJlt ...'tl OUl,)'IMJ can u>u>11)'
n>tIIIh OUl ,hc dllpllcale wnh con:-/)ux hllS, lhocn _ h
....., th""""JIOOI/IC' m,n.. wl.h ....1" ano:! obr.o;i,-n, ~
'bI)' Ilie "'-.I)' Iil<:
dId tlle urigI ......

,h"

o,

l':l"'''''

woO..
.......:f and
feeI

K"p )'OU. ")'H Of!

Ihe .... uer .. as 'fOu

Wilh prut.k~ you'lI gain confidfnc~


COIllfo.tlblt uslng ,~e duplicitar

f~n

. ._ _

31

lIoUl" Mi\gJC

,hOllllh Vau can', ste bolh Iht .,oxk

and thf paut,n at. t. h~ .. m~ IIm<! . Eve.y


"'''''C'''~'U uf Ilie
wlll Dt "pilUle<!
lIy t.he 'OUler (,igh O.

>1'('"'

Trammel Sase
(ve...,. router magician's basle bag

Iricks has li trammel in il. Here's


grui ane ror yo"r bag o' trcks .
ti'

_.

;;

II

:::"_.

"

IlO

or n .... tin~ """,Uish d~ :and hok$. ~ (rom


[-incI! dimlt,tt up lO:abtJut 16 ~ In ~C1". tlll,

"' tlK idc~1 u:lmm..... ~h:it Ili~r """" b 1" .1>Il~)' '''
cu",-,he [- .nd
~ lbc
fxI
It's !lOt /IOOd r:mlt" l>eyond Is .....",Iy. pol ...
~ pI'OlOl)'PC i> In 'he u_fn1( lulf ni "'" ROIbIr
'OQX/v.vd;lng 'hor .lhe h,d( " 'M", Plril Gchm 5f'C1'dS oeh
<lIy building furni",",;md lchol (h~, nhlocu ond pru..:n

do tho:K

,h;o,

."",11..!;,,,,,,,,,,.

2.onct\

<Ilnl.' p!i<>ns, indlJ5.ln.1 di>pla)' 00 ..... hok "" _


. ,."u
~ and nude ,ho" "rlgln.) .r,",,,,,,' lor 110 Pun""

CM* 100. 1'""

""m......,.,(I. Innulloenllk ,jmG;~ ~ ..~

IK>rs<:powe. ftlu'e' 1.
I'<'.emll, InKk

lI~e

ctlntnl"';'"

lo.... n In

Making the Baseplate


11... bo.,cpb .c 'ho.... " I.... pp"" 1'Iy. ...1tk:1t rd dwx.crUc ...
an,l,mcric:o"...utk ''Cl'!'io" "r ""ltic Klrch pl}'wuod It h1< II
pile> ...,,,.:.. ,1.." II", 7 plic 'lpk.':ll 01 tq!ub .\'. .Inch bircIt
M ...~IOIl . 11... >li<k i. ""'~1U1 ilanl"-..,, ,1Cnk:d Inclll<lo I
T-nu . a .humbscrcw or ~tI""ie,J pWlic knob. a" Iki
cnm""", n:oil. ""Li C~ I r. kM1g ",uuming ""rr..~ oJi corn-

monpb ..urr

EVC1llu;llly I ",:&41<: my O"'", 1lt\1~ [, ' 0 ' ~U _ I I

flbllI" muIe'.
n.., tr. n""d i> rouW>lr ,nnl,,,p'''''''pol '-'PUte
_
01 \.j ""h pt)'W<J<Kl. A " ~IndJ.k"'ll T~ . atcndillll
/rom ~ "" opoonlnjl, ou. 1<, .11 ..
d"'~n, ctl#,IKJUSc>.
oIIdt ..-1.11 1"'.......... 11 drh'c" Ihroul.lh ""'" eno!. Moo'c thr
!IIdt In or OUt '" 0"1"'"' .lIe r.d,u, oI.h" CUI. 11lm fi>< il>
~on h)" lghlcolnl.l 'Ile k>cki!lJl, knob.
II _II Nu,,,, ,,"Uri<. bc,l on 'Ile , ... mmel, ond o
pioInjIr ...,u'''' tu.,~ ahlll.y 10 inUI.,e: and <k"<'P<'1l a cu,
....". n..r....11) I nUcd mr .r. n,mcl bo.KpL>.C tu' SIn.11
~ rotI.a 1'0 mc. roll.i"lI 1'~I""h dL,k> .... i.h o j'..,.

""*

1. .... y ou hc: bascpb'c. The gool i. tu tu,':


6 ' Hnch!oJWl from ,1><' !:>i, ub 'o ,loc ,aii ""d of ,hc: I>;osc.
pUte lbc' Ict\gIh of _]>bIe ntt<k:d 'o achie\'c
pi
c~ In proponlon to Ihc: d .. nte ..... of.hc: rou,er ba...,
lJqcln by l'CII1O\i", ,Ite: 1it<1Gr)' Juscpbu, fn"" ,II<:

.Iti.

routa fO'I'II u>c: OII I~ , ......mei. .\I<-"..'u"" IL' r>oJlll>. :rnd


add 6~, indM:> ,O ti ..,. Cu, hlank 11", widlll ~u;d, tt ...
di:lm<1a of th<: m.... nd ,II<: ~lllIlh f".h ,!te """ .. r.o.<Jht>

pI ... 6'" incl1a.


Uoc <'U'P<' .. pc

1<1 ."lod! I~ r...,tory """'I'lalc 'u ,1",


bI:rn.k.'" """..'Il in ,1><" tlra'N1nJt /J,(.S<'pJ"'~ UlJ'Um. WI.h

39

Cuning USI
PiUt

Qty. Dlmtnslons

Sase
Sildt

)1,'

x 6)f")( 911"

M" lell' )( S'

IASEPLA TE LA YOUT

Millerlal
Plywood
I-lJ'dwood

T-,Ioi
etnte.llne

HArdw.re
I T'nul, )4",20

.-'"

-'Z

I thumbserfw, \4',20

c:

:s

-.-

x,"

1 utr;t!ong moun!",!!

K~w 5

(sin rol!'e<ltd wlU

1.._"_"_'.,.".d
_"_"'. _..'.O.'"'"~_'_._')_____..J

To lIuilk Ilie 1I"llIng of moun\I"V"screw hoit. Jnd

il

bit opt:nl

'tic. Ilie faClory bJ.nplatt 10 lhe blank wllh UrlH'llape.


TRAMMEL l,o\SfPlATE PlAN VIEW5
SECTION AA

ENOVlEW

Fl9

EDGE V1{W

IOlTOM V1EW~_ _ ~~

SLIDHOCK OETAll

o
O
g'y,."-

ROUIM I4l1lc

l OUTlHG TH E T SLOT

,.

.,.

')"-."'"
A. With a y,' str~ighl bit
In a uble' MOUnled
..,.,Itr. plow" IIroow
}t.. o.ep.

B. SWllch 10 /1 }t.. keyhole bit . Ilalst IIM! bil


flush wlth t.he bonom of Ihe IIroove.
AdJusllhe lenee ~ tIM! bil [UIS li IIOIth
in t.he $Idtw/lii farthesi ftom Ilie fenet.
""-ke Ilie Cui 1"'0 both sic!ew;l.Us.

2. Drill lhe """'" fo r the ",Uler.

UsinM ItIc hoks

iri III< factory b:ast-pI.,~ .. drili ~",do , driU """'"

I\:.>r

thr DIOIIIllinl; !iCTC""S. ~Iark 1.... Ioallon of It.. bit ....... I~

knIo>t th<: factory tu>cplalc (rom It.. bbnk. Thcn roun<moW;. th< """,ntln~'

_ <l boUI ~ IrIchCll)

for

"""".an<! ""'" a ~n

Ih~ M

.."..nlng..

C. lower Ihe bn Vi.' Ind


make" second pus on
u c h Sldt. Intrusing
Ihe htight of Iht nOlCh .

]. Root lhe T -tlkX. Thlll Is " jIOOd router I.ble """ ...
lllon. 1Iq,tIn by I\IUIlrtjll ~o-Indl.""kk X ~.lnc~p ",.""
II It.. pooIllon ........ n In It..
d ......illjl. S" 'IIch 1Q
dthcr T~ bil or. ~ ke)"tH.>k: hll Mlju>t ,il<: rcncc
110 1hI. bit "il! hc cunlnl! lrIto Ihc ouui<k oJdcw".<I1 of ,t..
P'OO'"C (Ihc .......... n f..,ht-SI rrom It.. rcne'). ' .... ,..... 01
'his bil lIhouId bot nt.M " 'Ith Ihc ",,,,,..,.. >i<\t:1t... II . IlO II>
.."inft an np llot T .'o!. ke I ("Ul Inl<) nctI ""-.<11 of thc
JPOO'"C 1lIc propcT I"ccd di...ction. by lhe "-.y. b rigIII Iu
Idl For """ lIi<k. pIow rrom cnd 10 bit opnHng tor the
othn. rrom bit OfIC'n~ 10 nlF.

101)"'"

notw.

4. I>rill fo r I ..d h.,;.t:ill ti.., T_nUI. M


lhe
"ilk b fIxcd In """'Ilon by I 'hum""" ...:.... IMI ', run
IhlUUllh ..... "U1. Thc lip 01 lhe K"n."W p<aon _Iruc lhe
.. idt:, j:amminM; II '""" ........ 10 drilll pilot lor lheT"'ul. plu>
rounlnbot"C for lheT..,,,, f'IlnF.. ,,"'" \"CI}' an:fuUy. liI>tt
you don'. ~>'\' mudl IhlckncM ..itll " 'hId! 10 WOfk..
Set 1"" N!q>btc on the driU pttM l;abk. ,,ith ItIc >lot
up AliBn il lOr drtlH"lI 1"" T..,,,, l'ikll. and cbmp it 10 the
",bie Urill 11'1<" apPfOprialcly 5i:eed pilot
S" 'kd! 1<1 1
-1>1 ....... """"""'" bIt, an<! driU a roumetbon:: t.kqI ~ lOr
thc Tnul fI:m8" Tot ,he drpth by scnilljl llot T..,,,, In,o it.
u~ oo..'n nd 5cdng II thc n. ... 1> n..... " 'hh thc
hult,,", 01 t"" JIot.
1'.p Ih~T..,U1 camull) ''''0 pbn:: "fum 1"" Ihum~'
i",o lilcT..,ut .

"'*

T-Slide Tester Tip


TIItt T,.ul for I h. alld ..lock ,ilS In

counlerbored

hoit Chi lltd In Ilie butplalt nUr IIM! IJII end of Iht

tJot. To INI tIM! TnUI's prong' . Ihrelld" boiI InlO Ihe


TfIUI. as shown. and lap an Ihe boiI head wllh.

. "'"

I\lmrner. {Hote

t~111M!

IItCUSilry hOit Is larg" Ihin

To h~lp III ,h~ sl~, (U, .. T~1ot In ilII '_Ira


piete of Ihe buepl~l~ Slock ""~h thl~ Iesle. U you
'OUl Ihe Tslol In Ilie bau. USIII\I Iht Silme w'IUpS.
As \'OU rtll~t Ilie lUdt, theck how 1\ fiu '" ,hls
tell~r WMn yOU ~lIn p41U the llidt, thrQugh the
lesler's SlOI, 11'5 JUcty.o UU In Ilie ba>tplale.

n
_.

;:

It

:::_.
C

..."

S . Cuii"" bqrpbk 10 ~ h~p" .."h iNT..... nil


iN IIIkk lod: 1mI*'1)"OU <"lin Irlm 1"" ~ ~ I f t '
lIIInn, ~'"" 10 1"" ~ ,.:-.,tlmp oI\;opc Thlt .. tIonc
'lWckly :anii noi/J' Of! ,..., ban<!!IIIW II yuu <Ion"! ....'" t.nd
""W. ...... oaIxT _
Thm sand Ihc nlIIo """".....ith hdt

_.

~nd

tipi 01 tIM: Il> ......... ~ ro ,.... It tO !It.


Whm II Ou pnfc:cI.Iy. driI:u>d ~vum~ tM hoit
for the piml
1\> OI1llke tl IC
ClAIhc .h.onk IfI)nl'" 8d """""'"
noii . Ic-~ ";'" h abouf 'Inch Ionjj ...."..
"~
hoIr, :u>d slip IIM: ob;k Into Ibt baocplatc

""'OI.,

6. Makc . 00 AI Ihe ~ lIde. Thc Niok > formo:d 11)'


bbns ."0 ... nIW 01 I _"00<1 .,Ip,
al furmlnl' ' 0fIIIUt """"...."n I""m for afct) 'u,k, tu 0JICf'
C "~>n ihould bc pc<f,,,,.n"'" n n a w'>l'kpoC , ....', 2 Inchn
. _ .... 1DOft' '<riIlIr AII ... <"UIlln" 1"" nal!hor .... _
'M fie uliM
: : ' 0fI8\IC" In ,tir oIrndr<Ul T..... " It h ...... , lIt 1""
"'""~

-.-

Ihc r:obbI:u bir ..-..


iM r:Ibbtn ... , .........

tt ~ ls ' 00 ........, ....

*",

00.."., "'""iIII

II

..-..m ' M lOIIjlUC fi .. 1"" ob . np IM Jhok (rom IIM:


.."OfI.:~ Sn "fi ,Ix rippina CUI ... ,..., .... wll f.U tu

tIM: ouuit)r 01 IIM: bb<Ior. fii 1"" >lkk 10 ItIr T-tIot ~Ih ~
bloci< pWk. ""'....... , ... ~ing; (ron, 'Ix s1loJ, .. """" Ind the

NA"'ING TH[ SU OI:

A.

the

t<!gel of I

1"-wodto

Using the Baseplate

!OUl'" ,. ." ..

::1

t""

_kplt<" /o<m'''91 u~..glle

1. Ch uck y bit 1" ,Il" colk."I. \ly 1mI1'"~~:::~~'~


>lr:IlgIw-bl! In>!\.' tlut)'OO nl:l)' "" root",-. 'l
ftk ..ith an ....piIotcd p<Utllc! 0 011.". 50 cboooor)'OlIr

..al.,.

fii il iri iN """...


II" JUO ..., rooIl, . ........ OI"
I dbL 1"<1
mcnd I oponI upcut tJ;t. Ii ... ~I .... cookr beci...., ~
ro ....... Ibt cbip up and 001 0/ iN CUI.

U'hiIc )'00 ..., .'<lll"l.l up Ihc ,.,....".. adi"'" ,hc .~';


(kptb II,..,.. a.." WIJljl plunsc """... 1t)'OO :an:: .,
<'<Im{1Id~1f Ihrouah tl>c "ock. "'"
dcpth 10
<oWd. lhidinnf ph .. nu moft' Ihoo "'" Inch.

t"" .......

1. ChKk Itle fIt of lhe 10ftgUe '" lhe


T.Iot . Re-rwlltle ~1S 10
,Hluc:., 'onglle wldlh. SUn ....... '
il Ilo, longue 1"00 """OW.

2 . ~ lhe JlkIe poo;tIioQ fOf" lhe dal.n:d M"..


..&l....

~n

1""

Ih~.

""'~

Tunglle
100M"OW

Ihc .....,

' ....n. 1"" Ih"mb.cn."W


I~'I ~ hc.." rou IttOUnI lot thc: oJ~ of,hl' hll
CUlt ... . dl.k, ,.....,/"''''
I>It frum
r:ldl ... , ""'''''''''' r....
1"" """'.". of 'Ix p>u 10 iM cIoIot pOio!l "" IIM: I>It II CUI,

t""

100 wlde

t""

JUSI.iglll

C. Rip ttle sllCIe r,om tht .. orItpl-eu

O. Fii Itle .Ikk 10 Itle T" 101 by pllnlng top Ind


edOl' of Ilie Ibnges _ 1111. bloc~ pIIne.
Plo ... tht tOgn of tlle f i I .
tO reduCt OYeQH W'kIIh
ofltle iWe
PiIne bac:k to reduc:t
Ihl(kneSi of fll"9".

S.I Ilie cOIIII ... rldl., by ","tU,lng lrom btllO


pivot. Uu I ""'1.1 "'IH 10< Ihlt . Tu," 1'" btl by ""nd
10 ensure 1""1
mtlllu.'lng Ilom Itle (Ulling

'r'OII."

edge. and IlOl the boctv 01 the bll . Mutult I.om 1""
cenifl of Itle pivot

I
I

1iIIII"1I<.>k.1"..I"'I~ It... hll In Ih, rad'u. m,,.,,"'" f .."" Ih,


pMK cm l~r 10 ti", ,".. h.,,, p"IOI or II,.. 1111 Sc:c II,.. ....Jwilltl
StltI'W lIN CulII" lI NfUI/",.
For ~ X1,.'tlI'K')',"'" mCI~ 1 n,IC', ra,t...'r 'h"" I I~I'"
~, 'O"" 'hc "jl<k

SlTTING THE CUTTING RADIUS


WANT HjE 0lSK1

<kt~T11Ilnc thc bcsI ....,nU(: <JI a.ttadt. n", nuy bc: ~bk to
.wi. ctt OII 'hc """or wiel,.hc bil R:1....,.n1 wttlltn <hc """',
'Mn """"'" III<: lod; mh>nlsm , pI~ tII<: hit inlO III<:
wor1<, and .w.lrn It... Iod<. Doe!n', wor1< lOr)'OUl Trr XI
unII Ilie
<kpch .o:./)()O. 1. lndI, .hen nlchirlft otw:
p; ..... in il> hok ... hi'" Irttpin8 otw: ",..1,,. ba.... tIppnl tip
from Ihe """"flie 50 tIM: bil 5 ck:u <JI."" wor1<. ~wiI<:h
on 'hc .. >Ule' and ~ it ""'10 ,"" worl<, p~ tbc: 00.

"""ing

Stlll unrum{o,ubld tkR:'. a .hiRl option: [lrlU .."R,"I.(


hok .11<: sune diametcr as otw: bil Set
<io::ptJI al" ~'tJI.
po!Iitioo>
mut .... "itI> ."" pi>vo in ils pilot :ond the bot in
IL' ...... i"l.( hok. Now ",.,.;Idt un thc .....cr.
W,II> .hor CUI >!arin!. it b .unpIe IIYU.". 1" ...... ing 1"'"

1""

MUS<lrt from 1"" pivol


10 lke ne;t' cU\llng
td~ of Ilie bit.

MeUU<e f,om . he pivot


10 .... f;tr cunln;
t<Ig<t of 1'" bll.

3. DriU . hc p h 'oc hule 1" lhc ~or"pk. "ou


aal., .......00 """"""s I pl>vt hok: In 'hc ...'0111. 1, <Ioco;n
Iftd 10 "" ,Ot>

<kct>, oincr "'"

",..I.".-(W...,..,...kx:kuv.. S 1"" <:OnttI kcd diotttlon.I>n,.... I """'plete ";r<:k, tf>Cft:2Sc tbc: cun". <kpth, md
,;ok anothcr bp. t;rq> it tip, md 1""1' gt1 """",

[li''''

b lm'" """" lhan a


drib bi., and bot<' 001)' ... Ind! dcq>
I:tq> thr driII perpcno.licubr 10 ,"" ..........

~ ~ '1Mnd\

1( )'OII ~~ 1'011111\11
Ilie ..~>rI< ~rwJ " t....
.... rime. pn"CC1 1"" ~rfaa: ~.h II MOIt.'U\lcr, )'OII
okfinj'dr (Ion '1 "":"'1 .h~ pl ..... pol'" 'o nlO"~ >5 )"0"
~ Ihor",,,.
What 10 "o, Slido: pic of ""pcnohbk " ..,,,,,01. 1_
'Wdt I'I)'...-ood, for cnmp"'_u n<kr ti,.. wol1<l*.Th" 'II
~ """ wortd>mch ""","J lh Itw. """"fK<'CC. 1'0 Im n
l:Iililr "'" pkcc: 1"'" "'ill hc ~," fn."C. bon<l il '" . lIe 1);K'kup
IIIII <.'afJ>C' 1:11"'. W"h .his d(>n", d''''I) . h" ..'ol1<plo: . mI
;"bod<up ' 0 ,"" worI<bench , po>lIionltl)l Ih<' e b n1VS ...""'"
....,. """,', Inlem..., " 'jlh 1"" I",mmcl ', lra"d .

oi. Clam p the ,,o r"pl.,.,.,.


\IIr<IIIP bok, )'OII nd 10 """",n:

5. S<:t !J,C roUle r In p lace. " ",1 ro"t. Wllh

.,....,ry-

!bing ~ " p,..,1 Ihe roUle r iln Ih.., ...."rI<. and ..~ ..... ,"" pl" ..
kU<> tht: pi,.... h"le.

w".,.

plutlJl"

t .... ~..i .~hinR

n)U'' ',".., Ofl"""'ion In.vl'"" '''' n"""

un .h., rout."., ph'tl)Ilnll Ilie bil In,o ,IM:

wott. and .""lngil111 ,1Ie moch'nc an",nd .1Ie pi,',,,,


FI . coJ.b:1>c 1'OlI'eU :In: a bit n..".., prollIe1n>lk. """ 1""
lII.ty

1""

pffi! 'o ,""""ri"'ent bi, "'Ith Ihe

"",1<,. )'OII h,.."C 10

.,/
A .... rfect ci rc' . il tne e nd r n u'l . Whelhe. vou
...anl a dtsk Of a hOle, Ihe ttammel b;tseplale will seNe
The effec, lViI range of Ihe Jig 15 evldenl: The
gfGOve Is Iht lal~st ITC '(OI> Cin produce, whlle Ihe
disk and hole ,ep,esenl the smaltUI.
'(OI>,

n
_.

/1

-_.

Vacuum Trammel
Rou! dn;le without lu.vlng ;il mark ;U the
pivot polnl. Vacuum pte ssure holds Ihls

.-'"c:
U"
.-~
w
w

.-U

A
t(

l"""""'. pUl" ......,er "" "' ....p" .... .....noI 01


oImply drA"'ing ara and drdc . II """blo )"" 10

V... "uum l'roducU.. ..00 Inlrod ....w


"'Cuum cbmping. (Sec ,h~

OI/thcm.

1""" 'IO.)1lM: ClGImp~ of'-.cullm =n,ntdl


'''''' r .... ".:.:n """" a ...wli>ll p"." [>IOIe "ith a riScht~

)'OU"..,

bttn wor1o:lnll wood and mdlnN

.bou.

wQOO.!w..... ' ng fQt. coupl~ of ~'I'S. }..... -v.: ...",ty .......,n I


OICOI'C of ' ... n,mc:1 odU",. O .. ,he ....., o:nII of thc , ... ",mel
...Jc .. Ih" ~lri p oll<+<nch ply....
,,-;,h I
~
al OI><" cnd ~nd .. 1'Oll..... CI~I .'.pcd 10 IIM.- othcr. 1'he

".>tl

.,..'01

,,,,"\1,,,,1 """",,pl' l<: """,,'n ;nlhc: p",">ou, clup'C1" Os MKnc:......"., in IIM: middk of ,IK ......"'. II hc'Il!irully madtloM!

111 flnL..t.cd COn1mc",lal n"m"",llikc ~icro-F<:n<:e '& cird!'


IiI! /tu'o rq>f'OOn he hi"" "nU.
T1IC ~I
M'" b "nk:1k- fb.""- .. ~.
8""<l "",omd-l""f'OM' ' .... mmd. bul il ', ~"I bn,.usc il
;llIu"", l"'" 'o..,.. dnok wil""'" m2ltl.... 1'1\'01 hol.. al'.. h"", In thC' """"pica (Il ' 1"" .pccIaI bcousc Il occds
"..xuum ",->tem .o ..'011< ""lUI! 'dveruxd.)
n.... crtUc2l dmomI ""'" lII.tIr pj>U. I!". """""'" liIl;
............ sud;! it 10 1ht ..'OII<. YOu fIO'i.ioo II>< pr..:. ~ . pulI
"XU&InI, ,",,,, It 11W111y Jnbo thoo .."011< and """"'1 ici k JIO.
y.,., lw1!. ,"" ,....."md ... Ihc: piYoc. XI tllo: r ........... an<! - . ,

I'"".,metl

Ih< <;Ia. "Ibm )'OIJ "'" d .. ''3oCUIIm,W IN;, ptvur bct;;r in>UnCJy
'CkA-a (,,,"u II .. ".",~ . N<> r...... " u " ... 1<>, 'M'
rnIduc.
I ..-as >j>Uf1"nI'O _~ ,h. fix,,,,,, by f.d F...-ri of Qu:lm}'

'''''''r

"a'

"""

10 ''''' mim

c"'p'~r.

"\'::UUII

Cl:tmpn~: 011

""Ihc:oi "

wcuum P<)/'[. "h~ ....,...,m "'- ""..


lIulrlft 10
'br e<W of ,lte pi_ hc. makinll ,he 'X\jum hoK
oI:>lu<"k I( yuu do '"'"",'''', hoK wlti.., maklnsc cu.)'OI01
1.- ,..,... 1'1_ jn>tamly. and '"CTY """"'t>ly hoId> dIC CII!
.rId lhc ItIo'OtItpctt.Thu. b
wood ... f>I1r.: ....
n""". I fiI!un: lhc... ,,"" c"""llh ~ In ,r.mmd
"""ing. "" why Introduce ."",hcr OII 'hc pn.~CI' of
_in8 thc prottM ~
Se> I an .... up ..;,,, a dcsi!V""'" """ ,"" IIIIln.tI In ,Ilo
ttII'c, of ,'''' pi"'" 1uclf. "I1>r ,....,.. an hr dn;oppnI
from ",,,rhc:uJ (....I'ft'd M from hop """hooI<) .... ,ha
,.,.. """ ..,,,,,'" i,. ""''CI' In ,hc ,,~.
1ItolL'lC
"nd ,xuum cw..plng ,.... conlem ......
13".. ..'OOd"'uldnl( mClI'lo!h. j, K'CIRlI riy)1t 'o """ that tht

",,,,,*,,

doeJn,

<1,,,,,.

II,

\'2CUUnl

"'''''''li:
tnrIlrl"ICl "" n,."" ,,It" C'OfItelltp<>t"'I) m.,MRI>_

onJr bi, of ...,"od In ,hOl


fix'u"" b "-"'IIhIr an Inch sq~ _ ~ in<:M long."I1>r ,..,..
of 1"" ,r.mmd b """.1 .nd 1'1>..<1 1<:. 1lM: onJr sluc used b"
. pp.....nc...,u a co"!ic<,u.:.'ott. ,,,,,

h4<"'1"':h ~uc lIJrmul1t~ 5J>1IicaUy '''' l>OOod (1"''''13'<


kln<b of pWlc.

Nn.,.,t....",", wIth It.... ncq>tlon of CUllilljll~ ,t....


md It.... looU UKd "IT con,,,,,.iQn2I

~ ~pplicd

"""""''<If1tins leduUquo md loob.


Iki:>n:: ~ Ilooo' 10 _~ md ..... tM ''X'UIIIIl
_ 1. I ohoukI empha>ilc WI )'OU nd oomc optti2I
<qOIipm<nl 10 anl~ IIM: ''''''''''''' lh>t l'IOIoJs , '''' pnu "'"'"
10 tIM: ...m. DcWb 0<1 Ihls an:: In ..., ncx. dupl..... ' \'xuum
~' OII ...., 50. Ir )'OU . . . 1 N'~ a l'X\IWIl sysICfll.
......, . nu po\nl In nukilljllhls Ir.trnmd.

Making the Trammel


t'. ironic. 1 Ihlnk. WI ..~ N'~ .his ~ woodlI'OfI<iIIjI/iJ;[un:: hcn;:. md it Iw> alJnoo;[ no ..'00<1 In il Ir. a
,:IOd <:nmpk 01 __ h~niI malrrbls """ IC'dIniqucs
.... bumllljl """" ~. Cl'CP 10 thc: ho/:Jbr wood-

......ur. You
pWclt:

(;IQ ~Iy subN:"UI~

put>

In lhh

r.~IUR:-"""

..'OUd r.... aImooI. aii IM


in bct. )'OU mighl mat"

6(>IJ>Clhing qw.t llandsornc. """" SOl1ltlhinll in .hc lr.dl.1on


o( cighlctfl.h<cnl ury ~ arod nbIJKunakC1'1l.
Bul wouIdn 'l Ibm IX' ironk1 II ,ul"""~l\co;on ruulcr

nM,umcd II'

li h il!lH~'Ch

v.tCUu ....d.mped ' I':I.mmd kn'lnitlr

h:an(Io2ficd uf ~ ..vuds.

1 . Cu i Iht pivot oolbr. Thc: I<cy "'.... pcJftcn, l, thc


ohort p;n:c 0(1'\'( pili<' 11u. ,.,.....". "" Ilie pl .... CQIbr. ~
dr:awings anii CWIilljl UsI "'" lOr 11':I.Il"""" bulii around
I I'Hnch-tD, pili<'. Th IX' 1Ionc>.I. IM Il':I.mmcl stx""n In thc:
.....,."" Iw> a -z.<nch.U). plp" .. 1.. colb.-. ~. nI ......
!iiH: pili<' ~1Iu11f)... do UW Ilie 1afJICr~ .... pili<'.
)'OU mlN ""ItN tht: dimnuIoM of . 11 Ilie JWU.
CuI Ihc: pipe: 10 IcnMth. :and <:kan .1Ie I>um {tom Ilie
cd!Ir:S. ~ il corduIIy wilh c:alill<'''. <kIC'1"II1IninJc booh
tht: _
and 0Ull0id0r dWnctCf1l.

2. CuI thr: pl\'OC . . ,. I nude

tht: lu.Jt ftOlll pM-

Comp. tsslon l[)ring

USI
Material

Qly. Oim e nsions

~\f01 ba$~

h"x S' )( 5'

PI.l.I.i(.

~\f01 plal~

h"x 5" )( 5'

PI.u li,

~uW1!nl b~,

loIo'xl\(,'xS'

~,dwood

p"'l~

:y.' )(lM')(6'

Plull,'

T,"nsillon

(OMtel.,..

H.rdw....
I "C PVC "1",,. 2' dlll. \nominal) x 1!1'

r b.~n b.1rbtd

hO$~ (onn~tlor.

male

2 \h.e~fd InSf'U. \01.'20


1 !)Ia.tlc: kfIQb. wllh W20 x l ' Slud!:
~~6 rrom Reld Tool S... ""ly CI'. (8002530421)

2 cGmpresslon sprin;s. W 1.0. x W Ion;

3 fI.ltlhead wood sc:.tws. '6 x 1"


2 Sltel tOds. !1" dll.. )( 36'
2 Sltel .ods. Sll'IIt dlL as fOII'tr'. tdgt';l,Ilde
rod.
4"

x.""rox,

_ _ .. ...1 ~_. . . .

II

"_.
=
III

r ""'""~ wllh ll Ud

Part

"

V",CUUM TIlAMMEL UPLOOEO VIEW

Cunl

_.

,..,...._.wd.

V" ... um la""

.lu}oIor

li .., , , " " ' _

Vic ... um Tfl,mmtl

4S

noi"' ~ a bur m:ocIe rrom dor po/)-arbona.~ OI"


mlsl" Ix nsicr
ea. tIM: pi>'Ol ba$o:: '() .h<o
~ optdfotd "" .bc Cu.ting u.e. y"" """' 0 bc
.bI<: '0 "'" 'M " .. ,ltrs of .hr ba.... .0 :align il on pi"l1

.0 .,.,....,...

:OC1'}""

al

(IIIIn. markcd (wil h ~f5) OiI a ..vrkpittc.ThIl5, ~


mu Sl "'" ruln m. hc b<bc ;,; ............ hul .b()
tIM:
"'er of.Iit ... ""'" 10 markN. (If)"OU an. ...... p<>IyarI>on~ OI" KI'}I,e. "'ne .hc p""'ccm"C ~ pal""" OiI il
an .......Itt aII 'hc lat""" nuri<> un il. AppI)" ..rip of ~
"1'" '() 'ht plltnolic.:ond mal:~ tIit mari< on Il) Card"ully

"rill. ~ndHll. mct~r hok-.I!rough.hc pllue a.

.m.

-"

.-

1.1

.!!:!
~

.-1.1

,ha. (l1li'"

}. Nou h e circular gro<n'" for the 1""01 ooUar.

u.., .hcTDn,md ~pl .. e on p.ge 39 on. p lulijtC nlU.er


for .hb """... 'ion. lls<: bi. ,ru" m.,do", ' he w:oU .h~
I'\'C p i"" .. ckN:/y "" """,'h'e. 1 u>cd. l.'""h bit.
&1 up.Iit u"n,n",1 ba5<'p1.uc by ,,"unill/o: 'eSl rinjlS ,n ":"'1'

,71.""

.... 'o;riol hcn fitling.!>c: I'\"C pipe In,<> .hem. Whcn )'0.,\..,
tIM: gru<n'C In.hc pl ..... twc.
tIit ""'" dnIkd In Uit
)'OUl" pl."O(. M. kc lhc 8"""'"
nnly III indo dcct>. iUSt ~ 1<> cuch 'hc pipe ..... """'"
... =><nUl. ' " tIM: sptt;aJ gI... """ .... 11 hon<I Ihc pI"" to
"'" pbte

:ocllionnl. JUOd

rit."""

Cftl,,,, ..

'''"''lC

fIO" I:>y m.I.llIInll 'he nte. hol<: (,"" on<:)"OU ~ 1JIItd.


plvor). o.,.ennu", "It .W:: of hok nttdcd
lhc ,~
ron""'-101" j .......111 ,,~ (1 u>cd braM b:..bcd """" ~
,,,,,:lor .... ith 10-1",,1>-11:1 NI'T "",le: th ....... un ;I).an<l driU (U
thc hoIc: .0
l1ICn " 1' .tIC hol<: fOr ,hc ron<ltt1Or
NQ<e "".. i'o',nlolul Pipe Th ..... d (1"1'1) is 51gnlfiCltntlj' <iii'

ro..

'ho' ,,'c

.h....,....

kRn. r""" .h<o N..ion:lI Cootsc


an f.lstcncn,!oO "'"
' M ~ tip. Sa tIM: Stttion ""Cut';ng l 'hn;:ao.b" In tht
.",......
S . Coluc

w ...... IO.M pivot b<aK. 1 apt'rimm.(,j

"'kh se>'ft'>l gIucI ....,."., .....1lin8 on 1kv!."UfI', I'b>tk

"'dder ...1o\ch 1~. :Il W Ioc::ll """"'.,.~.wn: Mlx tht


gJ...,'. , _ consoi"..,,~ and ~ . in
cin:ubr 8/00"0
In ,"" pi>'Ol ~. Set tIM: coIbr InIO pI:o<.'o;. lis<: ........
dtom... er """,.,,1 .0 buiJd up a Iillet of p"" iIfOUfId .hc in>Idr
anei outskk of tIM: culbr. ' o n:inbcc .bc joim
S<:t ."" asscn,bIy asi<k ,,'hilc: ,tIC SI'" cura. No
cb n.pIIjI ii 1I<"CCS.'iaI'}".

1""

6. CUl .he pl~'(){ pla.e. Thii b ,"" pIa.e """ Ou OI'Q"


,he pivot poM. 'yinJ
rou ..... '" ,"" pi"". Il "". b pb>tIt
In my [KOIOI}"pC. thoollt)"O\I rolll<l m>~c il oi pi)"><'oud.

t""

7. Shapc: .hc: p""(){ p la." ..... Y 00. thc

.ha.... oi !br

VACUUM TItAMMEL 'LAN VIEWS

TOPVlEW

StOE VlEW
"lc~um

f
,I

'---.../

hose

rlVOT lASE PLAN


TOF YlEW

,-

''h.

henoli,

m-

,-

_.

EDGE YlEW

i:::;,

n
c

~;;l", """",~e(onneC!O'

:::

--"

GI"e Ilie coli .... 10 Ilie IMs e uslng a special Iwopan


Qlue calltd ()eV<;GII\ Plastic Welder. Pu,lIing a plunger
on Ilie package di,pe.,se, .qual amOunts of Ihe two
(onstl!Uems. whlch muSI be mi.ed. Sp",ad Ihe lho,
ougllly mlxed glue on Ih~ Dollom fdge of Ihe colla'
and In Ihe groove In Ihe base. Thtn press Ilie Iwo
pans IOQelher.

'"

,.-- .---~

PIVOT PLATE PLAN

SECT10N VIEW

J
1

.-

Plasuc knob wllh


14" 20 X '"stulstud
pilI... ,"""'n In Ihc d ....wing P/nJlPlt"" 1'Ia". Thc h=k
in III<: ring illo,,",)'Utl \O fi, Ih~ , .... mmcl on Ihe pivo. h2sc
1JjItr" I\"$ ba... '-:oc""moScl on II><: W()rtp~."'" .101 Il!
_
cnoogh for ,h.... cu"m hQS<: 10 p""" Ihrough.
On I>bck phcnoIic,you ."",., golng ,,, Ix .hl<: 10 """ . nr
bI)wI ~. So .pplj. OIrips of m""'ing "'pc: 10 'h" p~ic
I:ri.>r<" doing Ihc Ia)"'">"t "'"011<."" :o),enutl,... ilI \" 'prll' ~
"""""' q( 1"1""" 10 th. plbtlc "'lth .nhl.. "f'RY :1<.1001, .
DriU IIMnch-dWnetcr ""le >t Ihe 1"1"" pOi,,! IrKlic>lw
in tht Bonom l'reu' of,he 1'1,.,'1'1",,, PI"" d",wlng.
l.1y oul 11",.rc ond 11", ,.~n," . h.:u "",end fro n. ,''''
"'" 10 III<: comcn; of the adlu"'mcm bor. CUI Ih. "fl8Cn~:
tht band",,'" \li i<I~.,1 ror Ihi,. Ihout,h ,,,her '001< ",itI! do

""

compre.:::-l
sp"ng,
...---...
14" 1.0. x ~ . long _

ENOVIEW

Th,eaded lnsen .
~'.20 _________ ~. pllOI hole
for insen

Phenollc pluol plale

",,-

NoI u><: <:;lrJX1 "PC ,,, bon<! Ihc plaI<" In h;u; ~up
"",",p III:.,,, iii)! et\Otlgh '" hc cI. mpcd ..,.. <k>8!Icd '" ,1Ie
.."QIkbr ........(I"i' mor"""'" .n Irvnlc .ppneh . inec ,,c...,
ulklng .1">0"1 ""cuum-el.mpcd jilj.. Ilui Ihc ,""h is.
....:uum d1mp;"lI <Ioc>n1 """' In c'",,,,, .i,,,",lon . nd ,his
II (lOC In ",hleh i, ",,,".,., wort.)
tblJlII. Ihc I...unn",1 lxucpl.>'c, rou, ,1><: .re ....Icr. fkr
)'OU ..... 1Cp='cd Ihe pl.,,, from tll<" ":'"1". tUU con file ....
!>nd tht cdJ!<' lu r. lr .nd '''''Mllh II><: 'I"'nsi';o" {rom.re 'o

BOTTOM VIEW

J. r

... -

114"

I~ ,ad. - . x , .1
vacuum T'3mmel

47

LlI'IJI"III. and to "OI" op the .pf'<"DtIC~ of tiI<' r>bt~'s ~


For ".,....
ti .. plate ~""k
the $0"2.1'.

k'"''

'"

8.

Kout th<: pivot hol<:. U"., tI .. pI""'lI< ..,.,tc' "nt'(!


....,th the tram"",1 haoIrpl:ttc for thls <>!",I\ltiolt "" )'OU dld
..,1 ..... rout~ thc """"" In ti .. pI ... ba$. m2lic tc<t CUt)
In
to adtu.'oI tlle router and tr.unmcl You ...""" a hlrty
tJcht fit 01 t"" poo;I In t"" hok," bit 01 ~rI ... thc:
pbtc turn' on thc:
ISOl't pru/llem. but >Iorl .. lf t""
C plate C2II r~ttk. bit on mc P'l'l , JOU ....,11 noe 11"1 !i;tti5b<:C t"'1' cuts Il>i~
t",mmd. Sa m:d<c >un: thc: t",mmd
._ adllUtmcnt III just rigllt bdo," nukil'l8 thc: CUt in thc: plate,
;:
AtI"" rouIq the hule. ,...par-ne the: pht~ from t""
.. ~""r~p Culthr~lItoIonthrband .."'t>o>
U with ..an """. Ale tlw: c:orncr> oi thls lItoI 10 """"" thcm.
and...- thc
to s,,.~ a.:.n thco
ctiIP ofl"" pl:ttc USinjt fi"" lCUld""pcr OI' .\Cr.t~

"""'1'

1'''''

t""

-.-

t"""""" rro"''''''

~
U

9.

M.ke th ... at/I " s l men' bar. Cm the lurllwood


r uscd ... tu:..,., but ",.nf Qttu:, hlnJ ...vot/S..,irI do
finr.
J.o)' out ""ti tlriU tho: hoks for tt.; tr:an\nld rud<,:0!1 ..,eU
:of for ,tu: k>ddng kn,lI>!o. Opcing for ",unIincso;. I "....u h
1_ rod> 1 boftd '~lnch4Wno:''''' looIcs for lhe'" In 'he
:ulf""n>enI bo, To lod thc
plate In rx-Itlon Ofl
rod, I uscd snt:tll pw.ic krtobs with \o.lndl~. 1
lnchIoIlll14 ..... IUmed Inw Ih"",<kd i .........
I>riU ,"" ~ hok . usins tltc tlrill ~ opttifkd ,." ,""

tn

J",

1"'"

1""

1''''''

i......n. rOl" ""'.om" II><: Insnu.


10. Mounlll.., bar "n Ihc pivot p~llc. O:uup the
palt. ,QfICtlIcr. J.or nu, . drIII oo countenink p11ol5 b' ,Ilo:
1I>"umlnw ""~
Ihr se""" .

Ori,,,

._'fftbI)'

I I . ,.... ak ... 11>0: rod$.",., I~


tu. t .....,
". of rod:!. 0rM: ...... Is ti", 1'"1' of tr~",n..,1 rod:! tiu,
<:>'tcnd (rom thc: ,...,.siliun plate tO thc pi\'Ot plate. 1 uscd ' ..
Inch ~ttl rod> for thJ:o P"'1"'"<': )'OU an ttrulnly """"k....,
>mallcr..... "'cter rodo. The Ib""''1It: UI spedfict ;,(i.incn.
Ion~ . . . Yoo can nukc tiI<'''' JonaI:r or .hore",.... )'OU

dc:sir<'. (Il<<0l ..... thc:'" roWI nn M IIn,e.."''''' from ,II<' tru.


sitlon pbtc "" aoiIy "" tbcy.~ """",'al in,o 1', rou ".

nt:t~ ~ I"'1r of.non rod> to ... pplm>mt 'hc: ~"":""~'

1ltc liCCOO<l "'" of roWI wn.,.,.;u ,hc lrommd '0 '''''


fOtt'''''. lltc """"ln~..1JOfI> 0/ tMx ruuter roWI <kpcnd upoII
thc: """"" . Somc nl:Ichlnc>, sud> .. ti", I'rn>d, Ilj,.chi. arod
R)""" n""~rs."""I"I"l:IflI'NJi><t1Ctc. rodo. Thc \).hanoAn!
~"I<i ... usa ontr onc rod, and i' ~ ~")' hcfty
IkwaJt . :md oth<.... brm<b and modrb .....
rod>, ....
thc: .~ :uwJ nxI WRocter '''"'Y. So UliC )'OU, !OUt ...
guoioX II<''''
T1Ic
rodo shoukln', "" '''', Iong. You'lI jjI<I tbr
minimum [ks In ,II<' OI"""tun: If III<' tnn>itiolt I'tlt~ Cln bo
soulll!lni >pin.. ,Itc l'QUIer ba$, ~:rso . tii<' rod< neo:d onJy bo
Ionll c"""l!h 10 rnclt rrom tII<' t""\SIt1on pb,e tn an Inch ...
"" bcyood tII<' ",.."", ', k..
se ..... or knoI:N.
MI ... sekcli"ll antl cuttin8 tII<' " .......... oi . . . to
1(rISI'h ...... dk 1" cut thn:odJ on nnc cod of ""'" ""'SIn tII<' lt'~n.l1lnn pI:lt~ b 0111)' IfI lnch thk:". l"" neo:d onI)'
tlt""'d ""1nch"'11 ...alon 01 cad> rod.

t_

""'t""

,,,ins

12. Mak", 1.... lr:IHsltiQn pb l~. lltc InIISitkm pbtt


h.. 'o "" c"""""ud t" ,,,... :. ... omodalc
fOtttu n...
1""'" lOr thc .~~",rncl rod5 Cln II<' bId OUl and <lriIIcd ba>c'd
on tiI<' tir.".... 'f'm .ult_ ,..,<U~ l.nJ_t. Dut U.., """'" '"
thc: "",te. rut/< tu..".u be: Wd out frnon)'<lUr """Ier
Afler.II<' """'" ""'T bun Wd out.drtU and '~p II ......

t"""

13. "",""",bie Ihc ,nommeL Thrn Ihc t.. m<t1C1 to<lt


""" ..,."",. n..b Into ti", t .. nsI,1on pllte: !>Iio.k ,tu: t~
rod5 "'tu 1"" :adjU>tmcnt t-. Orop a ;m;o.U rom~
"JIIIIlI " "cr the ~ud oi cad> Ioek mob. and
tbr
",ut/s into thc: iMefU in thc adjuscmcnt bor ('lltc JlUIJI'D'C'
01 'hco >pri<Ip i> ' " prncn'
lod<lnJj I<nobo frum
ribr.o.hng looIoe during ...... ) Tlgllt"" thc:m dooo'n 011 thr
n..b. loctirtfIthd' ~
TUrn tll<""""""" ftnlll.ll inlO Ihc: thc: """""m pOrI In thr
phUl Itasot. "PPII' Ihc: ''XUtln, "'1'<' ' o thc bo""", ...mc.: <J

tiu,,,.,,

t""

traIM,,'

tbc "'''''' r-c,

~..... "'" ...~ 10 """ dn:ksl

TUNSITION PLAT E LAYOUT


FRONTVlEW

SECT!ONVIEW

, - - - - -,. _ - - - - ,

I ~
Lr-

Hoit for ""'t~r ,od:


d,amel~,.nd Ip;lclng
v..... , wllh 1.... 'out~, u,Pd

Hoit for y,-dl .


uammel rod

hote;
h"le

... hh .1'>"13I.p.

l...
J

lo\~"

II

Using the Vacuum Trammel


\'OU am _

lr.lmn",1 with 1Ix~ ..... I~r, bUl dn:k


CUI1I", 15 )Irn<'r.I11y cosicr ""illl ~ pl"nll<' <QIJlc' Vou dnn 'l
haw: LO Ilo md I,..ISI tl>e Ir.. mmcl In kcc:" 'he bil fn:.: oi
111< ..."", as you SI"" Ilie rou,er. Vou ,Io.n II.,~ dlmeul.y
~ thc b;, 10 .10" ,lIceu'. -'nd c h..>nlliJ\jl . hc """ '" oi
<III bm>.tto p2SSC$ I!; nsk. ". ,.,.".". "",,11>1', 111<>. s... 1\1 n:co.mtn<l. plun"" ..... 'e.
th~

h.o.' .

1. l.Ioy OUL thc C;UL Hcc;tLOiC ' he Ir.mmd


<>C"alIy
~e<
_ , 1", dam Iw"d " ..... It... cutrlnjl
_
...... 1:11'<' ~. ~OU nccd lobyoul an.",ot thc
......., CUI. on Ihc pi1vc b;uc. -.nd "';just Ihc t ...unmcl 10
pooirion thc rourc un thc byouI ~nc. ,"ou dan ', tu,,, 'o do
Ik......, ....... jusL tnOU(III of an :uc 10 .... uP u.e, 1r.unmt1
Sa rmrk Ihc cmlcr oIlhc :uc. ""hkiI ,,m "" tlle """"
poiDt. :IlId.s<:ri:><:' brt of Ihc CUl:UC.

fii'''''

\\1th Ihc r.ocuum hoec OII 1"" ~ 'f """""" /i11 .... _
Ihc b;uc """",rtr .11gnnI. pull.hc .-.cu..... ""'" ""'" wil bc

fim,'" n.nI'" pla<~

4. AdJ"';1 Ihe CULt/LIS r,odi ..... oI.djustmcnl oi thc wl


.I"lI r ..... lu, '" ...." ..mpli."""'" by ~jJ\jl .1Ie Iocklnf< klloObo
"n II", .dltIMn,ml har. Thm Ihc ""'I~r c:uI bc """'ni in
"nd ..... , In rduioo tO 1"" piY<lC.
I I""k ,II<.: piruI ploiI: <M:r .hc ha:;c'. pi .. ", ~<>!Llr. Plunl!l"

Ilie bil 'o IlLe

.un.~e

oI lh" worl<picce (wi lll ,t... .....,e<


Looscn Ilie Ioding klloObo .nd
rn<.nC . IM: """(' In .... "'" "-'i ~ 'o allgn It "n Ihc LtkIOltl .'"
donc. tigILlm " '" lockJng knob<, plUJ! In Ih~
...... Ie -.nd you arc rndy 10 cui.
.... ;Iehcd off. of

oou~).

"'.1

2. Set up Ihc: roulc:r. "fu do Ihls . ..,kct ,hr bit lOr


tbt I<>b -.nd IiJlhlrn I in Ihc ...... ,cr"~ eo/ln. Nnl . .... Ihr
pIurw: dcptll. Fin>JIy. <."<lnn' Ilie n>utc. ' 0 thc 1...,..lIKl
, ..... an roughly ""tllM .hc cull~ ndluo.

3.

Set thc pivot "'-:.

Hcc;tLOiC

1"" fIi_ Iloi>x it

""""', il CaR hc pooiIionN xcur"d)' OII a pivot: poinL 0\11


"'" line todo Is ok61K">Ic 1"" poInt ...iTh (.....mir> pmdk:d

<:ou"'"'

""'1

"" "'" ...-ortpit- (.nd 01


thcy ........ "" It
onp:s
lOoxIJ lIlhcr). A1iJll thc Il,." ... cach ltn<1" iii on 2 crossIuir
~.Thc: pi_
wiU hc """"'Iy on thc deoIrcd pI1vc poInI.

;ur"

TO mounl lht Ir~mmtl on Ih, pivot ~s,. hook


tll~ pivol plate a.ound tlle vacuum hc>~,
shown,
and .eule il Onl O Ihe pivot collar.

a,

S. ROlll the arc. S..i,eh "" ,II<.: ..,Ulcr. plunll<"hc hit


about li indo Inoo ""'
f"",-, the """e. eoulll" ..
dod; .......,. If)'OU .'" culling rompl(I(1y IlInlUjlI, III~ WOfk.
plu""" Ihc bil dccpcr a. 'he (nil of lIM: fitSl IIp . and n.. kc
~ IIp. AlwIys rcc.t thc ..,,,,,,, counR..' ..."kJd<w....,

......n:,""'"

To set , Il, p ivOI IMse. scrlbt etOsshlol.s

OI'

tlle

,"01t"1!,,. ma.klngille ~slred Pivot poInt. Un<! up

1"" COrnerl of th-e blose on tlle IInn . s sllown .


.. hoeh ..111 place tllt .~Is of Iht ""'0I coliil dlreclLy
...... Ihe dtllrtd ""'OlllOlnl . Tu.nln g th val", on
ncuum pum" wlll puII tht vacuum . sucklng IlIt
bile 10 Ihe wo.k .

1""

_.

;:;

II

Vacuum Clamping
Clillmps in the Wit)' of )'our routin,,7 Here's how
)'ou Citn U$t ilttmospheric prtssure to dlsplitu
those d;,.,-,~! ciur it path for )'our .oute.

!
DI

.-"

ou -"". II"d in junior Iugh od>o!>I. "'c"",, ', ro,,?


Con", 0<1, :ulmi. 1 In OM nfntrtl. )",,'<1 Imprno
)'OUT fricO<b lor .uddllll ~ <lrinkinJt rup ""'0 )'001"
btt . You 'd bokll. "'." yuw- chin:mtl mou\h.no! Mrl.U
,IK ai. ""'. an<! 11'<1 1"" hang .h.,...,. Oh. nun! O".,., "'"
n:mo:mI:>a """. im~...t .lK-y.1I ,...""',

'O/I<'lh.... II.... ..,..,.".. . . . . d.,... ~hW3Y ro do ils wurt. 1oQ


Ihl- "-"prd . ....;uwn d;omP'nll .. in ''''' >C"!'1c of U>ltlJ! "'rpcI
I.pc:. bu, [, <k~ ', MI""" )'OU ro pry tho: pio:<:a apa" wilh
dili;cl wh.:o 1"" .n: tlont.-. and k .... ,-.:s no tdd<y ""kluc:
Consid<:. ,~ pOS>ibiIi'ict: You....., m.1lu:

WdI . ........ )'OU nil Impltl'> )'J'U' ".w,,"U<Io:injl (rin'Id$


wi.h. ",mibr biI 01 majlk. U... ' .. ,,"'''" p""""'" 10 hoIII.
worI<ptc .'hile )VU ruut 1,

0G, ,\Ir. ",bard," )'>II ',", ",,)ing 1""


!rjd?"

. "

f1<J,,", - " ." " , .

IM

'u hokl ,,"Urtf'k" :" in pbcc on bcnch (on III<


mu'

T~ ... n:

~tI.dl<':!o

be.,..."""

.. 'k""

,h.,

"1'1""'"

'''''0

'o ,......

lud(
'Oftt " '!l1nII
mct:honlcal damps:
fc:>tltonbootrds .nd OIh". hoId.uo,.n. ,ha!
KI,'o almtJo;.t lrI.... n' ly , """,,,,, ubIc: (ar arba'
1"'"

""",,,,,.(Qtrut.~lnll

N... uickcry.l......... plc: 5ekn. l1te "WJd>11Of> prin


dplc Inm"'-nI b It............ ....., ' ~l p"-.... IIe<J In 'he junior
hl,,11 cafete"'. Ilcmo-'1: IM ai. Ix,"'ce" Ihe wurkpi<'
('h.' CUI') :uld , ......vr1<bn>d\ {your flcd . nd Ihe}' ",-111
Mlck 10 nd. OIher k'I.1x oI .M:qI b>ck
.Ioc twO.
and 'hc"y !oI:JI.:I""c In .Ioc ~ conl~'X1, 11". """tly
~
",.cuum C'bmpln".
I..<>ok >1 .ht' moe;C "DJlhtfor>o.-.n.l \'Xullm<Ltmplnll
<kvi. hc VOCuwtl plote TlM: p!:ou" io. ,hle. bwnJ ,,'llh.
hoIc drilk'tl 'Ilro~ IL A '"X'UUdI " ' - b I~ro In,,,
hoIc 1l>m Sf'<.'d.II''''' 1.
around Ilie pn\nlC1cr uf
"'" I>cwtl, forming 'U)' .tulklw n:<:a&. \ '0 0 I:or Ilie .."Ori<.
pic"': on lOJI o( Ih.. pin... romplt'tdl' """nInJI ,"" "-"""""
an<! luminI!, 11 lote' ~ ' "h ~",bcr,' Sud< , .... :tir OUl ull ....
dwnbcr. and 1, bn~,m<'" ,,,,-'1mm dl;omba.,\lbhbnml
'J"M _"OfkpK.oo Ih" 1'1.." wlll "" .. ud< ",..:.ba
l\cC2u;c: )'<'" 00<\', ntl edamps or hooo """""', Of "",.
othct .....,.,.nk,aI d:u"p> 'n k'-'<:p ,IM::
pitt'c$ boo<.InI

5.

pb'~

hott2:ont.:ll o. ,'cnicll) .., l""" eon


tbdoa Of
IVI""',," [nlu Ihe .un.ce:. or l'OlII proIiIc un tho: c<ltIC':

............~out

.,txII . -

wort.'.I~") :

_' ~

P"'UI .".ch.,. 10 , .......'OtI< "itlnll


...iIa, ...........~ <It' Sllcl<y "pc::
. I""'pbto
Id: ftrmly tu ,1><- _pitt<: OI" !hot
hoId ,It(: .."00'1< 'Wtt Il> " Ixnt:h. 1c:J."IIIJIIh<" cdJIc5 IIRID
'I3mmd

,ho, ..

... ""',.....

1'"... , hIod.oo IltaI pidt: "I' .nd hol" ""Ofkp""''' ....,.


yt)Il '''' n:adr Il> kt gu ulll.
Thi, b a pr<11}' into xiollnjl ...rkty of ... cllum .... l>.n'J>I"I
lip,
I "'pc::" 'hol 1"" orgJ,;c ,h"", l''''nlClr. <'\lSlomlling
,I",m 'u rom jub.l'OW" ''''''''. ro- ..."'" hot>l'" ........ do ho,,,,
te, hc ",-"lcctl'''' o"'"" , .... malniab ""' ...... lOr tht: jlto.and
tOtI do h:",: 'u hur......., "I'<"COI cquipmnu ''ou .,.n, n,.kc
, .... dc:vic.. ,1"" prudu<'c:> Ihc: lX'I>Um . .... o::I.mpk'". you hol"
,,, h<>y 1< '"UII n~"'" to bo.,. ' plum~ ' ,o IlfIk ,IM: ....;uum

An"

I"o....,rful ncu um damp. un HCU"


\'OII' work 10 J bl!nch o. I lemplJ,e 'o
Ihe .. orle. Each 1. cUSlomm .
.... Ing
comm o ~ woodwo.klf19 m.1Lle.i.lL.s.

vuuum tapt, Ind

......" '" III<- jlIl. And 10

.,...."C. . Ih"

......,uum prod~

~, }"OI' b:n.., 'O h.." an alt "'''''~ Quilc fnnkly. 1

dori', thlnk }"OI' an ju:stlty ,hc OIJU>y n~ry ro. bo.h lhc:
...,..1Im "t.... ""'....J an ~ir roonp1U."" "1n.:.ty u" l!te t....io
r1iL>dArJI..,..... npmi~'icI unlc.... )"OU ano. ptO. 1Iut Ifyou
aIrndf baYc an oi. romprnso }"" 5houkl Ioot cbocly al
tbo dom"",,, ....... ic,.,. )/](m'n in tII<- ~""'"in, l'iII<'l a n<!
~

".,."..... in"".. I~ in ,II<-

.xuum

)'OU Nn I
nn~ ~ U,

Vacuum Hardware

Ihc 'OICUWII pon. 1b

pn:oo>I

"","""' .n<! con-

,..wd'....

Ih;o, 1'"'"

-'UdtnlIn,o Ilie! )1II"'" rrom ~ Lhc: ....." , toIl1" 'Y"ftLlf


indutIc fib~.. Qohrn...., n>iIy <119' milled""" dnncd.
Alth 1JW\uL.:tun:n orkr =8" oi
'""""um c\:lmptng. Lhc: oxu"m """,uri , ..1"",, Is Llle Uy COOl-

"'"SI""'" ro.

ponem in .11 01 'hcnl A, tc"M one manuf><:turcr.


of Gonconl. ,\ bssactI ......""

Q,,:al,ty \'AKuum

Prod""".

:lIk,,''-' f'J'U ' 0 InoUr up (rum Ilie! Ifw,..,...

VACUUM SYSTEM SCHEMATIC

Tht Qlotn,iaI ~ here b """ ,hal ... W "..,.te -.cu"",


fOII ran lum.", an<! ,,"OI ,,iU. You
.1...,.<It h.., rc:ad
Of hcM\l.hou, dttuic ."aC\IUftI pumpo, ... hil:t1 an:n', <kpco>-

mor

\l<nl on ... alr rom~. ll>c:sc: <kvlca .'"

vacuum fiUing.

rb-"Ic ' M.., rrom )'OIII" daopi>

(80(1.~~ .S48-f>.

pooduc\rtJ cqulp",,,nl.

ro.

~
."C1lttr cb.m('irls "'100 UW1 the 1l'P" o( cbmpiOlJl ~
iQ """<1 "",,-...nIng. Wh:1I )'DU ntt<l fur cbmplOlJl op<1>
2tOII> ", I pnno INI " o,,,,,m ... ,,,,,,,, of cumJlft'SM"d:tir

, ,
Worltpieu

inIo a.-..:uum. And "" , i, \sn' , magic ('hooJ&h i , ....., Ottftl>


..... M ..).
~

criLic2I componcn, b c:dlc<l I

.~wn

"""' uri

ni..., Somc manuf,c,u..., .. nil i , '"acu"m pun,p.


~ 1... called. 11"5 n:ally dIunk of .Iumlnum (u,
pboric) ..iLh liul<: gauJ'Ol' .. ud< <)OI k.1, ~ thn:c [I<><t>l. ' WO

. - tOr W-inch or Jo.lndl NPT ("''''tk>n.I I~p'' l"hrnd)


1In1<ljlS.1n.'kIc it< I ,,...,'uri. ""hl<h Is "",,,,'i;llIy I funnd. "
om'utl ..,.,.,.... up:lt111ow; and In
,I<..
'he al, no.. ..
mtc"d by th" ract IN' ,II<- oi... ;d...,..ttly undcr p","",,"'.
"""" il ". comina frum ",,,,,pn:sso,. h tuShn thruugh ,II<-

,h" "k...,.

AI upply from comp~n or

...,,00 $O r.~ ti ... "" h ..... '" p;l>I ,ht- adja<:n1' '"XUURI
1Q1. M oudts Ilie! a ii" righl <>ul uf Ih" pon. ' hus coeI'i",," '
~ p;LO 'he ,. cuum pon, thc 01. h;,;,;c" ou,
tbo aba"'" pon. ,,'" hl ...... " hc mUr ..."",'ing, by II",

,_.I0.Il'"

......

....,.. and """"' ,-.Cuu", ....1>..,' -""1 noe aU - i""O<JlOr1'"


Tb l:IItc ;0.1\"""'11" of Ihc

,...:ouon cmo1"" 1' (1.., ,-.h..,.


Vacuum Clamp,ng

SI

A vacuu m .... n.u'l va lve 1, Ihe hult


vICuum cl.lmp,fIO} SVSltm s. Tht
al. tnle., Ihl, vahlt Of! ..... leit;

!.

pncN o)','cm,crcdillnll tvu for IM i!licia! <:()M of,he \,,,,"c


~ 1 1Io.-. bf2t iI\ mind ,ttU .. )..... movr oI', yuu mq Aa'd n>(lfr
. 1. comf"'C'UOl" 10 um... lhc ''XU''",
~
The ,..",., mllM I>c _dlnl,u ' hc . 1, corn~. ",.
pOt" tlO\'e rinll .tQ\U1d S 100, )'OU CltI S'" a ..h.., , ... , wW
con'nI dlr 1 OI" 2 <~Ibk r.,.,. per """III" (drn) of.lr no,,
produeed br' ~horscpown c<'mpn:MOr
>'O')' .-hIc
II "",-~,,,m . A. tvu fIitIln> mulHpkd;omp .ppllatlom anei.
new 10 ("'mI' ~ ..... ai;I.b. yuu l>CCd ~cm
........"'lI OII" dm OI" 1T1On'. 1. wcs a t lt. .u 2-hotwI'O"'c,
C'OftI.,...........'O ,...,..nIC an.! S"M.ln Ih>. YDIumc al al. I1ow.
__1 Who, f1;q>pcno it ,c ..am"", ~y..em ndt rnon: . .
1
Ilow .tun .1Ir CtJmI'f"MO' prod~ Yoo <Ion ', )iei ~
gOOd ''''-"\Ium , """nI"lI (1", hoIdins fun:c S mJ ....<cd. 11 lud
lun!lC' (bf a ....."". of 2 OI" j ....:un<lo) .... ...."X\I:It<" ,"" .1.
frum )il.. anei lhe ty>.Icm """ Ina .billl)' 10 t'CR."OmC .lr
It::1ks. lf ,"" rni>m;o.dI bnwo:nl
\".1.., """:aIr rom-

o:
A

0)"""'"

In,,,.

t:i

....,...un,

p""l(>U,oced, )'00 ,,;mplr


'""""m 10 """,;o'e IlIc don,!"
ptr><IOI" ..

on:t)' '101 g<.~

e,1OtIgII

Jigmolking Basies
.\bJ<ing ,'.u,."umd.mpinll jijl; in",*,'d """'ldwur1<ln/l f2miI.
w- liU $OIId woOO. pl~"""'. arid pb>clc l:aml""'c. ",Id
IOm" acqu.1iRlmca tite acrylic. po/t'Orboo;o.c. and pile!IOJk p l>. .. k::&. !lut W':ltI!IL'f'S m .... "" invulve<J, 100: ''n}1
....... . b>r11C<J h""" ronnecf0f5:and .... Lo'cd tlnll~. """ >pedoi
lape
I)on I ...."". 100 ",,,cII .booJI r"" ..."..mlbr >uppIIc>
you ~ ''hrn JVU buy a
')"'cm . j'QU1l undoubI
nlly 11"1 roUu( \'anIum
nuJl _
.... men. of fi in",
ond. knJ!1h oI ...,u!>k _ . "fl.". j'QU ...., m:o.k. fcw ~K> .
j'QU on buy _
rrom .~ ori!Ji ...1 ,..,.,...,. ~;"Ings
.rMl _
, .... C2I\ prob>bIy lIu)' fur _
rn<IoMf "' I loaJ
11:11'<1"...., or .u... parU SI ...... JUSI ""'Ich IIK >t,,")'OU gol
in tIM: (lrilflnal ru~
Tbt f:&mill>.rs Ind '''''1u;rJn r:anco ....., . - lOr .hc III(
bo.>cs. ThIS II " 'hen: I~ issuc u( pon>Sry C1.lRIQ "1'. 11>
e mtc I ...:reu ....... j'QU ...... t .U UIC .lr ou. ol tI'" VXlMIRI
~-Nmbc . Tu malm.ln Ihc: """"""". JOII ,II) 'W(> thin~ ooc.
~ oi. &om kq'Hng M<.:k lA. 'OO r....,. cuminuc 10 ""'W
it OUl, Tu 1"'"""" oi. rrom .occplng r-i: in ... 1"" \'anIum

"olt......
n.. ....- ...

krrm Ihe \'anIum ch>.mbcr an: pbsrio-acTylic.


I>onar~ . ~ . t>-"ftI

pb>tic bmilu.,,-

" ....mode ..."00<1 pn>ducts Illc I'"lticlebo;ord and mcdo_


dcnsIry fihc:rbo;:oftl (,\101'). In bcr ...~ OIC rroIid ,,"00<1 ~

....-o.

UnprOmplo:<l. JVU m;ry nvt .hl.. k 0(.......,..J .. 1Kirlg P'f'


tlruWly pot\l'IIfi 1 ttJUinl)' <Ion' .. ,"ou i<now. wJld
llut ronskk. wood's
and tllm . .....,11. 11 <IocS nlaU
,..,...., .har It ...'tJUkI bc po ...... ,SO ..1lcn
think 0(. "'OOG

lot"""""'.

".....r

..;.~:;~~~~~;~~~
,"O.>d.you C21\OCC''''''''1,
I/W'I

"nK"Iu,", ... ,xuum

.hc

1'1115 dotsn 'r _


)'OU C21\'t ...., wO)()l/: 1. IUSI _
lRa. M
idnI. y,... 5houId ...,.1 It ... ith ..,...,.,.; cart. 0(.
film ftn~ . ~o:c "",Ibc. polrun:liunc. O< point. <II' CO\'<T k
Mrh pi2>lic IamlrWc. l'I)"NOQ<l ,hould II<: ~. AppIr
PIy and 1W. 1c IIlrdr pIywuod OIC "<11' JIOQd. 'hougIr Iaon
p/ywtlo<III m .... hc: Iftkd orrdWIy_ Ik ~ "'iPlani
>bouIlibinll'-okb In thc: NIIO-Ir).... \lOr p:rnicicl>o;oftl . ....
I ""'~ '"2Iicty,
A final n<MC on thc: "'"'" "",.<"tIaI. For ''X1.Iurn Jig, re-

".1'1

"""",,m

,;oe,."."
"'P"'.'

'"P'"

eh"",bcr. rhc ch:ombcr'& ~ muSl bc n<lfIpotOUS. Thut.1he


bcSl m:"",Nh .u ...., lOr rbIloc p;utS 01. c"''''pinll ~" ,har

S2

Rou. tr

~IC

Se&1 wooden vu uum Ji8 S w i.h .....IIac. polV'


"'fl~ne. o' some olher foim flnl.h , TII ... ,uled. JIIIS

miU!_ 01 ",Iid wood and manmade wood p<od"" ...


whlch IlIltnd 10 bt poI'OUS 10 Somt dell'H. wlll bt
Ins likelv 10 luk II . Awtv IW<I Of Ih,u ",,,.. 10 bt
su.e Iht jig 1. suit<!.

foI'

1JaI;c. So6d ..,.,.,.. ~ ~ 0rI<I [(O .. i,h


In ICm.,.......U", o.nd humidily. A ""- boanJ m"Y
OI' wup For thlJ rn>On. you ohouId tI>'(,.. ply"Ood <It

-.1

cap

-..w~

MI)!' 01" ""nlcld>omllU ........ n hasc.


Tho ~ oI'hc ''aCU'"'' .~ :dso p,,"}') a . . . hen:
"'"'" Z01 maint:UnlrlJl vacuum, :.tI..... 11 . 1> con,lnul,. 'o
drawOUl .... lf you' ",h", nI<>O'C> a lot o( >T-lf>d 'h"" ....11,
.... 01 n<U"m-l"'" an ....,.....,11 ... lIh ~ Iu, porou~
..m.b. Th n.. kc txoc ..... 0( . . . .""n .~."'. lho1l1lh. )""
.ut 'u "" ~ :ahout uslnl.l nonpot\IU> ..... 'C .... " in
~ )'OW" ii!!>.

In oddilioft."'" won.pI'" i>. OSII mcmhc'. I, rurm. twl


~tt...1XWfII .......... bcr. n:mcmhcr. Yoo
'o"""
11.1)( ~ It> "'" higlHuI""'" vaii.., It. plus .... hen
.\l1)f :and odln'''''''''m;odc.o """,'.-1;01,
'ro Iorm IIM: 1'W:Ca.s m.t. ",'hen II', WOttp;c It !>ill
0I'Ct Il, bcmmcf 'hor .,..:.. , ... ch:Imbtr. you oull!"" ~n am
oflhc bo:t!<: uslnS'"XUUIIl Ilpc. Tt/It i>. h~sI')' ",IaIiw ~ foam __
"tlppiflg. "' ~h ...hld. )"OU
_"" famlliar. 1)"pi<':IJ1y. '':K'UURI .apt' It !o i.n<:h ,hkk """
~ ind> "iIlt 1. """ jlf'tSMI~.i"" ~,.., (I'S.!.) <iti " " "
... Tho ~II-lhk:" .. pc Ii.hc hol on-.... ",oo """;" tlw.:

doo. "',,"

......u..
01

"OU ....,

A''''''

VACUUfOIl'OlIT AlTEllNATIVES

....

TltA()U(;H PORT

,onnt<;"'.; ~ '':':~_-

",.ndJnJ "[lCOUJ>I1IinI ,,'I,h nlOSl ''3CUUm"''Y'''Cft'~ .


,"M' "'''l' Gnd t ap<" ,lIu ', 14 Inch ,hid:.; ...... c ~I'>
pft"(cr thl> "" IU ""'li" "'urI<, ~"'-"" ~ brioJl!iC5 mi ...... ""'l'"
.,... inqt:ubririo hc:tter. !lut >t...... dnr of""J' thidcr UPC:.
Si"'" ~ nn .Ik,w lal~11li """'..,....,." hc:" ..,.,., IIM: dw'pltIJI
iitt lf>d IIM: ",-"",pIL-rr
t "",ntiOflcd tha' 'xllum "PC 1 imllar ,<> elu:oetkdl
wm ...... 'IIe. "rippi.... Y<>u "" li><" 'hc ..,,:ulte,
pin,. b,,' 1, ;,n', ~. lnilk-n. ~' ....,uum .apc. and II """"1
Ix ,. k'"IIl.u"n~ M'i..,.. " h..,. ~ """'.. m<nt.bcd """'"
......1 Hmc~. " "3)" cru>hC<l anii doon ', ",oound "'hen ,""
I''''SSUIT b ...""",.,.0,1. Sa <:mploy " fOr liml,cd-u$c: '''''''
p!>'''' bu, 001 fOr ~I~"'plns plat.,. aRd OIhc. jlg> '~' .... III
le<" ~ lot 01 IL"".
10 appl)' ,lte "Il<". )'OU .. mpl)' I"-"CI 'bc "'Uf ",pcr ofJ
"'" I'S.!. b:Kkinlt :and ..,.,.,. IIM: '~pc '0 Lhc (K.IkIl) tu",
Oboiou!-ly. rllc "PC m .... con'plr,el)' ~ ,Ix ..-",-""URI
"""'. and .ny IoIn .. bct"ttfl pk"ttS of "'Pc
Ix buncd
ju>I "" 'ilIJI'ly'" p<.>SOoillk. V.... "\1 _ , In i00i<;''11 at 'hc jigs
>hown In .11<' ....,." kw patIO. " .. t I ,ty IU ~n,:I""" Ill<"
..... ~'UUm a ........... i'h" "n!ll<". <'O<I.inuou!i
J tta.,.. ooty
OIM' _il juInl. II iMI ', al,,'"),> pul1lk. o( counc: .~.
)'OUU ..... , ('UrJpk' of , ...""""'" " 'Ix,,, the '0lIl 2J'a la "'''"
IlIIonot:d Im" """"', ...IIIL bmt.. In ,he ",nilion .. rips. A
>tril' 01 'Ix I~pc la ~ioncd III ,..,"'" "" " _1I'Ite; )'OU
'-""- "'" II"le ' o ''''''' rll<" ~m ,,( tll<" ''aCUum,opcn ,Il<" gat"
10 ato:nd it.

"ri.,.

m""

"rip.""

Making a

Self-Tapping Fitting
Iore o ~ .h.ough the face 01 tM t.r. ....

file ~ I\OIC" Icro .. It.. m d, of. brus ha...


fi"",O. liS shown tn It.. pIIoto, and It w,n cUI.n Own
th.eods In ,h. ""tuum 11Oft. It wilt tII"n cui th,,~dl

!n,o li .... ooden base

"'t

ar.U" sah, W 'M nOl{h II tuy 10 mllh.


onc:e Ihe "110<>9 iS IfIstalled. ltavt 1, In jJl.ic. The
notch w,1I cUi ut" lIme YOU lurn IllnlO Ilie hoIe.
RemOlnno lInd ln51IIIo"1/ IIM! fu,,"Il tOO m."y "",.OS
w,11 ~IU~ In" Joon fi, (and" .... cu .. m luk.l.

Sor, a .topped ~ Into thc b.u,. cdge.


So" hoil:' In'o the 1>'1$." Ixe. juli dtcp
el'HlUl/h 10 inltffecl ,he fiffl hOil:'.

''0'"

Sore.1IoIe Ih,ouOh ,1Ie laet 01 Ilie bl,e,


&ore.1IoIe Inlo Ihe tdge. d.illl!'lg Jus, dHP
ellOUgh 'o In,elste' 'M Ihrough hole.
Vileuum Climpl!l!l

53

ti

ii'
S

il

rI!

Iii

I
..

"Iltt: final

""1' ;" 10 plumh Ih" ~ ~ 'loc ' ........"m ,-.h'(

cat! ......,.,.1<: ~ ai.

'-_~.

frun. II'" ''X ....... ch>m""". 1010l, yuu


h...., 10 driU ',,",uum
""le ,11>, ""Imob frum .11<"
.:,,,crio< uf ,loc NI imo ,hal ...Cuum ch>mbcr. Thc: pb<...,.
"",n, oi 'hc: hol< bn', ernk'al. i, 111>1 ,,,._, '" ....-rlIR>o<k .1Ie
ch.:tmber n.,..,., .h.,....,i"" !lp<tng 10 ml'KI. an<! 'hcy :an:
"",,,,'n in ,"" dr' ...m,; llocuum I'tJrl AII~r",lIlt.w.
MI.". I><,ling .h. pori ,han 'l'I"'tpttI, ~ fur tiI<" jijc.)'OU
i....ull 3 6111"S ........ Iy barbcd _
00II""'-1 ..... T"" (>I:Istic
' quldl-diK<)rU'In:t- fluing> tha' ' )'pk'a1I)o OOIItc wi, h ,hc
klt. mUSl "" sai....! InlO III<' port ...i.h a oIlk."OI'"

1'''''.'

'''''''uni

TYPICAl VACUU... SySTE ... FITTlNG5

, ... ullr. f .... abu ll!lCd .hrn<.k'tl brA"" iU>d ")'100 fiulng>, lIot
.~p oi .tIc 3pproptU.C .hl"<'a<l ." cu htnds In 'he
.h~ .. 1""311.he IIUI"ll.
"1"0 nIT)" .Ioe ai, frum ,hc ji!l'O .i", \'"...,uum .... h..,
",mo ." ,he ai, rrom lhe dumhc. ,o "",>le .hc "~~oJ
",,,,,,mhc,). " ... any rubber. 'in)'I. or pl ,lc h"", !bit
cn<>Ujjh 10 ",Jth:;t:tn(l -.c ....... " I.",,u' coli.
.".., ho>c ... pplle<l w;,h .he .)'>otcm 1....," 'I\6.I""h.;",
tlI;unclc . ''''''lnch-<lu,.idc-<lbm<"'C1" clnr .inyl t......
.."O<b pcr1cctly ... 1.10 'he 't"ICk-dlsconncct fiuiflp, U ..
~ . ..;.h .hc _
.IMI n)'lon fiu"OSC" And lhe ......1
..,,"" "on:: h .. y:o.u. uf 11", ,,"me h<>5<' fur luI( .. Iu,

..".u

...,"1''''''1' makcr ""'1'JIIl'*

Plutic T-con ..... lo'

If )"01' ch"""" ,n u>c Ihc qukk.tf&onn"'-1 nlunp,


plug . ",. Ie fill;"II inlO ,tic lis iU>d. fcn"lc Inl" 'hc lDe
'""'" )'UU 1"" III"""''''''''' ~ _
fron. """ ItIt .,'"
nl i, ,O ."",he . \\on.., J\.., found b 111>1 'he _
onw b;afb(d nuUlJl> C".lSiIy,iU>d h ..... bo:' n:nwwe<l frum
ju>I "" ebIIy 1>O)'OU n n ....... hc ............ h "" ........
d~ iItI> whethcr)'OU
,hc .. uid<-dI!iconnl OI'
n.1<ubr Cn.1np.

\1""

PJaSlI~

+ .... ,

V..cuum Testing Routines

conneeto.

In 'hoo<y. perf",,' '"K\IUm OI sa 1e,..,1 will InUl' In


""""'I'he"" pn:uuI"C "" ,hot "",",picc~ of .houI I
pounds po:' "'-!um: Ind! (poi), In re:tliry. t>ow<:\'c,. J'O"
'o fxtor in ",.,~ti.1 f"'roiIilf. 1""
o( nn~

1J3II'-

Math in a Vacuum
""Il lip

'o

,~~aM

hoit.

l,au .... 'Ioed

hos~ ~onneelo,

bUl

n ippl."

m.I., / mal ~

lrau ~owplln"
ma le/ma l.,

11\ usefultO clIlc~la,. Ilie lo"e hoId."lI \'OU.


wo,kpjee., ~SPK"11y when you fi'si SIIM wor1ung
wl, h VllCuum clamp,"9. II w,1l hei, you dt ..... ~
sOme v.cuum ~ .. ~ li .. o,kp'~Ct Un IM
securt(! .. aII a g~n piltt; how sm.lIl" plale you
Cin m.. ke INU .. ,II Silli wor1<; .....1 \'OU h:lve 10 do
'o seCu", p;t,dcl~bo"d .nd NOf ... ",kp,eetJ; lnd

" ""'
" tl>e fOllew,ng fo,mul,,: D,vtde ,1Ie VaCuUm
Use

l,a u 90'
.,Ibo ... , f e ma ll

l,au 90" .,Ibo... ,


mall/ f.,ma l

........1 (,h, I""l>et of ""'reury indlc.Jtt(! ,n Ilie ",,<>gel


by 2. Ind mulllPIy 'M quo,ltnl by tl>e numIM. of
squ.,e Inche. endosed by ,h~ ~uum "I"t.... ., m"k: It Ihe ""ugt ,udl 22 .m;Ms 01
me'eu...,. lInd IM "I"t endeseSln 8 l< O-incI! 1fl!1.
tl>e holdl"", fo<c,', 880 poIInds OII the enU,. wo,kp!Ke_ Tha!". figu,1MI 22 ,2 .. 11, Tl\en 8 l< 10 .. 80,
~80l<tl

I,us Slop coc"

B,.ss nop coc"

(closeei .

(o~n '

.. 880_

The ~uum I.. vel wlll tell \'OU s"'""'h.ng lIboul


lhe POIos'lf of lhe .. o.tplece_ You Cin leslll>e
c!.1mp'ng pille and get li ba.elt~ v;ocuumlevel
,ead'ng Thtn rte:btck lht vaCuum le ..... ' wllen u""11
tlle pilite ..."" d,fferen\ wo,tp,eees. Youlll~e.'"
v.cuum level Vlry hom ..... m.lt".I,o "nOlhe"
lnUme 11'1". lhe hoId'ng foret wlll bt Ihe urne
w,lh li glven
",gud"'u of 1'" m".'''1 be,ng
WOfked. TI'Ia. Iln\ lrue. Ind 11'1111111'" eompu""on

Oc,,'

WI~ II<CMi 1\

1'1,,,.

.... .,., ~ ,.... ,""",",'2].,,,', "m"lrncy. Th" . )'OU11 <loI1hl


lcJo <tId .....itb
IuIr ,h~ ,h<.,<>""I<.-. 1 1'............"'. fiu'

.bou,

....u .iII ......... h;d'~' ... o( 1'''''''''''' f'I" !!qwn: fOOl

.' ""'" idn ... "'" a quiek '''''' QII


..u 1kR-'. "'"""

"""f)' """. jill )'OU

1. a..dr tIK '-.cuum .'2],-.: hy C<Jnnlin~ i, 'u 'Ile """"


~ air line. Thm OII ..... ai<. and "Ol'" , Il~ oc,"k., ~
,~ pon ""Jlh )'OU, ronll""". Th<' PUII<' ""'ul<.l n::uJ
2610 28 _
o( ""'-"""1}' (For ~ 1000 ftt,
In bd. MIbt ...... I iodJ of m=urr.) I f '"c ,,--.<ll"~
iIII~ in 'his .......,. MII,..., [lUmI' "",k<'1i n,,"cri,,~
w adllbl cii<' II..... p.."..un: up tJr
l.CaInt"<t d.r p,. 10 ..... '';11>-.: " 'ilh III<: '~uu "' ... -"'"
DaI. 'Ibm OII ,hc .-ah-.:. ' PIllli",' ,,,,, ,...,tmn, CA"'erll",
iii) """""" p<.>rl "';lh ""'" fi....,.., If ' Il" ,,,,,,eriot 1.
anii lhe pump .... 1000C<.I prot><'rlt". )'"''
!booIId ~ 21 Ind>o . ... mcn:ul}' OI' """e. If t''''
oo.c JDOt k. lhen:: b lc:lbJc: In ,..., ~'),,,m ; Ulh., che
~ Inh M 'hc ~ n.. ,nUI 10 ponm. T.,
~ tIM: ~ \'X'Uum """'1 """",11* .1'1' 10 I.,b,c
_
<'Of1'KI chc probIcm. Otk IIM: roulnp. on<.l n"'ke:
""" ctq an: """,ni
anii ,.,.. pn.>p<'ft)' A['ply .1~
lctInc! nuD< 'o ,IM: b;ubs Of 'hln<b 10 Imp""" C"" '>nI.
... 1!1t but Is I """"" producI. lppIy lI<kIillorW ro.:tts of
trakr 10 le

.bo,..,

1IOIIt.,..,.. """"

<.10,,-".

"'r--

'-.cu"m POl" :dk..... lt'" ' o pu1l tbc alr OUl of ,""

"""nn" ,"" _ 'o,..., pIa''''

cIum"",.

This b a ..'1I0I0.' I<>c ht'Tc.... ,,"'). ,<> ~ ""<>dplc:ces rllt"


mullng open.1un> ,han u>ing 'hoK
p.1<ls. o.,., blj\
ad'';In\>l1l< b chal ,ho: ...'Od. is deva,ed al><:Nc,..., "",,",""""h
by ,"" pb,e 'hit:~ . ... ,..,.. h,,,.., a Huie clan""" tor 1
pik>l """ring ,,-hen doi",~ CU1S. (lM h~y. don '
muC lhn"'llh 'ho: \'X'Uum "'*1)
lbc: cLamp pUle: doQ nrnl "-' ho: anchor-.:<.Iw work
hcndl in ......... "'If ,,,.,..,...... Il 'ron, pw.hlng '''''y rrom
)","., ..... ~.... <.IotI1l.' " o:unpIc You an lu..:h ;, 'o 1 ,,'Q<'\<
""oeh w;lh ~' l. 1, doan', ......, 'u bc: ....... n,ed un 'Il
hori:eonl>I.
." '..."ed on ,1Ie """ o( I ......u..,nch .

!OU'"

ri,,,,,,.

ROUTEJI TAIll. CLAM P PUT I. PLAN

ia

T04' VlEW

Mo"lhk k Krylic. poPyurbonilt .


phenolk pllSlK

Of

II~ '

tA

fi.....,.

il
OI

'"

The Clamp Plate

"""'io;"

Tb< ptinury ohopma<lc .,.,.."mdampl",


b wl .. , I
cal damp plate:. "" I ......... o:u1tT. it 1$ .simply boatd
0/

pbotic pand ..ith .-.cu,,", ..""' ""'1inIn1l 1 '...",,,m

d\amtN:t (Of ~ o( contIfiIed ""'mbc:n) un ono: ><k_A

VKllum poti
Vacllum ,ape ipplled "'olllld pe'lmtltf of t"" plole

EDGE VlEW

8rus fitun.g Ih'uded


1"10 pllO' In pilite

ROUTERTAILE CLAMP PLATE

Cunln,
Pu t

LiS!

OIm,," slons

Qt y.

",,'

~ ' 1(8' xll'"

Hardware.

VilCllllm tape. \6' x \6'. apPf(lx. 42"

a.mp plalU can be made In a.mosl ....... llu . n


thlU ~..mples demonslflle . Ioth the ...... llnl piile
MICI Ilie mtdlym' slnd one are huv,1y pO/yure,hln~
llIIoc 111l plywOOd . Ih~ IJr9tSlIS lWO pleCts of MOf'.
gIuM f.ctIOflct I nd c~'ed ..-llh pluli< IIm,"ate.

-.

,n
IilI

8,au VICllllm fil1;n\!. mile


""'!'Ii(. ~ar_
tltl, /IfIfIIK"'",,,.

QmI 1iM<lQ/i( lIn "II '1lI'''1oIc {II'

Vaellum Cllmplng

SS

MINI.pLATI: PlAN

n,."""
MINI -PLATE

Cuttln. Llst
P,I..I

..."

19-sq An

Diml!"~io"s

<l<"

IIo-"

s-" S"

_0<1

Vold fl'ft . .

Hardware

Yileuum I~PI!. It""


Quk:k~,s.cOl'lnt

vICuum chamw

SECTION VlEW

Qukl< dls(onnKI
filtlng. mile _ _/ "

Joi" ~ppro)(. 42"

fitllng . ..we

"

tonOUVlEW

"

" ' $CI.ln.


v.c:u"," (~t

'O'

~~rly aOsqAn.
wt~~m ehlmbf:r

SlCTlON VIEW
Qllkk-dls.conn1

MIDI-PLATE
_~_~C;:u:::
nln. Llsi
Pilrt

Qty.

::::"'::":':'"'="::":':':1-'o'

nUl"!!. m;l!tc

~"

.onow YIEW

Dlmen ~lo n ~

'O,"

aw" 1'"

)1.""

YoId"'1!I! pI ....... ood

Hardware

ptywood

'

Millf""_

~",

lIKuurn tape, it- x

appro. O'

Quoc:k-dIKOI'In,,1 "I",,!!, ..w. _ _ _ _.I


... L..;;:;;;;;;;;;;;;;;;;.;;;;;:;.;;;;;.
MAlCIPlATE PlAH
TOI' VlEW

VlCVUm tapot

V.c:~"m d\ilmbf:r
01'1 I~ 0II1y

MAXIPLATE
cunln, Llsi
PiI.1

Q1:y.

Dlrnl!n ston s
IIo-" Il'" la"

Hardware
2 pn, plastic

Wn'~le.

111-" 12W

2 PCS, plastIC IIm,Nlf. 12W" laW


VICII","

l.pe,;4- x 1<1-.

apprOK

Qu,ek-dls.conn' filUng. m;lle

1114"
II \4"

,.1..

...

Mille,lill

IOnowVlEW

' ...... di.I.

II'
V.c:wm POtI

"

I---...,--_.J
-VICII"'," \.lpf

'"
S6

1101.019< ~'"

dwioj>ii", pIoIcc ('2tI " " " " ... a VO<:IIum .i"". JlISI .eal r.,..
......,.,.rr,ith Jilkone Clulk"" al, doon ', ",.. k arouod.h<m

In&o tbc .-.cuum cllambcr.


Thc truJ~" o( .h" ..acuum..:Wnp pIlo.", ot <'<I<InC. is
)'OU <2l1 .....IIM \'OC1Ium ~ on both bco 01 lh<:
pbOL Thm. by ""0' al'pon. )OU ('2tI oimullmcously sud<
Iloo woot: ' o """ pIlo.e ond """ pblc 'o."" bo:ndl .
H<w OK pbno anii euUinI! ti5U; for (u." >lltlh.1y dit
....". rumson."" cbmpillJlpbu, ro"" .
Thc ~f9 is . pll.c
",pile"" .lIe moun'IIJI libIc In
1>Ic:. ~I' 'he rom", ou. o( . lIe ....... <1'" table anii
dnJop Ihlt 1'1:1(" 1'''0 h. pl.>cc II wiJl hokl ...mpittc so

.1Ia.

.1Ia.

fOII'' ' ..

,ou OU ,.,... around ,he ~ . """

s.",,,,,,,,,,,

t,.AM.NATIN(; SEQUEHCIE
I Apply la"'I....I~ 10

.1Ia.

flushtrlmmlng bll
'-.J

_o.

ra.:u.

'e

2. Apply laml .... 10 1


Of>pOfllt td9f:s.

lrim

Making a Clamp Plate


~ an:

u..

botlom. ,,"" " ,'" Ihe


I<ImiN.'e n"slt.

p""".. , and daIi<oa.

lOIld il, and perfona .... MI" """,".ions


appty only
"""""..ni or b'cral Jon:a.. It )'OU lift .lIe ",,,ri<plccc. he
plai" will. o( o:oursc. puii up OU' .". .he " .... e abl" .1"hc
,,*(1" u.bIc cbmp pb." is "'" a holtJ.dowlI.
Thc
.hrcc [>1 ,,_ arc 'he """" hu. fur ,hei< fttI
al ",.,eml5. J 1""
'o <kmonso:r,"" U.e r1lIII" '"
... ,ttUb ' lui ~.... n loc uscd . ",<:II ... thc conIJau ... 1om
.... , aR' flO>oIJble. ll>c mlnl-pIlotc anei tI><' ",u ~ pblc h:,,~
tanamt dumbcn (III bolh
whlk ."" midiplJlCC bas
,"KUWtI dl:lmhc, "" onc oI<k only To USC' 11. )'011 O\ll
doR ~ '0 .......... hcn<:h.

na;'

Dnaikd InlOnmtlon OII 'pp/)-~ pIaotic: brru ...., .. <':10


.... fotJnd in 'M dvpI;cr -CoMo.n Roulcr ,...,." lbp- 011
1'<'11<" I~. FoIIow 'M """"fl~ t.u",jmllj,1JI.
as )'O<t
'pp/J' and uim.tIt plulle laml""'''.
Of ~ . 1t)'O<t . ' " ... Ing pWtle lQr Ihc b;,,;.,. )'OU ('2tI
,;.kjp ..... igh. '0 S.cp 3

;It""

.t.. laml .... le 1I0sh.

,1Ie l>asle ...... 10 m:d:illJl a dam[> pIlote of 2"Y oile

lIId :ttry ntI.cri2l.

1. Cu. ti.."

~.

Sckct J'OW" ",.,,,rial. 'lcmembc.


. . pJutia are ""'" bea...., '''cy OK fb. and non
potWl. M........ tle .tt.t good.
IIUI "'1"")' In ,hcl,
po!06iIy an<! ",il! und<,uh,C(ily nced l<, bc o<:llC(i. For
".., oppli"""oo . ,,,lld wood i. okay. 'ooupo It <Jooj ,,,00
LO ",up amIII ",III IIccd 10 bc /ialcd.
Otfl'C"dinjt upun ,hc mlI..crial anii lh<: .sIY'" <II ''aCUUm
p;II'l.tbc plai" """ bc aolhln as lIi. indt bul ~ Mftl.o tic
dIId: .. 'II Inch. AnII .0 hooot lloc helghl <II11oc work
..... tbt wod< surbtt. JUlI .... y ..'aii' .0 .... kc ,lIe ~
_ _ k indt .ltlek. To:K/tk1lc u.~'SC grc>,c, hclghlS.
,... prob>bIy wlll nd 10 ftI",,l.:tmlo'le 1....0 OI' " " " " b)'Cn.
Gh'en d"~ par.lr1."'c .... . <k'e~ how ~ )'OUl' ~
tIiII tIc. :lOd eu. u", t...c (or ~ pIico). GIue-lamina ... 1""
kr<ro It neca.<al1". lhco lrim ,loc edac> 0QU<Ift" '00 noI

,."SII( l.iml.... le

a.., n.,

2. $nil tJ>t base. I()'OU OK """'II pIywood. 110 ""',


....... carduIIy. fIlUIIJI In any 11"1"> tx:t ..ccn plia whlt
lI"OOd pu"y or .sa.lcr.
"""" 000 plywood ""O loc ~al"" salisbaorily ..il h a
iim ftnl>h. !luI don'l Il<'
or hapluurd; gIeI 1"" baoc
dIrouPdr ....'"IlIcd. Slocllac drko qukldy. so )'OU ClO apply
..... .,.. lhrec C'OIU In fairly .oon or<In. ._
poIyurctlw>es
alt 1210 24 Il00 ... 10 dry txno........ ~ La.u paio. dtk:s
foidy qllkSJy .... omy Iea.~ roIon:d
on .."1>I1<pIc<."'"
MDI':onoJ panldmo.nI """" loc CO\-"n\."<l ",ilh pl.stic:
.......-IOp. bOI1O<11 . and cdp. 1"1115 ean loc donc fulcr,
IIbirJIt.lIwI ~ll:ocklnl' or paln""II. 'OO 1. "mure< lhI' ...,
pblr ",II relll.lo Ihl. "otll' fftlJJy .... /s l loc pIloI".

:::;~".'1.

fl" l hI,lmmlng bll

AP9iY l;itml .... le 10 lhe 2


,e"""oi-ng edges. ind
Irlm Ihe lamlolole

n,,"h.

4. ApplV I.ml .... te 10 lhe 101'

,,,,.Iact, and bewHtlm


Ihe 11....1..... e.

"astr

'o

15'25'

bewllri"' .... ,11!1 bit

""tJf.

3. DriU

tJ>t vacuum

dtlII. <II.,.,..,.,.,
)'OU lI.iII

pon." u.1'OUIIh p<ln", cu)".o

"fI&ht"llJlk

port or

T.pon <kmands .lul

'nI" lloc ~ o( II><: t...c 10 lrucct hok drilled


VKuum Clamp,<'>g

57

ot''''''IIh.IM: surb<:e , ........ 'el>.IM: diamaa oI,IM: hok.o


.h~
and Kf'" ol.IM: ftuinfl )"OI ..i11 bc ~.

!'i'"

4. I.,-~Iall ti ... >"X.",m connet)r. '" pIuli< qui<k


~bcorultt"t r,1II"l1" a ro: R. In tbo:: ptOpCf-MttU bok. Ta
...-.r ,1><- c<>mltt"tlon 1><1""11.1><- flt'infI and """ pIa,,,_ano!
' . _ . , 'o 10<>001 .h" nul"l! ' o ,1><- pIa.,,_applr a diKTcl~ amoum oi

Iillcoo<' .,.. ~Il< .0 " '" " nnS' NIt>!; ~ thru;ti"8 k ln'l>
,IM:
pan.
A ,hrc.kd fiulrlll is gOOd """"""-"lOf ' O..,., n pb>Iic
tft ~ ,;in."e ~"u Cln cu, ,10"""'" in ,IM: p!:I:IIi< .mh ...p
"l"Ilotigh }"()U <OIn' <..., 'h......Js in ..."0001 ..."ilh.
~ rnodify ,IM: fiuiOI\S 'hn:ad..o lolion 10 Il ..m cu' Il> .,......
_
thrnds. (Stt -M:dting a kl(1lt pr>!rllI ~1'''''lI' on ~ 5}l 10
I . . ". <05<" hin "",,"nll- of sllk:on., ..... Ltn' un lhc ' hmol!.
"in ooIkIifr ,IM: xal.

'""""m

,.p.,..,.. ......

!!!
t;;

CIt
"'I'
"'p".
ii; ........

5. Oudi".,

d.~

The Vacuum Push 810ck

i,.

11""'lt1' I"n, ""111"1\ ,hl p"",, bIod:.


lT1iI)'
P"'"l""K 111\. ",,,01 ,h.. > ",II .. I I,kc abuut II.
,"ou .,.. " ,~ l' u . p",hcr. p......kkd thr """"J"C'CT .
wi<k cnou~h ' o 1''''''1''''
tO tbc
11".......,fI'l l"
,,"OI'kpc:t,
pk<.-",;
t an:
bu, '"",11cr ,"" .. )"OU w:om 'o """",,U''CI' oround.
,,'1,10 fOII' finll<" .... Su"k ,"", wuri<piea 'o 'bc
fOII CI" wurk aii a n ..."" ,...,
..-i,1I j"()'" h;ond
1l1li' hand.." up aw:o, fron, ,iM: "un " .
lIut ... bcn: h '~ n:aily ....,ful is "IlI mpcd 1" ,'be.
i, ........,., ,.. ......., clarnpi"ll plate.

"""n,,,",.

",,,.,,1"11

""'OJI .

'w" ..,.,
I

<*.

vacu "", chamhcr WI ,h V:>CU"m

On snuU plate , ,..,..'11 "".'" only a .iOglc li"" <>..


um '"f'<'. On ""lI" pI;I.e. fOI' n.. y ch"""" 'o oolli.....
-,""Cnl """...... " ... "" ,IM: pb'e <OI" IM: u>nl ..,;,10 ...Wl.
Int'di..... or Iarttc ..." ,npk<.'C!i. (Stt "'" &>1/(,,,, I'Wu> 01 ,Il<"

.. dn"~ "'<Lrf""It.. "",,,.)

u.., '''''' ....Ie""m t:lpr t>n a ~"mp pl.te.Incc 1, Is clei,int'<I ,1> bc LO!oC'tl f~ ... ntly M:dte sun:.hc sun.c" 1. dCln
"""'" :&ppi}inIIlht upt. ~1:Ik sun: ,b., c:no.b bun tightly
p","I1..., ..m IeU alr

",.... ,...,...,hcr- ""

.-

Usin9 il. Clil.mp Plate

,."., bask

proc~

hu bn:n nutlined "",..,r.'

tlm~.,.

pIa'" 10 ,IM: '"XUUm .)"'cm. "".10 .""


pb'" ori a non.,.,..,.... .....t..a-a WU<t.

C on"",", ,IM:
' iM:

'~ um off. ~

. ......a

U""" oop, i

~.Cft<>p. C\....

Iht

fIu<J<. ' ~

,.'" ......n.pk<..., ., 'Of> oI.bc pIa."


'~um .)":11 ......

:mod puii 'bc Ya<"tlWA. TIM:


,,"Of!< ..iU bc """"..o '0 tbo:: ....... ~e .". 'bc chmp pb,e
tI"n: an: >OmC corn""""""", IlUMldincs
l\tm on Ibc

. ""'" u,,<kroi<k ."aCUum dwrtbtt "'.... bc ~ """'"


p1t1dy I>y 'M ..-ori< surfatt (nlCaRinll; ,"", )"OU "",.,
b .." tIM: plate ",".cnding hcyon<l ' hc bcnctl'<>P c:d/II:)'
.11"
.o~ .~um dwnber ~k.,...;"" m.... bc
compl ~1clt CQ\..,rnll>y ,iM: workple
. y"" h:l,'~ tu " .. I"ul" tbc vacuum t~ )"OUl"

t''''

fQUUnS opt""k!n ," ... ha......."u". II> ,;oon "" ,..,.. pIndI
of!' 'M >-.cuLln, II"" or
olT Ibc '~un, pwnp. lhc

,iim

hoIdI"lI fo ......, "l"'ppe~,." .


~.o)oJ ... ,.., 10 no~'"'.',, 'he Inl<w"ilr.tI 'bc ,~um dwn-11<-",. 1( }"OII plu"lI" 'h"'''l\h ' hc worlo;plea. fur
cnmpk. JIU" ~'1I1""M plu"ll" tlol"OlJllh i. i" to tbc :om
"","'"ring tit" cl~ mp pLt,~. or .hc ,~um v.ill bc
bmoctocd. ano! ,10" lookIinll (u ......, "'III dl.. ppcar.

Il1lh ........ ""pe""""". fO'l1I <.."..,Iop. se",", of ..""t


,..,.. "'" ."" CI" " do. y"" "", ', ape.:, ,,, huIoJ 1a')III:
WU<tp;ecc 'IOi'h nuU pIa'~. for "",,"'pk. ur tu w<r<t '''''
~"'If ..... pk<.'" IM:kl hy I'OU plll,e.

PilI. hl ndl. On yl>lI. W1IriIpMc:. by us!'19 ,IN!


~~cuum pUlh blo<.k . Here rm prolillng ~h faur ed9tS
of ~ small bw,d on 'M fOII,t, ub.e. With ' M vuuum
pUlh bl<>e. , I ~"t (omplel! con, rol of ,IN! wort<. r/e"

10 ,lIe Ultn, of "f,lng 1, ciur of ,"" 1.bltlop. AneI my


h~"d Is ~Iw~ys wtll clu, of Ilie bit.

Making the Push 810ck


I ~ thl.'l pusll bloci< Ilurlj' blJlll'- Tha! '. Il",,>d rur IL' >Ce'
aar:bry 'fl1'Ik:llIoo-ao a , 'isN1dd c:bmp pIa'e_ b Ul I admit
IIoI>it> lhc jill', llIili'f .. a pu>ber. A namJW b:t.;.c_or

....... '"JC'Uum ch:lmooon 'hc """" b:t.sc:- mIW'I 1............,


.. ....rutncss. M}'OU pin apui","'e ..'ilh _"Uum _,
J'OIIllkvl:lop " ><-'11><' 01 how ...wI )"" can mak.. a pw.hcT
. . >titl Io;o,~ C'I1QlQIh l>oIdonI btt 'o do ...<:ful ,,'Ori<,

2, Shapc tlK h and grip . To h<" truthful, I wpe<l


pmtotypc bmdlc b)' bondillJl: .,.per ~, 10 bIod; of
wood " i ru pr:ty :M1l"",I.... and Ihm a..lio(il it on lhc boruJ
..... Tbm r ",n<kd to 'hc p;llIem'. MIIC!I "" an ooeill:ning
SpiooJIc sandcr. And 10;0,-1,. done Ihat. 1 rould confum .tul
thc _
""211 pt\lP<-"r!y JIl<.'d lot rny l>:InoJ and " ... ~........
fonobk 10 grip . Hul . .......
IIY, Ih.. hand!<'
lIhouId l1.c 1:1.11,-"". ... It h II1.c hand ltf'Ip a _
, '", ...... ,h;on a

""''-"'' 11'' ' '

~"

1. CIII Ih e p;aru. For Ihl. litc. 1 u>ul Applc PIr


btalllC 01 I~ fJII'''uoO "~b anod i,s low po<O>ity. It Ius
1.,..' RWr!' ' hIo pI"-"- _ ..... _
.YOII OI" ....ke IM b;ax
01 pb!IiC. and """ a ..-.;>od Io;onoJle, Or t"'''' CIIn rnak ~

........ IiI ol..-.;>od.


<l>ooIIr)"OUl"

_nUl.and

nil Ibc poM$ lu IM 0I;",m..

""'" opcdIit:d br lh<" CUUtng USI_ Radi... II1.c ~ 01 ~


but.ril/X:.- br l't>IIlinl! 'hcm usi"g Ilte 1<-"1"plaIO lIoatIxd
.. m. ciupi ... . ""';"", T..."pblcs 00 pogc 6 or br WId ....
Ihna OII a bd' oandcr,

To makc lOC handle 00 Ihc pusi> hIoo.1: sht",-" In ,IN:

phot..,.
"",Ic:r " '!th.

rnadt:"

''''''[>b'e In lwdboanJ and u>ul JlllUlJIt

'~mpblc

"u. *

ii

_ i4-lnch bI, 'O'ilh I ~.l) htt.hlng


~ bil ",ilh a ~. l). httshlng
_loHnch bi' ,.ith I 1....cf1.<tl). ...... hl~

VACUUM 'USH ILOCK ' LAN


ToPVI(W

'"

l '"

'""

,"

I'l' rad

sa .,.

,.1."

~ua ..

l'orm Ihc h:ond-grip op:ning In .he .cmpb'~ I>y drinill8


soatc ..uning ....,., thnt CIII "", Ih~ ...asI.. ",ith a Ah<"r
.."'. Cut
D<li on
IOJ> corn'". "iru Ih<" ..00 ......
'00, Tbm ~r"", I~ Wpc and ,mOOth ' OC ~ ..i th foles
an<! Wldp;lpn".
li) cui Ihc la.rwJlc M~II". hond Ihe blank 10 a btp:: p;ca
o( ":'"1' ,hau ~ OI' cb"'))C\I 'u III<-" ~_ IJM
carpcllapc for Ihb.and 10 boi,,! Ih<: ' cmpbl r 10 Ilie ....... "
StI up'~ tOIIIc:r ",itb 'hc: hi, and bu>J11n"and lUI,Il " ' " lhc
lwM1lo. l'ry
Icmpblc of( 1"" handIc , Swlleh 10 IM
1"OI.lfId<J<= bit. and r.ldilb ,1Ie cx~ co.!aO oIlhc IYndlc
l'ry it fiom thc scnp. , um It """r, and rodiu> 'hc: ~ on
,lIe othcr >ido. Sand Ilie finl-.haJ hand ....

u...

u..

u..

_ \4.

3, Ils8nnbIe tbc: p us h blocI<. GIuc: 1"" h;andk 10


lOC buc.1>til1 pilot hoIai and oIr;'.., ...,-..--.u sao:w, 'hroU(d1
thc: ........ tnl<> 'hc h:lndk.To prt\"nI' aIr ~apply' U.1k
oIlic'Onc 10..... 10 , .... se""", ~ drMllJllhcm.

4, [)riU Ih .. "ac llum VOn, '"'"'


loc:alN al Ilie end ,,(.1Ie IYndk

"'au barbm ho.~ eonnKlor


IOTTOM VlEW

Olt)

II _

''XII''",

poM III

', hc In lOC ""0)'

VACUUM PUSH ILOCK

Cuttlng Ust

,."----,

Qty.

Oi m l!nsion s
]1,." 1'"

,.

n
i'

lIuidc 10 f"<>lIgh oul Ih ... h.1><'


li) rnokc .hc ,Ctnpbrc. o:nIug<: and .pply Ihe p. nem 10 !!I
,1Ie .cmpl.." ..ock. M )"OU du thlo. ""U Ihc
Id;
h. Incit '" aJlow for Ilie o/fxl t.n..-a:n Ihe lIuidc bush'ng ~
and ,II<-" blt. IliIIRuide bushinJt: combi",,,io,,-' Iha. will)idd
h. Inch 01 o",,", IndlMlr (buI.~ not IimlINlo);
CI

W" 3"" 6

Hand!!

2 dtyW~1I iCf~"'i. _6 IC
Br~n

t.~.

,.."

Applc
Apple

PIV
PIV

li

barbed!>olt eonnector,

Vltcuum

8W

"'htl~ rlil l

m.!~

~., ~ppfO~.

24"

Vltcu um (1l mPlng

59

i
IA

" '!om ,hr """" bIoct b ebmpcd br iu I\;ondlc In 1 ,';,c.


Oncm~ lho< t,Ii2mc:I .... ol lho< pilol h<>k: ntnkd for 'hr /1,.
Ilnf!; !'O.I'U u,;t. anei <!nU thtotagh tM m.c.

--'
r

6. 1rn; .... U Il,,, v,,",,"um oonnec,Or, li )'OU ...... I


pWllc '1uld..tl>COn't! nninll. """ ,'''' male. AppIy I hit
o( 51lioonc i!nkr "> ,"" twboo. arid p<a.s t/M: liuIII!. imo

'hr

~ a hno.s ronn<'CWf. ..hicb Iwo tIvadcd botI)' '0

~ I .urn into tM pon. File notcll

l1:li

113 'o

5 . SeaI ,'''' j\a. lho: ohellac 01'"' ''UT1i!-h .0 l!aJ 'h<:


<:rKitc jia Apply ' ...... OI'" tlU'tt ro,,,... Whilc it'5 guod ' (1 .ry
ro >OJ tM In".... ...rf:ool.hr '-.cu"m pon ,)'ou"""" ..... m
10 dotl 'hr pon

lift

t;;

Wllen .... ng .hc: YlCuum p...her. "",~e 1, tuhi.


,/te ..."Ut1t he(un, bcg1nnlnll ,tu: CU" '""""
.umlllll on !he roti,.".. Aoo lfr"u ..... n ~ffo"'!
u"",. [1<'d:tI..a ... ,cd ,"",""um pump.
ti..,

the ' htcIds ilO ,"" III,


'ing o:an CUI lta ......... 'h~ anei .urn "'" littintt iIlto ,"'"
port. " bot 01 tili<'ont ~ "" tbt Ilundo ",in ,,"""'" I
I!I""'I >ni,
a(nlOiS

7. Ap p ly .h., vacuun ape.

,..,.,.a.

on ,"'" bouom

oi,,,,, l1li.

~ oul ,h", ...cu"m " "'"

Ind .pply VKUum

'"p<' . row>d ,h"

Usio9 the Vacuum Push Block

To ...... ,"" \o"Ku"m I'..,h hk"'k.)...... JQ,,,, 'o .uiuot )'OU,


worI: h. biu 5o",ewJQ, Yuu C'On', ~"" CUt. ~ In tIlC'
_ _ 1'10'1><0 ant/ CQn1plt1" ."" cu' Qac:tIy ,hr W3'f )'OU con witII

... <If'ilinary pu>h >lkII:, 1f)'OU ,ulI"h .1Ie puoher 'o Ihe ..-urlr
ant/ pull ."" ......... um In m<k1.ll. )'OU m:or j(:fk .1Ie ",,,,*
cn()UjI.h 'o botdl tM cu' (dc:P"ndllIS <>ti """ .. ha, fIW>I'IC'
'" cu, )'OU ,..., maldn&), _ w, the aci '" puUing thc
' ....... um ,,-m ~ )'OU from 'he ~ 01 """'ing
,"'" CUI iI')'OU ,..., U$intt
cod: ot pInch damp 'o open

>1""

Thls le ,.emplue fo. I flI.boud bend, 1$ uud


wlth I ,ou.t. Stt up wlth ~ pattern bit. I c!lImp ,ht WOI'k
10 I wOlkbench wlth il el;lmp pll'e. ,hen s\lCk Iht 'em
pilit 10 Ihe work. WI,h IM hou. txtendlng IWIV ,.om
,ne 101' ed9t of Ihe""""'. il. sllown ht .... I cln tOtII
bOII'> s!de con.ours ind ,ht foot C"'OII, ln OIle pau.
60

ROIIter "'iOIc

The Vacuum Template

/fflJp4l1~

":~~:~~::;~::':

<bal _
..II "Iop
/bit .....,..., T1Ic ",'OrI<pM:a' must
~ In ..,."., "7)'. AII ,..., ,cn'pIJlc doft II

A. A

."" cu'

8 , A Irmpk"t! lbal d o"bks 111 1' ,,,"',,.. pilite, Thll;


01 ''''''pbtc is pbcctI 0'.-." ' ....... um po-n. "<~' I
plr:ce Il bld on 1"". The ,-.cuum Ilo pullcd. .ucld"!!1Iro
'c",plo'''' and ,he ..-ori< '0 Il.., I>cnch. Tht:n )'OU
Cu, .... ns a pllOIcd hi' ("";'h "'" piIoo: rkIinII: OrI
,,,n'pl':lIc, 01 """"").
C A "'",/II<I1f lbal dmibla ..... sini M f1wbn;
mut.". 1abIc:. 'hls
II 101 Iitoc ,""

,t""

,,....p!.:o,,,,

fotm. <:XttJIC that

tI ~.......,

oon 0I1wt<k OC

aId in martan-crW,. II arowtd thc bM.

In nch rorm. 'he JIUI"I'O"C ol Ih<: ,cmpb'''' II wha!


<:xpccI_l(I o:nabk""'!O~., dupllc:l.c parltI wIth
:olh", ca... 10 ullr II, )"OU cquip )'OUl" rou,~, ""llh
bu!ohIng. ""hk:h ridc aIong "'" cd(IIC oI'h<- !
the bi' dupLlc'a' .......... ry cun.., .nd con,e . .... It
..'OfItpl<. Or )'OU chuck pilolcd bit of""",,,
1l....... rimm'Oj!; bit . Ot' . pUo.cd proftk Iti!. o,.

A. templa'e thll doublu as e!.mp pll.e mi ....


mln he vlcu"m plplng ilnd Ihui much of ,!te h;asolo..
In ,ht setul' being uH-d ht .... lM ~uum ""1"0 /lis
bn In.erl..:! In _ of ,"" bench\ dog hoit . while
!ht other dog IIoIf:s h.ltve been cove<ed w;. h COm,",,"
packl"O ,~pe. ""lIinO tht vacuum cllmps Iht work 10
the lempl~l~ Ind Iht t.mpll'e 10 the bench. Tht
~s a ... clu . Ind I cln ron. nUlhu lmm'ng bn
complt'ely around Iht perlme'tI wl'houl "oppi"O .

VACUUM TEMPLATI: FORMS

"- lDIPLATE MOUNTS "TOP THE WORKP1ECE Ta


CUIOE THE RO!JTER.

Roul~'

II

tnh"",~ ~a

L TUlPLAH OOU8lES AS A VACUUM ClAMP PLATE.

Ta mpl l ' . rolldn" Dn Ihe ...... ' e . ,"bl . Is


If
yo"I"1It v"euum ellmplng tqulpmenl. Here Iht fdllt
""
Ind fn.d of" bQf..d are be,ng 5hl~ wilh I plllern bit.
Tht Itmpllit Is 1"" bln of Iht slcd Ih"l holds Ihe
..
wOfkp,tct . T"" wo,k Is sel on Ihe lempille, Il\)hl
~
11I"lnSII"" baek.n.d ~nd SlO!>" Ind IM vuuum
..
pullf1d. The sltd an bt mOl/td
lI,ound Ih. bit ,

:J

1."

con.ou.

WOf1tbe",h

(. TIMP1.ATE OOUBLES AS A SUD OR PUSHER.


SI~d

fenee

]
ROUlt. IlibIt

..;m.o/WlI<."""""n1 bt:IrifIg_in)'OUI'
be>rq ride!. oloon$l llK
1Ii<..nplro:.

l"mpblC '~

roulcr'~ roIkI .~

cdgc. Ruidinll 'hc C\I1 in

1t)'OU"'" <Ionc I""'pilile WOA:. )'Ou know Ih,' 'cmpbl"


.-.uma n",~ bc belween Ihe rou":' I .. d Ihe WOA:.
0Ibtr IIaKs. II "'''',. bc Of) Ih .. oppOW'c side 0/ ,"" work
_Ilie n:O\lIcr lhc ronncr J>I"""ailii ,... I>m )'01' "'"' H"lde
. . . . . 01. p;>lI"m bi' . 'hc loII"" ....I>m)'OU ............. "ud
JIbcd bII (lDd,,"'''II nU>h-trimming biu ond p;klle<! p .....
..... Im). IIilIh >'anWJIl cWnpinll "'" ,empb.'c 10 II",
wort.)\III caii Id,.., il boIb "''2)'3'
I <'011'1 li'''' )'O" pbn~ lor p"MCob.. ,,,cuom lem
pIN. lIa! ";1( Id..,
ic>'zn 10 )'OU. obO'kMb'Y
TIItI'C...., coupk o:nmpks >bown In ..,.. . .... hkh ~'o."'''y

:an,. ...

IIK ""11<"1'1' 1IkI. 11>ou&h The CSXDCt" oIlhc joi> i, Ihl.


Mlkill.Jl I neollm I"mplale is :o.Imo6t c:nctly ILke nul.:!n,
damp pll'e, (Sn: "lhc ClanIp PbIC ' OII p;>jtC 55.) Thc
onJr ti,""..,,,,,,, 1> ,hc
<It .tu"" 01 "'" pllle . 'T't...
""O Illai apply 10 m.ki"ll "Ilmp pllio .pplr 1" muln,
vacu"m lempla.".
F<It Ihc lempble. ""'" n<>np<lfOlb .... letW. Pbotlc il
k1n1. Itllf,lHju.l"r pl)-ood ;, gOOd. ,\IDf anii p;>nldc11<... '" 1.., only r.lr .00 mu:<, bc .... ell ...aktl ... lth
n""I"'rou~ IIIm flnl.h.
Th" minimum lhlek...,.. of Ihc lcmpble <kJl"tKI.
upon Ihc ""rface arc" of lhe ''''''I,ble. upon Ih.o 'cmpble
n"'l"ti .. >!lf(nCH, atKI upon ohe tin" oI .... cu .. m po" )'OU
~ ... u.iJI8. \l1th 511" pb1;Ik:. a ...""Ullm..,bc" Icmplale, ln"
'h~ 1"'f1. )'O" can gc:1 by ""I!h ),;.inchlhk:k >!uff In
pl)"""'-"', '1 iAdl il "'" minimum , 100 .. Of '" lnch b
brun. MOlII 6tunp Iu,c b'll<' lil""" .. I.o. of 1:1 lneh. ~
l~ 10 fn Ihcm ;nlo Ihc cdgc of. \,-inch-thk'k ."mpb.e
b ""ti""'"
Mue thc ''XOUm .empblc 11oc ....... ..... y "",'d mao'
lcmplole. 11 "'" an: ""'"" Il \O UK " 'ilh I lJUi<k:
bu>hina. hc mindful 01 o/bcI. ill aii ~ , malle lhc alp:$lIS
'mooth as Pf"I'iI*.Poy IlIcnUon .0 minim .... r:odII of Iruidc
romcn.. AlI IMI I...... pbl .. ~uff.
Ap[>ly Ihc vacuun' tlJI". Thu ;" " 'MI
an on.lillM)'
le",pbl" In,o ~ VICtlt1ln .empb.c. If 1'''' ,,,,"c an)" htoofIh
ho~_ monl... ""1000 .... , h.nJ.tuip "UlOUl ~, Ind IIK ~o" bc
Sun: 10 ..,""mllllhcm w;.h lM l ~pc . l1lhc .e",p"'" 1,1" fii
hel ..,,,,,n llK ..-ori:. an" ,he beneh IOP, .pply Ihe lapc IQ
boIh fKCS..
Ik'n: 'lud hul usdulllp: If , 1\(: ''lI<.'\lum "hombe. i.
,. " lo'J I tp><>d k/c:110 6POt liule: p;>lcha 01 "'pc 1\(:.., 000
lhcl'C' ... "'" illl~ '0 :ICI . . plllan., p""""I1n8 "'" lem
""'le (<It I thin ...mpkce) from 1Joooo,1"lt undcr ''KIlum . ln

a..,.

' 'rAS

Vlcuom Olmpn.g

61

IA

a'..,."., .ln""Ions, hln l<,n,pla.~ (O< ","Orl;pica) an colIIJ'io<' omo Ilie """uum pon. I>=klng ltu: ..
1", ..,
untu.ppy ~ for ,""
!'lan Wad In J>O>Itlonlnll ."" ' -.ocuum pori. If ~ "
Ih"""" porI. )'OU "'".., 10"'''''. WiII,rn: nning Ind """""'"
l>O>e bc: In IM "'"y o( Ilie rQUlW II il Is , right 2rogIc Of
Ti"'" , )'OU tu"", 10 ...., \t"~1 ,"" bir hl, ,"" Onlnjj:l

"'00"""0""" .

. ._ _~

~
al

.-c:

,.:,,,.Ol.

A Vacuum Manifold

Using a Vacuum Template


Wb>t con Ilcll)'UU abou1 "';"lI '"""uum .cn'pl.,o lhal
tu""",'1 ,0lil )'OOl 2ln2dy! No Jlruggllng ",ith <"nk>ao!
bat dam ... ond edmIps. Conna-t lil, "",piu, 10 )'OI'
.~rnt ~Ii...n it an lM "",It, Ind pun ..
Tbcn p:t h",,) wilh )'aU' muie,. It'. , .... 1l1li
simple.

''XlI''"'
''XlI'''''.

pans In fbgnmenl Is I needless fr"str-a"on, j,h


flndin<;l tl>t S"'lIchon-a-(o,d. The """ .. m mfmfold,
mounled ne.1 10 Ihe v""um ""mp OM VOU, work
beneh or !OUlf. lable. Is al wiVS Illere. Use 1\ f
IIIlf-doun I,mes, and )'Du'll Ilnd )'OII.stlf ,nch!MO
ou._"htwt evf" iook,ng-and lumlno' "flve to pul
~feu"m_
Tht nlee III,no .bout Ihe manlfold Is Ihflll's
assembled fron-r stoci< (jwn<;lS 1 bO"<;Ikl It Ilie loc.1
Ilit'dW1Irt "o~ (wh'cll IS IIQ House o' "'~Insl, I sptnl
r<>ughlv $10 fo, a Iwohnt mantfold, .nd I (In upand
li for aboln S 10 pe. line, AIII"-t filllngs ore fOf lIoincll
pipe: III ,re ""dt of bross. Vou Ju~t it"w IlIem
tOO'fll>tr and !tllhten 'tm ""tII '" ",rtnell. Mounl the
""n,lold besidt tllt v.cuum pump. Run I vrnyl host
1.0fI'l lhe pump 10 Ilie 'pprOprlatt birbed connK'Ol',
R"n I!osu Iram Ih, otht' conne-ctots to tlle Pl.",cuLu
1"0

00 yo~ hh il .""Itlo on ,ile limp rll'l~rt? OI OII


' ". larnp co.d, some"'h' .... belwten IIM: Ilmp i,self
Ind Ihe plug? 00 VO~ Ilkt fumbll"'llin IIM: IM,t.
findll'lg Iht co,d, then 'u"",lng yo~r 1l"9f'S'1o!Ig IIM:
tord ~ntlllhltV com, ~pon tht ~""tch?
Vul!, l ltlo:, Ilie S""l~h an Ih. Lamp belltr, 100. II~
II",aV' ,here On Iht I.mp, and know,ng whert Ihe
Ilmp Is. I know wh .... Ihl s"'ttch 's. No "'mblln9_ I
don~ tven
10 look diretllv It Iha! Lamp 10 lind
tht ~wneh and HiCk an the ItghL
The vacuum min,lold is the S<It"'" wly. My
vl'~um manlfold, shown In Ilie dr,... ,ng, gl\lts me
~"erll vac~um circuIt!. f,Kh w,th In on/off ~ ..tv. (or
.tOp cock), I Can ~t il ....n of J!!lS, OM by ane,
becluse the manlfold provlde-s .. setNf1l1e on/off valw
for each j'g.
SUit, p",~h t\..mps on vacuum I~ do lhe "me
.hl"<;I. Su,e lhey',e d"'iP, luI findong Ihem 10 open a
~acuum lin' when)'OU ITI! CorKtm "ng OII kHP!"II

1"..,.

J'Il~

t>f,1ng ~sed
Tht vac'p"mp and mani fold are ~onsLln" In_
sYS1em, whlle Ihe jl<;lS Cln be Chll"'lled os necns.ary_

MANIFOLD AS5EMILY

li~ .........~

CannKIDf - - - - ;

Turn hiftdle
90" 10 open
brlncll.

AddltloNl bfllnelM!s

Cin be Iddtd .s needed.

O"

Hose "om

The Generic Baseplate


hule, Ji9 millli"1I arte" Involves filbricOiling il SUbSllluu! (or
ilie flctory bueplilte. So milki"; il precision plille should be
l'IIII1in~

Here's Ih"

.C
3
.'"
.
li

~.
O

"'"
W

10

"'1'''''''' )'OUT fOtl!~r'.

ID

~ )'OU

...... n. >OI""I"lng 111:11'. dnr .


yo" an ....,
loc wor1< bt-ucr. M~J'hc il'. a b'll<'r b;oscpl>'c )00
n .lIItr, Of """ .... I'h k"'l'. St"~l cdsc '" ritll- aJunll
bct.. ln ...,. C'aX, It ", a bol'q>tl'" ,h'l p"""ide. a runetk>n
.... IK faclory baKpbl~ <ioa "'~
8aKpIa'Q '""' ~ 10 maI<c. 1J1(l fu.- SOlI'" applk::>'ions,
J'IItd"On doon', .... ner. ' \MI b<.: RIOUIIling""" W h<>ID,
,..boft ... CJpmlnR lOr Ihc bII. Auad! II
rxtory~ l('ttWI, and )'OU ..-.: md)'
I'OUl
!lui 106 ..,."., applk:o' loftj. ~ <Ion roti ...
D:lmplel:' ......pl:lt~ ro.. ..., ..,;u, , ..... plalc tUiok<. OI" Ihe
CroIioII>ir IWq>blc lin (>OIjIO 1. ""1>:>1 ...., ,hc clur.lc'lms.1a
It. ~ I>o.scpLltd

'o

"'lh.""

oThc bit ~i ng mu;! "'" p,,:cbc:ty silcU.


I Thc: bh <Jp<"ninl mu.'>t hc concentric ... i,h.1><" bit u"
'!bt ~ptllC " '".. "oeI,k H1IO .lIe ",m~ I""'llk>n "n Lt",
MolIa neh dn", 1. 1. In... Jkd

AChin'in/I tlli> p~ is nor diffl<Ul IIUI )"" "" h ..c


.. t.corpomc ttnaln prtncipks In )"OUr <k>lgn. A"" o(
........ ,.... mllM _"Ori< eamully
lei., matc ....,....,
ith I iii, opc n lnj'l\a.
................., on "'" bit :uIs ...uy l i .... o..c..., tuU' ~
......,., .!It cnft 01 fillillll >Udl1 bo,:.,>IoI" 10 )'OUl" 1'O\IIft".
!W1I bol: abk w"""", ,hc >IUII whcn m;I!<iroa (IIM CUMOftI
*pul(:! In <hb huok. Ik:lr in miod w, .......,. nu IJOC
broo ....,. 10 do M, II .... ,;0 x-conJ;roa 'o ,hc ,001. )'OU h:"..,

h<u<pI:a"" ..

II

'O

II
~
ID

10 wort< "'ilh. )'OUt in'mdoou. anii thc >IIill>. ,""'...., oln:ody


m:iM~n.<L J'U ""plain thc cI>oIce. ,h:lI " 'UI 1'ft>I"1I' thcm.
~h'Cll;u

J"l" ......t; m:tkc ,h" ChokH ,1\;1, ... iU wnrII 1Or)'OU.

Design Keys
'fll;""

I .th"'J7 II", JW ,iJ<,Iul SC"'''~ 10 allmb 100 "M..


v<1'Y ""dy. your A)tl,cr h.~ p;u1 1",..1
.....,,,ring
II><' t.a..cp13lc Th .. woriI ..... llh II", 1>c1"'1' ba.,"'V"" C
bcca...., .1\;11 baK'pb.c hu bllCflr.ll klc:a.inll plllll.hOl Il.

"'n;"'

cu. In,o <hc bat<: 1!>C1t TIu. ~'"


IM ba:.e onJr....,., ..~ ~ 1C1'C"'''
don', pooilion ,"" b>.!oI:pb.e: 'hcy ""'"'Ir k.... p;' rrom
f.lIhlll olt.
.,.. "ilh ~ ~ """'pb'e. 1hc 1l<'fnI'S mU>l
pooiIion 1"" bascpbl" t i weII :as 5U'UIt' " A.......Jhnd
o,. panhcad scn:w. " .1Uo:h hu nu upcr Inct>fJlOf"lnl
InlO i~ hcad Ikstgn. """, ', p<Wo.lon. bascpb,e ~
,cmlr .n<.l :K<:u"",,cly Uflles.> Ihc hoIe In ,1><' bucpb,e
"".ct ly m ches .he K...,.. .I\;InkJ <.I1;&""'ler-.OO
... ",, ', wtlt.A f1,,,h,,,<.1 K"-..... O" 1"" OI' ''''' hand . lus '
'",ad ,"", t:lp"'" In,o III<' .h.nk. !( II", hoIe tor i, ;"
" I"'"-"<I . ",,..,..,w ,,m C<'nlcr J'Klf
1. ""u'a)'" ...., IM ro"'.... 111#/ la kxul" l/xt hli V/"'''' ''II'1
~"'npol"t Tu 00 .h .... . uxh .1", h:uepL11c 'o ,h"
A)tl,CI' "'ilh II><' moun, IAA I<:......... ,hm po1<"k II wi,h
"1I"JO"Ir,g bit. lf Ihc b;uqlb lc tiu founll il> cen~ an
thc A)tl,CI' .ia <hc fb ,i>cJoIkcft-'w mounlinl!:. lhm ' hc
poin, o( IM ,., "';11 m:on: ,""
o( tM bit :am.
""0 holl(r.o'S

~ ..i111l anlo

....-nt",

"

Making a Baseplate

,loci. """'" ....1. S<-rond, )'OU ~ "",n, 'o jI(:I . . . . ,~I

l1OOO Iong k><>k .. r-- """Cf, illl ~ , :ond llk


mountinll .."."... b d~ .un1nJl poIm. Th.11 infllrm> "'"

hod~.. <>1 tl>o: "''l1l''I' ~.!iCI I'''' ...... n ('Qfl. inucc


lhc facIory ba:lCpJ.'c
1l1c- Olooa 'CunlngThn:;ods' ln tlle . ppt-ndix , ....
, .... Infomu.ion an drilling :ond bpf>i"lll>olcs.

:>boul Ihc ",,'~n' o(lhc JOI) A}'OU 0111y ",.klJlll,' b<IlItpbtt,


or"",,)'011 """ ..... "lJI..,..,., ...""" an Ihc ru11l", b;o;cl1brn
)"" .....,.,. lhc n," '~ri> 1 :ond n:al1y ]ICI 00.-... 10 nw.:n,

<Ii".

1. E.... , .... t(: thc: b;I!>Cpl.. tc-moounLing l1C.-c:w". \'00>


m.y wcU no:-t'd 'o ~~ 'hcm. a.cct. 1hc!CttW. "" 'he
""""' , and <ko."-,ru,,., ,,'he,he. OI' noi Ihory ..ia ~ for
"'" new b:L"'p",,~'
_ Arc 'hel' fl>, hcadl
_ A Ihory Iong cnough ' ... ..,., "";,h 'hkkcr

.!! -Arc 'hcy MURI)' cnough'

il
:=1l'O"''''

:al..,...,.

basqIb''''

"unJr.

lf f011' """<1'
h.. Ioog,
tLo'hn<1,.,,,.:.....
0<:1. 1f noe. COfI>kk, , ..... ,op<iont;

OI

"

_ 0nJcr a >CI <>I1onjjo:r "'...,.., for )'OUI' mula from m. il


on,kr ""n<lor, lik~ \\'oodh.1~cn (80().~4~-6657)

OI'

Ea[dc

A........,.(~H~ II ).

_ru" f011' 10"'''' 'o ' M

Iocallunl",... rc .. <>re and

1\1Id

tLoll>ead :lCn".,.,hu fii.

_ UI'I!'* )'OUl'

"",,<1' by

driJbns OUl :ond ,.ppin, Ihc

"'"'" ' O:l<;'apl "''ljl''.d'''''","cr ~

Tho: Iinio 1..'0 opt ...... arc c:lSy. lf}'OU ""....i"" ,1Ie ,hin!
opIion, I..,rc arc muplr <>1 .11"'. l'i~. " '11m }'OU rctlrill,he
~ hoIcs. bon: ali lhc .....,. .hl'UUjlh thc ~ Ibnjjo: Th.11
~,.,., WOfI ' , <lIsro<on ,lut
b011om .... ~

,1.., ..,rcw.

UPfj,ad. y .......... ten banplat. m .... ntl"1il


K,,,wl, 1 ,~pl~eed th,s "",ters 11nV serews tlloe bJ.d
_sI wlth \Hn(he'~. To cIo It, I d.IIINl new hale,
tll""'9h Ihe ro ut~r bau. close bulde Ihe o.j,glnal
mountlnq-screwl\olts. ~n' cut tII.tJds In tht ntW
hale. u.lng tM p.opu tJp.

, ... NHEAO SCAEW VS, FlATHEAO SCREW


1I"'SEl'tAl( I'tlEC'SEL Y "'UCNED

fauory baY'pI;!le wlth


for KreW .... d

(o"n'~,bo.~

SCRrW STAATED

'~nhud K'~W

l1a1e In b.. tpl~!e Is


oIj,ghtlV I..gt. tllJn
Kftw sIIJn".

al-

The

'Cf~W

SNnlt I""elln ,he


an lloe left, lea~in9 J
~p an Ihe rj,ghl. The b;r"epl~tt 1,
off'C:tnte' .
b."'tpl~te

The b;anp!Jtt Is
offnnt~ .

SClEW HALfWAY

The .. nde'slde of Iht ",.tw he~


toucllts '"t b~sepq,e an 'M
left,bll1 lloe,e', ~ Q~P On ,he right.
The b;anpl;!tt Is s1111 o ffcent ~ .

SCIIEW SEA.TEO

AStM leftw i, doiven lunht . tloe


baHpl.te 1, pulled lefl, ckHlng
tIIt ~p on the . Ighl. Tht
ba.. pJa,. " b.... pull.d , ~'o

~
I ~ll

Inuplate 1$
oflcente'.

~lIgnml!n l .

..... ~ 1001 WIJcts_ More InlO......uooOI >boul


.... ond othtr appropNlC nw"'- an bc Iound In tM

...

Sila: ~ .... Nknll a go:nai<- ba!iq'>b.c hn't:. ""', al


"-.-.: ~ do:'u. 00 's ati Improl'nlk'flt "'..., ,!It belory

3-CuIW bbnk. AImooo: >ti)' riPI pIa>I"'. ftO<Q a~


_10" xryIk u. a phmoIk. an !It "In OII ,..,...,. lahk
_ . 1Iti\ a caohIde-tlpped combiflllilon OI" ",,-..," hLolk
~ wilb lui 01 .""'h).1l>e bond ..... ru .. pl.t;.liCf "'cU.
a,<doII) II" rll1rd orr.ith meukuUiII, bb<k" MeI don
. . . . W """"'. I!><m '0 CUI .!It ba"'" bbnk. JUlI OUl lhC a
MOI >lDi3h' bit. guidcd tor TILUn' OI" othtr
_

ti . _

AcryIict ud JIOI!'afbotuo:o; 3ft thft1DopIaoOIb . ... hIm


_ thrJ aR" .......u.~ ta bal. Gmrn", ............ lin.
~ thaa. and lbcy1I ...... up .IUI wwk. I Iu>\:
-.o" !IOd poOkw In .... rq;anJ ... Iht WIic.-- ()ft ...,
. . . . . . dw
01 ...., . , . . kccps il .....,. (In MIdI_l1li< ............ .,.. ckan ehi.,.. ..d . producq "ft"J'

..,.h

-"'-'
4. DrUI W mo..ont.lng
Ihoo tbI: iJ

1>0""'". 1"ht: .ridiol p.on 01

""'inII Ihc I>oIcIIn thc

C<>n'ttt ~.1lIc:_

. . - opproadl b 10 bon<! 'I>r be .,..,. buo:pb.c '" 'ho:


\IIOIIi: ....".,.mlr ""Itll ~ .ape ( ..hkh b >l1dy OII hoth

fidet).Thal )"OU an "'" Ihc """,nlinjj: hoIai In k ~


lIriw JOll do 1R)-1hinll doc..,1m; ti", bit. l'"'" bldd !hal
.-om ~. hIl._ wori< jtbI fiM for drilli,. In ......Ic
tor ilie ~ I>a!q>b.c 10 d>oo:tI4' tht cntn'CI hII .tor
Now tt.cr.. .... . wo .....
oon . . abwt .-Itionlr1l

,,)"OU

,..., f.tocwoy b:;u.qIWc an Ihr bbnIr 'Ii1th ,,,", .,......, dar


bbepblC _ .n:: NkiI1C. JUU Q/l"mply pfunlt ....., ....., b0:I.,..,. p.vt 1II)""'t.rn:: OII 1,,", bbnk. (...,.,".0011,. JUU"I trim thc
CU:'ilom lloM"pbtc W dupIio:"Ile thc

bel.,..,. OM."" thc bit

'-'P<'n .... wla mii "1' ccnll:n::d In 1,,", pbtc


A//gHI.., lIN ~,. f'" .. 1J>aI.. s..pPOK" Ihn't:
lIOtH>IJ ............. try JUlI Il;...e 10 .,.,."e. thc belory ba<cpI:alc
.....,.. paniculo. poInl on Ihe bI.ulk Thc: f."."10" plate """
1 bil opcnil1Jlllul sudtk:nty 0 .... h'-'lll< OO II """ no li11($

'l> Mlp)'OU 11111" H OII" poInl

N_ ",h 1

, ..,. 11Ib..

With ,!It laelory !'bIe on Ihc: ""'"", . nd .. 'CI")' ... ",U


dian ....." b.. In ."" coIIet . .. n::tdl
.ap(" (n'tt .hc bit
oprnl,.. Thm OII Ilie ..... Ier md bon:: a ....... In thc "'pc:. &:
(1"lIh b
I 1>1.... l"OUIef. mon:: prublcrn>tJc "'ll> I VI
~ AMer. In
l;atter Jit-.on, da.mp thc lVUlcr O~
_
III I ~ .... ""-tI thc 1kptI>o(<IIl 1d/uStc:r. NQw

tm>Idr1,

casr ...;...

1""

.unI OrI thc _ I n d """"" thc drpth odfuoter ro makc thc


hok->1lIc: trkt, vi COU1"K. 11110 bon:: I c:bn b;)k ..ithout
I~ thc upc.. You ....,. nd ' 0 IppIr K"O"CfII lIfcnI 01
upc..Qr uor duct upc..
Rcmowc thc pbtc rroa. ,"'" muter Sip' ~ thc
.... 111 thc apt._ n:ntcr thc hok on thc bb.nII:s ttnter",*,1 Thu mar...,. thb h 1m.. IIIc:.:md .o......., dqn::c la
III. lIut
f)'OU 1.rJ iI. ,.,..'I IlnoI l ...ut. ..d!.
11_~11 /JOII'Io<II,., ,.,p.. "1th ........ <."U:MOm I:mc-pbtcs.
)'OU ..~. 10 ,-,""n. thc ..... 'er Iwwllcs I ~Icubr "'ZJ' 1"ht:
orim ...1on oi,,,", Iwodlcs II noi aIw3ys nidcno ..ben ,.,..
Iook ., Iu!ot thc bel.,..,. ba>q">bIc In tho!.c oIIo.atlont.cb<d:
bxII: and lOnh bc ... <UI thc fOUItt. ~ory
bbnk JO tlvt ......... you an:: .. dont . ....., lVUlcr bancID ....
bc orimtcd .1Ie ...,. )'OU ......... han.

""lnk

batcpb'<._

ni( Pl.UNK METHOD

A. U!.e INwpl.o.lt '0 ,tlf<'


proptt dtll! bit fOI" llot

.""

_"'9"10"<1'" hoIeli.

. Sllck U'~I tf,~ to Ilie b.utpC"t

C. UsI"9 tlle bot~plll<l 1l.!I\>Id<!.


d"III11e mounll ... K f n j hoIH
In the bl.ln"-

Ind plu"k II IM."t down OII Ilie

pl.lnk bl.l"k.

~~:::!':~~'i~":':ilk bl."k
1Ii!'"

for

b."pl.,e

0rI11bit
P1ulk blank

faetory
iluck
.0

o With. Hber ww. \fim the


1ItI... 10 wi.hIn 141" oI.1Ie
faclOlV buepl.o.lt..

flll.OIV bU<lpLllIt
uuo;k llilt 60wn
.obtio!o; _ __

lN.~epl~le

'.'<1 down

blank

L Ttim tlot ne'" lN.~pblt


tlush with IM faaoty
p!alt with a 1Iu,1tlri...... ing bit.

=::

"
_

!
"
VI

THE HOLEINTAPE MEllIOO

IQouI

/-tf':::?~Ca,pellape

A. "Pply 2 Of 3 laye..
of maskln!! ,ape

;oC,on 11>1 tJ;J


_nlng an ,he
fu,OfV bnepli.It.
Plungebort I ~
In th~
wI.h I
sma!ld",m"e' bl .

Mnklng tape
(2 o.r 3 laY"")

'"pt!

HoIe boted

'--'''''--''-_wl.h \oi" brl

1/ J bat ...

buupIatd

If

""'''II-'' '"

no paum
!'bn D 11"1 ain worl
)'OU ha,'t

IN, )"OU ."" rontforubk


fIlhC".l>U1 i. 1. prtti>c" md I does ha .., "1'1'"'.~ "" no:ed_
a~1:>k: '"" o( """,n,;"3 tcn:o>"S . .. ..-tU .. a ctnIl"riJII
pin 10 chuck In ,ht ",tller ",~k:t. 000 non buy. ~"""
pin fn>n> 0.1'1" l "oo1s (1IO().~3 1 S~S9). HaJlk" Arnmc:. (8008722S I 1), aod other bit .nll muie, . cCCSO<>'Y >'CA<k>r$. Tht
pin does ha.", <><hor ...... ; Y'''' woo 'l br YI-"'~'~ S~."..1t
on. lOull!i'XJ'llOr onIy one JIfUI.-t<J,,,,,)
CuI tho: bnds 0/1" 'IM: ,,;:..,..... md Ale <li" griod " lIOiIl
......,.", tho: _
"1>. Thtod ,IM: .tIC..,....
,1>< .~
hoIo In II>< fOUK1""S b:o>t. Ylilh aii IIM: poinI. prolfudin,_
fIlI2l
Otud< IIM: ttmcrinJ!: pin in IIM: cnIkI.

"'!O

OI

;-

...

.
3:

II

8. CUI tht [\lSlom r------"".~ D,a~ls


ba.tpll.t blllnk
" d,awn
'0 lO\I!!h .Izt.
on blank
Wilh " peACU Ind
/"
for euuom
"'"ighltdgt.
." "
baStP~lt
d ..... dil!jo... ls
10 """k the
etnltr of Ihe
desl.t<! bl,

"""""'1.

/',< -.""...,
\

openlng.

-"
O

OI C. Apj)Iy p,lIlelles of I""------~"

e_'lipe10 ,
butplate. ind
rtm_1I f.om
,he roule . Align
Ihll>ole In ,he
tape ave. lhe
eemt,ma.k by
tYt. Thtn p,e..
tht biltpl.te
fI.mly tO
,ht bllnk.

Align hole

"."

ctn'e.ma.k
fU. polnts .... hudl'L" sere .... on Ih. d,iII

",en. Ane. eutt lng .1Ie lleads /rom Iongshlnked

u.e

K<t~ of Iht sllme slzl IS


tw.sep"1tmovnl>n~
Krews, ehud' one In IM drill preS>. as shown. Wlth
IN drill press ru!>nlng II I kIw spetd. hoId I fiiI rllt
agaln" Ihe Up. A ctn.ered paint ... iIt qulclr!y develop.
Do Ihe rest of 1"" sut ... s. In .u.n. in Iht Slme woay.

THE I'OKE MEllIOO


A. Cu . ,he hNds f.om e"""
b'lSeplaltmounllng sertWs . file
o. g.lnd polnts On Iht Shllnks .
Uot l ' o. long~r sntw.

11
c. St. Ihe fOUI an .he
euSlom bl.Stplltl b~nk.
P.u. down on .ht .Oult
0 mark ,ht blank .

'1'"","'" ,r""
- Poln!t<!IC.tw
I

shank

c\

FIle Iht C\I' tnd to" poln .


Ctntlr Ilie painl an
,he shank.

D. The pain!> an ,1Ie H.t ... shlnh


and!1ot cen!e.lng pin ...111 dimple
Ilie b .... ~ . TM ma.h lift Iht
cenltrpoin!> OI.M mounlll\!1
".e... hoIu and IM bit Opening.

Bit openln; cente.poI"1

Moun!,ng screw IOCi1Uons

66

Roul " Mag ic

Urle up II.. cm.ni"3 fIIn OII . IK doiplatcd spot OII


dor bImk, and !o(:t .he mul .... IIt'mlr OII .IM: bbn~ n,.,."
,..., .......,. lw\I on ."'" touttr '0 dimpk .IK bhnk wi.h ~II
. . poIMs--tM n.nilljt pin ', poIn. ~> ....,11 '" tv<:ty """'"
oftht 1C1no.... ( A >idc bencfl, ." 'hls approach 15 .ha. you

->

QI[

orIm< tM ""'..... 1"" IM ""'y you " ... n.

bI.ln cunl"" ... "h tllc basorpLlIe,.nd .urn lht: bit. t'Oupk
",vnlu.lon. ",-1.11 your h,,,,d.

o(

7 . Ro", tire hh opcnlng. 111= optlo... for doinfl


.hls ~~""" l() mlnd.

on.1Ie neW

/!Ion IM Itto.mll"g""'" boJk'.. &o<k up ,1Ie ,,'0<1<,


po<.oittI a dc2n ho:o"',:<nd j( J'l<l cl:unp ',
r",,,,
1ht: dunp ;r..11 wr,h . n",her wuod oer.p Sc:1 .hc drIJl'.
lIftd 10 bct",,,..n SOI} .oo , ,(JOU rpm I'ttd lhc bll In.o ,IM:
_\JIIt 5Iow1y .nd .....a..lily W' .. n "wt<11Ijt w,h a ,hcnIlO'
f!b>tk,- lhe bi, ou. oI'1cn.o cInt . hc ehi.,. Uoo ', >lOC>
dor bIIln ."'" ho~; it m:oy ]ICI ..ud:: ."""' ...... t.. tip .....ro
1ht: bInI;,hrough point. _
thc bit e>'C11 ~
Afu:r txwtng lhc huk$,
juot: enough
.... thr mount.i1l8 M:fn" ,,m bC' bdooo 'hc ....&0.. A .undIrd countCTSlnt ...'><b jUSI fi"", In pb>Iic

1h:I,'.

ruut,.,.."'"

I U.., .t", Y-fI"!O"ing bI.


altt2dJ' In thr
plunlJlO'h<>r<' "Il" k.
1 , 00ud: dllk"",. bit in .bc IOUI ...... ond plwwM><><~ a
..,~ hol< lOt
particular ....
3 JI~_ ,tir ..... ~ rrom Ihc """'.... and drill hit

[lI'''''''' 1.

.h;a,

- """

n
c:

...,..,.CQiIW. ,.......

S' Trim Ihc blank tO fiu:, lIow }..... do ,hl5


"pon 'hc final
If.IK b,t"",
plat' to"'''' .... king Oi indccd IIt'neri<:, 1. prob>bly will
*'f!Iit:I'" tM >luI"" o( thc (.e.ot')' ['b'e . If . h~t',.1Ie ""'"',
r.... ,"" factOl')' pI>lC "uek." ,hc new pl.,C Pul. p,"em
lIk 01/. n",lHrim",lng h i, In }'''u' route', Orient 'h. ,....,
)'In. smdwlch >1,
pil'" ....rIng rida on IIK f.K1ory
""'.,."" Ulm Ilie nrw pb.e .
Ifl"" nrw pblC "ill bc """'" oh>pc OIheT ,h2n.bat o(
dor ti(oory ba>cpl>'e" " il}'OU ,...,.,. , uoinj! ."'" bnoty ......
D I P"1""', .ho..... rim t.hc /1CW bucpbte on 'hc o"'" ....
OI'
,,'ith sabr:r _
(Jt' """rt.5n: .Ix ~.
b _ "!""dlk tipi OII C'lllIi"3 'hc m,,,"""1 )'OU """ u:sInjj,

*t>md> 10"""", C<lcn'

:1

....

:'

>h."".

.h.

buIII,..,.. ....

6, toca.o: .ho: bit o pcnl"g. ~; Y1IfOO>'In" bI. In


tIIIr """""'0 coIkt Moun, """ nev.' bo..cpl" "_>l1I1 wI.lIou.
bit opm ..... -on .1Ic rou'er. O<.>o', c,'cn plull .hc "'".."
.. ThilIs . 1u,nd-f><>"....mJ npc.... ion_IlrinA .hc ti p or , lIc

Ali,n'nll". bl.nk "ndIU 1". driU perfecti)' i.


.SStnt~ 1. W"rth li Ctntt,lnQ pin In .1Ie ehuel<, Iow /Ind
lock 'M qulll Ju" li hah" 1"'" of the worltpiue. SilIti
Ilie workpIKt wnlil you' Clnttrm;\r~ II dl,e.:. 1y unde.
IM pln~ polII' , a, !le , CI"mp ,he wo,ltplt<:t to .ne
driU po-ess .,ble . Tlle" unlock tht quill. changt 10 .lIe
app'oprlalt bit. ind d'lllihe hoit ,

A Zero-Clearance
Opening for a Piloted Bit
Bo't 1'" hollln .... 0 Ilepl, for" bo<t .. clurlnct
hole f(Jt'.1Ie p,lo\ bonn, wilh oi !i-,nch bl" Thtn
,wrld! 10 Ihc plloted bIt TIIe ~anng PUltl
Ih.ough 1"" firs. hole. U shoYon, ind IM bit's CII'1lt'19 rdOes uiWld Itle 091"'''9 J"II tnough 10 PUI
'hl'OU9h. It\ a rtro-tleara"u Opt""'9.

~ 5:::,:i,::o~n
Itr~p
I , The mo.Of

UIt

Ix 'Jind and

Iugtf .".. IQh'

~rtd,

In .
Tlle Centtlc hstpllOlt

-li
.
II

67

lIy "","l'd<11I1I. ~;. hcr o( the n .... ' Iwo ""lIon> . )....,

wlll

~1bU'"

.h..;ot

'he bit .,.,.,ni,.. 1,

" c n ,,::~

pcrfc<:tly. If

,.., .. U5C . heV1IfOO"lng bll, Il wlU iii"" )~'" a r~ ir1r b~


diam<:tc. opcninSl.
~n tM ,.."In b pIunJ!c mo<Id. bonng W
il' 61 ... 4I/I1furw;>.nl JUSt se. lho: ""n~ r Ull .11 apcn<bblc
"""p of ..."OOd. anii ruut. Of C'OUI"oOt, you don ', warl' "'" bit
10 "..
IIKlr in ., tM IIo.scpblc, IlO t:oor.. Ilie oprnlng In
If"IC1'nDI: ...... I'Iw'8< .nIi fr.:tl W 'l' 't' fur
then mraeo "'" bit .nd . l\ow Ihc: "'Ori< 10 cool .......,.,...
wil)'. 'n "", "'. . . 'II'lin. E..."n,ualIy "",'U hnoll~.
When tM rouIa IS Iln~ rnodd. "'" wof'k .. a
linl .. RIOJft: "O<I\pli"'II!cd, 1t onIy be,,",uljC tho: _ hine Isn ',
do.lw1.... ro..
plungc CUII.Y"" hol.., 10 el.mp lM

-ci".

.!

."

S
u

1IoubIc-in>""'.

''''Y

II

!:

OI"'' 'n"

f'UU""

Makin9 a Baseplate
for Template Work
Ve ..

-,~
In Ilie

II dam ""ni 10

milk cllstom b ..cplltc th.at'lIlICcom


mod.\t sundard ttmpl.lt ljIuldt buSh'''IIs. To bo<t the
lbM!tel bn OlM'n;ng. use 1"'0 Foutntr bUl
Ta ."sure \1\;111"'" aponlll\ll! cOf>Ctnlfk W'll> Ilie
b.t "'1. mounl lhe bW>k on Ihe !"OUI"."CI IIU. VgfOO'Vl"9 b,. tO JUSt mIrle Ilie Ctntc. of the olM'lIlog .

1114' b.oupla\t r'om I~ _Ier_


Clluck I Unltl1r>g pin In I ~ d"n p'as. ~I tM
b~~pI~lt on Iht uble. Ind paSI",," IlS etnterm.,k
prtc'~1y bo!nutll t~ eenle'in9 pin', POInl. (Lomp IlIt
""<epl..It In pliKt

ch\ICktd In t!lt dnll p'US. Ckmp IlIt


plite <o II cloutl't movt wllUt \'OU
eNnQt blts md

""0--_

'"
. Chlnge Irom tht "nit ring pilI.o. 1\10"
Forslnt. bit. IIo<t I .tcu. ""'" dttp.
LuY<l! , ht pilit cl.imped In pllce.

C. Ch.nge 10. 1\11 ForSl n" bll. 8ool!


complettlv !I>rough l he pLolt. Tht
re"u!lls .. I \II" o~ning .u.toIJndecl

bv Y,'"' wide )( JI\>" -deep rabbet.

,..,.,t """

ttrodcs......cc opcning. Bul chmp Ihe modtinc 0UIdy.


:and IIM: 01'"'" "-'" wlU worI< floc.
I>rim n~ Ilie opmlng on IIM: driU "...,.... IJ ..,
.pproach. It pm:ts.r cc:nlttlng is a pL "'" ccnlcri~ ~
Of smoJl-diantctcr bll 10 llelp you pooIllon IIM: _pilor
"""ur"cly _
IIM: bll. 1I<: fU"" J'OU ~ " mp IIM:...-or1<P<tr
oncc II 1, po:Wlloncd. '!'Mn dullll<' 10 Ilie- bil nttdrd
"","IC thc pn>p<:r.ti>:rd 1Iook. ....... driU,

acuon. drm Ilie counterboni_ It JUni you dan' bare lD


l!>e Way Ihrougll Ilie plalt, bUl do bare dup tnough
IIYltlle busII'ng); nlngoe wI)I!>e flush ""III Of btlow

Ilie "urf.et.
Cornpltit.M hOit w'lh. I "tnch f OfS\M' bot.
Oon't movt """ workP'tCt, 01 count. Just ni"""'" ~
I 1II"ncll bn lrom Ilie cll\>Ck nd nipllu It WIIII IlIt
I "'ineh bn. When dtlU"'g.!te<! IlIt bot III.d for ..
<"ond. tllen ~k II compltte-!y OUl of Ilie wGrlc. FHd
. I n btltllv. llIen b.idt OUl. Repe., IIIIS In-.!Id""'!
Iwan unlll Ihe b'\ completelV pt"'I~IU lhe pllISlk.

A. U... up plalt for borlng Iov ~Jlgn,ng I~


Ctnlt-m\il,k on II unclt, ~ etnterlng p,n

fOr

Chuck I I "~ndl FOfstntt bn ,n 1!It duH prtss.


niplating Iht etm'ung 1)11. W"h an In'ind'OUI fHd

<~n

~tmovt

by 11.0 motO<,:and wodc tIM: ba<c up an<! OO"'n OII


IIM: dcpclHlf..nrl
o f tIM:
W2SI1 't

, ""'''''"' pin
c..nle.lNlrI<

m~d,

Iov v g.OOYing bit

T-Square
~

...st Ihe scralt-board fencl!.


MIoke yauuelf '" squilrl! 10
._ide those CiIIsework dildoes .

T"'I~

15 nuok 01 twO ~ t-cnnI ......hcr 10


fom1 a T. ], ', ~ basic, b:L>ic NUl....
\001.
~e l'oundf""" Bol;"'c mc. )'OUlIjICt 1 o..- 0(11.
And it 1. kind or ....... RlC;lJ lIow casr k bttumo::>
up
lobdo CUI TIle T.qw.", "" ...... "",up .1"", "..,.. iti bIf!
~. y"" <k>n', h.. , ,<, 10 ""'"' It.. fuli knItIh
~. m.n palml.k11lllly Illgn ~nd cbmp I Mr.dWunlp: 1"
Pli: Ilie muIe,. \l:11h T.qUlU'C , !\insle .ido IIW'I< ....aIy
.tIident ,Su k"'3;aS the T.qU1J1: " kn OI ~
II il> aoOa'. )'OU ('On be ...u~ ,h"" ,he: dadu "';U Ix

""""""'IlrIIln8
'o .....

of.""

lq.W't ' "

,hc .,..,

la Jddillon, thc cro>...t ... acI.;aS' br~ , ollowing 1"" 10


........ ,"" ' H>tC:l1 T-6qw.n: "'ilh IliIlJ!k cL:tnlp lf f!JU ....,'"

"IIIi* I fOII,n:ak>ng In un.u.>med hoorcl fcllCC ~


....... *lIk mmp. th., cb.mp "")l,1d becon,., pi....,., With
.. aarot.r but.cd nnnly "lI"ilW
"",""OII' h>ppm.

wurkpiL- ct4F.

"'al

Jo/..ItIOIjI I T<JqIW1O. 01 COlI ...... .. =Uy IOlIgb. (Wink,

__>YOII ha,.,

,o

,'''o .....

si"" arni ~.
;ght-af'I<""'ruc
...... ~.,. -1'00I\:I1><'_vnc p;ctt, c:uktl .ne Cftl:<>Dar
...... hnod.
lpi.... 'hc: . . . , of Ilie "'''",plC<:<'; .nd

"",tf

"'" "'Mr, ca&d ,'''' ~c or ,1>0: guide or Ilie bbdc. a;<o:nds


'". rigII.;uW<: ac..,,;o tIM: "'''ri<pN:<:C~.
TIr
TI"""'--dIi: OUl Ihe dnw!ng- h:o>
~ Mf'O<ftfl 30 and 36 hlChc!; Ioog arni ~ hm<un
II Ind 12 In<+a ...... I'<>r nim)w ","(!r\,;, a $IIUlk1 JIllI<k il
moR: ~ , lf )'OU do lot o{ eobioc1 """"', nWc~ a
n:3D)' b;{I:T~"""',an<! ctA both ca><: skb.1 """ II"",

.,-p;c.I

A lot 01 ~ m>kc IhckT~u:lmllikC copilll


T... ""hlch is 10 uy wilhout C:XICflSio"", My Tii<!"""""
fcnca llul atcnd j 10 6 indici ~d Ihe c",,",,", ta
:IC<*!y thc """,er ... It aib I cut, Thlo 10 p;1nkul.rly "",,'ul
",ith b;g ..... ,en; an<! ,,'ilh lhoo1o: "~Ih otralghl~'d u, <"'CI'oUed Iwq>blcs.
Onc<: ,..... ... into lhc h:tb[I 01 ......11 TI""'" tQr
~ .-.." an<! WOO'ft. )'OU m>y ~ln 10 dmom .boul
,..-akq lheT........, 10 "",kc It C>'CfI
10 \1.'0( TIu, ')
...'ha 1 did. aooJ lhe ~tli an: lndudcd "","" An.! 1 . <Idnl
cbmp _ l i l < t """" UIiN ..... IQUtC, .ubk kocc. No
fl1()ft fuml>lln;jl " i th
d:tmp;.. ,"""'. :aI'Ic, 1Il0l hook.,,;l
an ,xuwn c'""'pU>g. I ....uc .,..""'" T........,.,
tiut kt'. ~;u . .; '11 pWn .,..,111. T.tquan:

tu,..,

c;I.,""'"

""'*

"

TSQUAIU PLANS

TOf'VlEW

'r~~~:';.~

,

______________-,~~______~;;;:::==:J

ll_________ IL-1~Sbl'

EOCEVlEW

Making the

-Square

BASIC T-SQUA.Rf

Cunlng USI
Pout

Qty. Dimensions

Material

fence

/01-)[ 3)',' )[ 30'

Plywood

Cronbio ,

/OI' x 2Y>" x

9 ~'

Hardwood

Hardw.are

'o ""',

Whl'" II h cuier
'ht: """ In Ilie fcncr tNfott
,""",ml>llnl' ,..., T"""""", 11",,,,'. "" rnoon wh ~ )'OU . .'1
n:trotll ebm"" 10 an okJ T-sq .......

Making the Cla mps


2. "",,mble lne r"-IKT and CI"OIjOOr. G...., an<!
elamp IIx' ""'"" logcIllcr. an<! chcd:; 10 bc &un: lhey arc
c;C:In/y ,;q ... "" An oUl-<lf~ ... n:T M 'I a jI& 1('511""1' Whcn
Ih~ 8fuc' <bioti. drill pilot l>oIoN ~nd iim.., 111= o, Ii:lu,
"-~'S el ~ apprupri;olc 1tn{:'J\ 'o I'dnft>ttt ,1Ie g11lt: Joi ....

Adding Clamps
lbcT"'l."""' it cb$sic JIjI. It ha> unIy 'wO jWU, nci,hcr of
,hem """. ~ II tu... slf13Ub' pll'P""" 1..... il (ulmls f,"IIk..-..sIr. lbc 0<1(" ,,~ )'OU can
II i> 10 a<kI ,,"'mfl>

Intp""'"

SQ I did.

lbc elamp hIock ronfil\Lr~ion " bum>".~.,j r""" ,1Ie


optil "net Two an: 1lSC<l, '" you C'a<I ..,.,. One, ' fur.... damp,
b k:>o::l, .... (i;",cdr uodc, Ibc Inlcnn-tion o( 1"" b>tt and
~~ TlIc:<'Ql\ll cbmp"""nln ...... """,nllo 'Ile
""""'- To _lhltT....... "",you ""1 ,'''' ~f'""Iy~I""
'hc ~ 01 ~ _
. and IiIlthIOl ,lIe ft~nI damp. 1"h~n yuu

.w. Ihc """""d eJ.,mp 1n10 f"O"iIkln and 1"""" IL

\I:'Iolk you don ', ncnI muell Stuck tu makc thc ,,1anIp
blo"..... It .;hould hc .hieL II l"Otl OOn' ...., an 11,14 (~
q......".) lIan.lwood iri !'OU' ..:np bin, then j\I~
lIIin"", .cod!. You c:an en'n ..... ~.

1. CuI a ncl .. hapc thc dam p blocks.. TlIc ron'OIC


.00 dimcn>ions o( tbc damp blocI<> an:
In thr
dr'''''ing aa",p 1),'luU. NOtt tIu., ,lIe '''"'' damp blocI<> Olt
oJljlhlly ditr~""nt.
TlIc daJ1\j>S arc ~ ,,, !Onn "ilh 11011<1 ","w _
...
ci<Jn:ary ... nder. ' ''''' an e,,"'1]IC Ilie: paITem , tr.ruSa II 10.
singI~ b<Jard of chc CorrtCI cIIk1<n<:M, Ihcn _
""c rn.
bIocks. Thc l<U>Iltr wtll make quldr ,..an: 01 """""""~ .....
hkn<!i"l!: clIe fdp,
Alterna,I,..,.) Y"" C'a<I ..... "'" cII<' dlmp bIocb " 'I,h I
t:tl)k.mouncct! .. bc1 __ y"" ~= ..,...,. clle:m ouc "" thr
cablc .. w; Ihc <kt:I1b oi <kIInlC Chis ..... n:blnl !ro Ilie: dift<..
tioJm for m:okl"ll thc Split I'entt ""...., H7

"""""n

~nl>h ,;hapinjl chc cbmp """'It> hy .. ndinll ". mi,.


n ......... (bt at Il", jaw '~ tip 1"h('n ..... n<i-o""" lhr

HQUARE WITH CLAMP$


TOPVlEW

,.-- - - - "., -----..,

I "dla.

".
Yo "w,de slOI, centered an Ihe blade

EDCEVIEW

FI~t{I

elamp

2. 0rilI thc holes in lhe b locks. The elamp block


... """",,,,d ta 'h .. T""Iuare with l4-inch "'''';;'11<' balls . ....1i
il! ,bat, thc I>Iocks
~Iy t "' ;~ OI,t oI posi. ion, ",h;"h
...... be P"-~IY :"".o}'ln,,, when you ~n:: t"l'ln", 10 Ori .he
""",.,.. b:h eWlIp hlodt Ihen::fon:: h .. ati .Ugnm..." pin
~fronl t .... tOp. On Ihe Ilxed elamp,' .... pitl isoc"
...,.. p;tnhc2d "'''''' ', This ,.",,,,, prujt....u int(u hol" In t ....
~, ~.,.,plng tI>!: hIock from twbhng, On the mo,,'. l>Ic
cbmp.th< pin is. MOri pictt li[ !4.in~h dc'> ... ci llul pr(Jjc<:U
Ioto lh<~ ,
1b pr<l'i<k .. Hu'" pl~l' for ti", ",alin UnII bolt,,-< ba",
""""h hok (for one bolt) throush cach 1>I".. k. ,,-~ ""'wn in
Iht Ur;n.';"g CJ<m,p De/aii.
DrilI. pilot hole for lhe "1Illnmem ....,,'W In lhe tiu..!
ellmp bIodc. t""n "rh.., p""hcad sen::w im" 11. .. ,hown
In III< oowl,,&- Lc:t"c Ihc he." pI't>lrudlng al"'UI h. iru:h.
0rilI .. pilor hol<' for tlte oJignmm' pin In [.'" m",'Obk

TSQUARE WITH CLAMP5


Cutting Llst

_101"

ruMP DETAll

Qty.

Dimenslon s

Materlill

I~"

Hardwood

IW x

Allgnment pin

)4'

x 3)',"

dia. )( 1)4"

Do ... el

Hilrdwilre
Pi'llhud sere"', <1"8 x l '
1 carrlage boii. "',20)( 3W
1 urrlage bolt. "20)( 4"
1 compressloll sprlng 14 1.0.

le

1" long

2 Hal ... uhers. 14" 1,0.


2 plastic "ing nuts ... llh " ' 20 threaded loserts

PATIERNS

]1
I

I square _ Yo"

~~1.
C:::::::'=w;:
,w===:iIJ

FIXED CLAMP
TSqua~

71

damp bIoel<.ll><:n fii"" ~ ohon pka of do.....,llnlo Il. Ion ..,


Ih" do ....d p"'''''<ling abmn )t Inch .

3. """1'31"1.: the T -<JUllre. n... sloi """ il<' rottlcd ""


II'" "'<net .abk Of .... llh I nliF II\lkk-C<julppcd pon~hk
mut... And}"" """ do It a(,~ tIc T~ i$ """,,,"bkd.
Tho: opccifics of lhc sloi an;: 1f><rot,'1I In 1"" dnMng TSqua ....
lI."ltb

i --,
-

f
>

z:.

"'

at.,.,~

l-1y out Ind drillltlc """"" ......... ' hok n ,tic CI"<"lOObu
tljtrr thcT~ is -.nbkd. T..... pur2I"IIy InstaII tI><: lI~cd
'o llIiIt. ,1><: locuion of 1"" alljtnn>m,~ hoIc In
ItIc cnJMDar. Jus, """" Ihc cbmp tunl aplnst Ihc: ""","""r.
",,<llhe: 6Clt"W hc:ad will de", II", .."UU<l Wh<:rr 1""" nee<!lo
<lrill ,!te I>ok.

dam"

I><~ts

4. M" ont th", c:bmp!l. 1n.'iCrt ,he


In Ilie hoks In
,hc cbmp bloel<5:u1d 5(":11 ,"" /t(->(b ... I,h I"wnmcr bI<:rw
Slip ,"" bol .. IllfUI.Igh "'" TJ ..."'. drop I fbI W2Wt "'..".
lhc oIwtI< of ~. :uId lurn 1"" winII nulS 00'0 IIM: boIts.
Allgn.tIc ......... Ind pin 10 ..... thc: bIoc:b.
Ta pop lhc dompo &cr 01 tIM: ~ , oIIp rompI"Q-.... aptq "'.... "'" _ Id:orc: knlIIw ~ Into thc: TJlI'lI".
n... 5ftriI1I ..iIl puoh thc: bIock _.,.,. f..... 'he:T-fqU:l/C.

Using the T-5quare


Hen'~ ho ... II ",o.k,. Hook the l-<lu~'e oye' Ihe
",o.kpltee 00 that the 1.... of Ihe tind clamp II
"galnSI tbe bollom surfiCl. Uit VO<l' o!fsel ~~
10 POslHon the Sq .... ,t. KHp lhe c.oSSbl' ;lV,UnSI
the ",O<Itpitee~. TIghttn IM fi.ed c~",p.
Sllde tllo! ntO\I3ble dlmp toglu ~'ft!IIM ~k
tdge, tben t'9hten tbe ""ng nut. The ,l'I ..... tt 10
Ioc:kecl In pLMt . eady 10 gude tM 1GU1!',
You un Set llullh-t .. O<Itpoec:e m~SI be su~
patled In,. W""V th.t ptOYldeS "USI lor tl>e clamps.
Ht.rt Ihc ...0 10 dogl/ed 10 the ",o,kbench,

~tlllIl iln illrudyuse mbled Tsq~u... Cin be


Oo<!e an Ihe .outer table. Gulde the "'0' lon9 1
le nee Ihll\ Ihln..." than the squltt\ bllde. Ma.k lIto
cente. 01 the bit on the fence. Iod the ends of the sloi
on 1he ,q ulfe blade. Lo ... e. the wo.k onlO IIt. bit,
Ind .oul untilthe bit marie ~nd Ihe el'ld "'ltk llign.
then tip the ... ork up off the bll. Tike t"'o o. th_
p;ttnts to 'OUIIM !lot.

Vacuum T-5quare
\\K"uum pfCMUn.' is a grc:U ....,.,. 1., hoId I
.........peQ: "" "'"

T~n:

..

n:tu' grooo'C Of <bdo.

C2fI

~ ~"OmmonT~lW"C hak~'.':.~~:~~~:~:1

"","n~ both
....... h an<l 1"" worIcpic
Mi ......., nc.;d> '" "" cWnpnl at bolh

!III

pooIlk>tt. ~,,<l 11"'1 ""O

il<' probknt.>11c ... hen 1""" ""'"


12lnchwl<k worIc~ """Ing on 14-1r>ch..-1dc
heneh. I!>"" ,..ilh the 1'",........ ",illl nt<llfll elamps
'bo>'~}, "'" tu .., ,,,
accaos "' ..... IInlkmotll

!la,..,

.."""'~ ed!Iteo.

NoI >O """h a ......... T~. J""'.., "'". . . . ,


pbtt an<l appIy "'" V3CU ..... Rom )"OUt datkJ.
'XlI""'- """'.., "'" """"'" 10 lhc ...",1 ..,.... an<l
. ., '

1"" YlCUlIm . Obotiou>\y. )"OU nc.-ed a .-:aalum",;"~;";N;'1


Get lhe: .xtlllm <k<o.ib n 'he: dtaplet -,:..:uun< . .
~"",,,,

Milklng Ihe Vilcuum

-5quilr.

,;qu.:o.", ,II"..... In I
""nle<! .. tlle bqtInnlnll 01 Ih .. dt.>ptc . FoIIOw

c:un;:'~"':""'~~""~~~~;~'~:=1

MilW"C. ror Nr
lhc ""'"
w<ntlon.
roItJ.l"rtt pIywootl ro.. lhe:
~ }"OU
""Ol1Idn1 apptr I ftnbIt to IlIr T~"",,, UfIdct nomW
cum>l~ )'OU ough! 'o b! tlu> Jlu>'Ion. ILISI ,., M."2I
JW"f;K'.:s and ~ , 11r la"'.
Whm Ih:1I b donc:. ln".lllhe '"X\Jum 1CCnIlOt"ic>.

72

Roule. MIgIC

VACUUM TSQUARE PLANS

Qukk..!iKonnKI fitllng (miile)

llCTlON VlEW

,------\-- -, .L

30"' - - - - - - - - - -

,.-

".

!IOTTOM VlEW

,.

f-

,W

Fenct " . plywood

,.

Sit

'W

"'""""
('oub""

P$A,.bilektd ..... cuum t.a.poe


flow !pt~utel>ll VilCllum ItlU .Iong
fellCe by ' openlnO' brnk In t.pe.

,,,,,taU

1.
tho: vacuum pon. DrW I huk for thc
Iiaq f"OI.I8hIy ...,""", ihoa'n In IIK <lnwlng.Applr In.,.,...
..0:::.1 beId of iiIIioono:: ~ 10 lhc twb t<l .,.... of thc
lIIIc finUt'- ..... in<cn il In thc hoI<..

VACUUM T"SQUARE

Cunlnll Ust

P,n

Qly. Diml!nsions
\<1" )( 3101")( 30"

fence
2. Apply tho: ' '3C'Hlm tip<:. As )'''U """ >iCc f...... , ....
_ ..... tM YXUUm ......, '" divklc<l into four ctwnbtn..
AfIPI' tho .-xuum IOpe 10 'IK bou om 01 tht kn<'t. Yoo Of!
.... tItt (Of"fta1 can:fully, "" ~"""n in thc dnwinJI.or )'OU
..... I COOIIn ....... run of th~ I~pc . bc:nding 1tf"OlIf>d tlle
<anoon.On)'OU tu.." lhc "nlin: pcrirn<:lcr IOpcd. ldd thc
........ - ' ..... ctoo.un:.wIp" ("'hIch I caJI flow 1PI0" 0fI

"_.

for 06- 10 l t~""h wkk

_ onIy thc fint


lncreun.)'OU opcn """"

wv<l<pM:c~ .

oftlor eh.",bc:tJ 10 Ilie .... CUum.

Using the Vacuum T-Square


~. if)'OU ;o.n: usInSc ''aCUUQI lOr dalllpI.... """

'e

.. lbt ncuum pump roft"""lmlly IoCItlnl ... )'OUl" worIr


.... iIOd """"cd up 10 1"'" aU romprc!6Ot" Snllnl up

"Joqwn:, thcn. 15 nothin3 more !han $WitchlntI <he hoo<:

... -1i8 to anothcr_1ikt ""'iIm .... bIu In)'OU. muIe.

"*

Qomp Ilie wori<pic to thc bo:nch ()"OU can


'" i, .....,.,., 5Ii<Io ..... y f ......
)'IIIL FoIJtlon Ihc Ttuart In n:bOon 10 ttlt byoul li""", for
. . tul (lISillJl an oI'l'>c:t 11"..,.). "uD I ,"I<;UUJJt . ..... )"OU.rt

..aun tu do Ihis. uf~)

l!Odf'o mw.
don~

t~ .t

.uc" , JUJI aboul .nywhe.. ti you

tuvt tO fun 11>11 fi ....ole 10 'l"llhe workplece

posijlooed wht't thtft~ room for '" eOllplt of tlilmp._


tht workplece.
o!:IW\letion 1. lIS
vocuum hose. ;ond
flulble e nougl! 10 bt
dlrected OUl of )'Ou, WIy 11>11 Ilie rouler's palI!.
~"1Im 'lKk, 1111. Ts.qUl,e IlQhl tO
OrICe ij~ ;Netd. the T s.qUl~~ Oftly

th., "

9 ~~" -.....~"'~.....
~"'\

Hardware
4 drywall

SC~WI.

Hi)( 1\<1

vacuum lape. ".)(

)6".

IPpro . 36

QuIcI<disconMCI fil\lnll. m.1e

........ k> thc wurkplc .... kllll

Appl y

Jl" )( 2101")(

Cronbar

M.leri",1

Offset Gauge
A 6 10 12-iMIl-loog S,tlp 01 ..... 1~ri.1 is .UII is. BUl
offsel goo"ge ,,11ow. you 10 P<>511101'11 T-l.quare
s,",ed,1y and .u'.I~Iv, U511\9 1 rnark fu< tlle dado\
~. . . 1 staninll pO'"!. The III"ge's I"'k .. thb: It is
~><K1 1y IM"_ width u the dl .... nu from tlte blt's
<uII'''9 edge 10 Ilte to;,,,,pliJ.te\ ed!le_
To "'.... t ..... }I. (I"mp" len(e nu. tM~. of
I ",oo1tbelKh. BUl! tM 9-"u-g<:' stock 10 Ilie fenee, Ind
UCk It do ... n .... ,tlt a eoup!fc 01 bnds o.- suc. It down
""Iit urpCt t""". Cuide IM rflUle, lloog tlle fenct,
(UIIo"9 Ilt,ouOlllM lIock_ Pry up IM \IoIuge. l'Ou now
llaw a "'ay to j>OS.hOI'l you' T",u e wlM-n "s,ngIM
routc..nd-bll (gmbinillUOI'I "sed 10 ..... ~e IM 9-""IIe
Mall< Ilie II'IU(Ie Inde~bly ",,,h lhe b'l and rwtt,
used. Ilokt 10 d.dl ....."11'''11 ....... In Ilie J'II, 100.
To .. se
}I., musure Ind nuri< OIle edllt of
ttle d.Jdo. You clon' Mve 10 "luare a II... Icron Ilie

11'1

f"..

You don~ hl"e to ma'. bolII .. dgtJ. Just I


tltk m"k~, dado 1,.11 vou netd.
Nlon one fdlle of tlle offsel gluge ...hlt Ilie miltt,
and bUIIIM T-sqUIlf Igilnst the otlle. edO'. The tSquII'\ <rouIM. en,u,,,, th.t 1"- len't 11 sCluI.e 10
the edoe TII .. offs" O"UOf ensu'u Ihll Ihe fenee Is
tM PIO,",' dlsun(e from tht dldo loc"l,on,
Quoek. s,mple, Ind d'rt<I.
If '(OU f~llok. b~'ng pl(kv. make ,,,,e VOU hilVf I
d,ltl'enl Jig fo, taeh dado-cuItIIIII bit In yo~, (ollt(
liOn. Th,s doltSn' mfin Simplv one fo, ..leII Jlz. brt
VOU """ ... bul 0"* 10' tVf'Y indwlillllli st,"'ghl. VOU,
~In(hslt.l'lk ~Ineh itra'ghl mlY IC\Ullly bt 5ltohlr,.
d,ffe~nl ,1'1 eulling d'ilmtlff thiln vou' J4-'Mh-sh,nk
b~ 01 tht .. mt ,IZt_ And II shoukl \10 ... ,llIoul
sayoftg-b\It 1'11 ~V h InywilV-tNU you CilI'I\ IISf I
g.UIJf CUl ...1110 ont ,outer 10 sel Ilie T-sqUlre fo' USt
wuh il dlfferel'l! rwtt._
slng~

,O oHs. , lI.e Tsq ... r.. 7

ofof
In(hes
I,om the
~~:~:~~~~,;~~(1"(ouple
S('.p
hl,db41,d
o, Ih,n
S(fIP to I"e ben(1t tOp wllh
I II0hi 'oalnsllhe fenu. Run

:;::~.~:~ ;~~:::,,~::.fen,e.
(utIlnll throug" tlte
SC'"p.
stock 1. Ilte o'htt gauge.

wo,~plece_

Usln" Ilie oH.el 11I"le Is u simple U 110111'1 1119


One 01 ,U tdges ... lth tlte I.IYOUI muk. Ilten butung
tlte SClu". IlIaln>llh. 0110., t<lge , Tl>e T-squa,e's
(rossba, ... ,11 en sure 11111 Ilie lenee Is Squl'~ 10
tlle .. dOt.

Routing Straightedge
De<eptlvely usy 10 USI!, this self'dilmping
,tnlghledge SilVU time in senin" up ilnd
. .kl"9 51rilighl-line roUI". CUIS .

'<>'

8""'" thc ruu(~ r wh~n m.klllll "",lllhl .,,,,,.


hom:'.......ighlc:d1lC "'ilh bull' ln d.n,p . Thc
ebmps "inetl n <.>n ,1><: cdJco.:o of ,1", ",orl<pkcc.
lit'COIIioa tht I>lr:aif(h,edj(c ... )'OU ~-an .Ii"" tloe roul~ r .I"ns

1:

".., Ihln Cl\OI'gh 'hol I on .. ~h It


~1Hh1d< .."01'1<.
p/c 11",1', IylnJl 11;" on ItlC Ilcnch IQP. It Is nsr ta ~

For yan. I ,,'(H'\<cd .."'II Tq"""" o. whll,~..'"r


lIIllIlM I(:f:Ip I lud . , 1wMl.> a ~"'mpon r~nc~ . II ..,emc:d
.. ~~. thl"tl la do. bul il "'b/1', .1 ..... ).. 110 I(

huy. And 'ilO' onc)'Q1I bllY It d.m jlr.1nd . 811' ......,,,. tlmc 1
look In my ",.. II~I . ' .r.>y tu my,,<:Ir."M.n, i, SUn.- is em,,'y in
Ihe",. So n.'"I;"'Y, " m ... 'n' ln""l' y ... ruj!gling 'o m.kc my
w'Ml<lworkln~ doll.l ... 8" futlllet. (Sou"" b m Ul.ltl)
One .... y to do Ih., 1. IU ma"" !iOIl1C . "....,.,.,..rid. 1
non', m.kc .. N,,'a bi, o,. ~w M. de. bUl 1 non n.. kc.
"'am"."n llilide ror 51""8h' N .. tU CUl . In" .... d of
In\'c'>i'Rj!"O ' n . commcrd.1 unii. 1 put ab"", $12 into
C<Nl,n,on h.,d"",,,, .nd a co .. "lc ur comfurt;.ohle pl . SI;"

-...

........ plccc ...;os ruln'OW. tot c:nmpk, (110"1"11 I dlmp


..... cnd 01 ftI)' Slr:ai&l"~ cuuld Il<' d .. llenJ<'. rol

"'-P ont ~nd . 1Mn ..,.,11,e r ~"OUkln't I'neh IIM: 0111". cnd
-td.. damp. So 1'01 undo 1"" firsl (!>mp .nd ","n "".... Ing
....uit 2IId thc ln;p.tCtJII'= ItQund un tIM: bcn~lI 1"1'
MPt il. K!O>'S. ~ No Pu.h II funhe . \0 Ilie n>dl
- . ....)N E'"nlLu:ony 101 IICI it donc
Sol Ihb ~ is ....'ORdcr1\l1 ,~,~. 1><'11 ar
....., ti>( _por ". "," I>Cnch "'1'. Ihcn ~-wnp tIM:
"'"""'. . 10 ,hc: worl;pIca n ... cbmp bIocb Of ;.....

wor1rpolc-a
redom" , he work"ic II.'iC:lt.

(oMn "I:Ia 10 l)!acr Q"

Qulte r... nkly, 'hl. ,. a

wlthout

ruulln~ ~ry

ha,illJl 10

,h., YQIJ an

knon.. The ....... 1<1 nome fmo' mr O<J<It.an<.knd$ eoIlcctWn.


, .pcnt >boul twQ hau", m.k111J1 the Jil TI><, maney 1
a"fn', _pc"" OII ,hl' lIul<Ic I dlll .,.,nll un ,,,ul, ,lta, I
ClIn' , makc

7S

ROIlTlHC Jn.AICHT[OGE U'LOOEO VIEW

!..

tM~

bloc

Making the Straightedge

c ..nlng Ust

"',.

Dlmensl on s

Millerl~1

/I'X4"x44"

.""",

II' x 2')(."
lI"x 11',')(4"
1\11" IC 4'1(4'

..."'.....
Itiudwood

H.lrclwood

p/yto'ood~""",,~~:,,;
..
~:~; ;~:~::
ebal""'
"

Tbif
N: Il sinlpl)' I
home-bn."""",
In <XiI,,_.,.,I".

1Ik~

bk><.'ks 0I1OId!cd 10
I .

JIIP' '" ...... br ,"" ptywood Iimu AI OM ~nd b


hod ....,.. A Ihmodc<l rod c:umd> t"""-wh '1Ih
bk>cI<. ""'"' rod hal
bkx:1r. Of! OM mei"
tho: ha. Thrn tho:

tianlw....
1 brus th/'uded

,n~n,

11'-16

1 Ut~ boii. N', 16 x 51t"


2

"ylol",,,,,," nop nUl'. "',16

1 "ut~ pLaStIC Imob. 2)1." dl.l ""tII 11'-16 blond


b<n. thrudoed In...n; 'D~l fTOm bod TooI
S4.0pply Co.I800-2H04211

6rywd ~ ..s,'6)( "'l

urr'ag. bolt, 11.'

"'nd8 _OM', II" '.0.

16

x 2"

"a...

.... UIt OJI9O$Itc md


biocl!. il :uuct...d 10 !Ix iii .". I oInP: boii tn.
tbtou!Ih I ~ adjIlM_ -'<II In "'" lma ' - t i
knob ... Wt bolt ..... JOU caii
IIM:

oi.

bthoatho:~
I

tho:liI8,~II ~_~:~?:~~:~~~

pipe'
TO ....
duop. MIM: tho:...

..-ort.:and Oft II. T1Io:II .....


hnd md."" pinch ,"" wod;pkcc tWollr

"""'s ~ >boul Ihb It !ha, .""


'"IOJ-' rrwdwtlom
bok. MOJ' nulS. Ind 'twudo:<Iln>tn 1. ..
_

an<! ( hnp. And Ibr 1I1fiIwlJ....

,,,III' .haI.

wor1<:>!

ulM/', ". 1.0.

I "...,~ plnlk .noO, 2)(0" ci .. , "",.11 "',16111""'9"


br.Iu I hrf!~ Innni 'OK 12 1 'rom RtKl Toci
SIIpp,,", Co

1. Colka
lheIx"'"'
hanJ~.
1,..Vbu
r~~'~'E~~~
Ilo,..,...
ohoppInH
JOO Iqm
_
ci 'hc
In "....r.oh<>p
hlI<\Iwat1:

... tu, ' 0"

don,

ha..., "I"IK local tu<\l ....'" .. III

.ho: ~noI>o . ....... ,...... """ .....,. n...J


.ub!.ti'lIla. ,......,

e"""'Y'''I,. "'"

16

Itouttt Mlgoc

kOUTING STRAIGHTl:DGE PLAN VIEWS

.,.-

TOPVIEW

[OCE VlEW

IOTIQMVlFN

II }'OII'" mind 10. II" ;d>ead :md m;tJu, }"lU' own


W<IO'l<b knobo. lluppetl 'o lil<c""" biR
knob:l
., bortIII1II <I>Ot"' ond ..,."., rom""", In woodwor1dng
....... Tbry..., <lur.thk. pro>idc Rft'" le>'<:r.IjC ro:: ca!>)"
~. wd ..., " ". :tU du, ""1",,,,1,'''''

pU,"'"

,1La,

2. 101:01: the fe " "". I "",,<1 .IwJ>1Cl"dc blrch rIr-><>d.


. ro:: '*-'y. h"t I'd rttOmm.tnd tomc !fI'" uI ~
"""" ~ It ., .. ~bk :md ..........
CuI fOUI' "..,mol,,, ,IK dimnuions ,,>if...d I>y 'hc
Oaairts U6I , ..... an . uI """""'. m;tJu, ,IK ~ 1o;Jrqp.,..
1IIontt. 1t }'OIImake il alIo;u )6 lndIO 1on&. ..... 'U IK ablr
~ . . "'" linbbtd gui<k IICRM mnd:onkl;oed Jhcct ~
picco.)1JU ....,. fiod IIK ou'" k.~h a
- - . :. 1'hc l'lnI!I< uI 'hc guitlot <hown ... 6' Ind",> "1' 'o
w... ~u,1ons

.-

""'oaulIrr ......
_

lhc sIof "",". 1 did Ihis <III , he ".,\I1e.

lMocto Mn\Rh' hoil, SerilK Ii!'lel "'mss

,.1lIe ..i,1>

,1.., .. r~IW"cd#.

...... ...., "Alb o f Ilie Mot On m:w<ing '~I'" .ppllcd 10


.... mute...ilie frn. ""',. lhc w;,j,h <:>f'~ rou.cr b .. Un...
'" ''''' IJ'Pf'OPl'iol'" m:oob. plWI#' tht ...... on.o ....., bI',
_ lIntlI "'" cmI nwb IiM "I'. thcn III' , .......... "1' 01(
.., biI lkpa' , .... prt'lCn>o. makl. . in<:tannIl""" dec"",
CII> umil ...., oIot .. romf>lctcd.

j . (optional) Apply "'m;n.;lIe 10 It., edgal,

I~ ...

olly usN my stndgh'cdll<' fu. quilc IOn'" IIn>c beii""


Mdding 10 I.ml ..., ... , .... cdp-IO

....., okld . ... 10

"f'<".k. Thc laml""e <lrct.'ln "1' , IK pIj.,."UOd ~ 100.


SlnIpIy t:O<Il ,IK ctljp aitb contan ttmmt. ond appIf ~
10 ,IK hode> uI ....., pbotic IamiN", ..np.. ruo. Whm ,....
cm ..... Ia dry .ud: ....., larnkwe to ....., pIrwood. bumbh M
..ith a}rolkr. ,hen ,n... ....., cdp:!. Ilu!oh Mth fIu>h.
trirnnImR boL Do "'" cntIs lIr$L Atit< IIKyW !I(:cn ,nmnlcd.
appIy ....., lamnole ' 0 1.... lonR ~ 'Th>t "'''f. ,1K Ion!l ......
....... strip5 ..ilI 0>'Crl0p thc cn<b o( the!horl l>rni....... st"fI".
4. C UI li", c bmp!n& blocks. U,., ""nlwood . houjl/1
1, <lucst1' , .... tI.... ""nlcub..,. "'''''1 tunJwood. I nu..It ,...,
h~ ar>tl p..,.."n: "">cI<!; rrom o.>l<. For 'hc 1211 bIodI . l ..,...
cucd. popi", "rrell' rrom ,h., ..:nI' bin bcatlSC' h .... juSI
,hc rigln ,hldrncM ond Ielll9h Cutlhc50: ~ 10 , .... dirn('n.
,;ions J{>ttificd I>y ,..., CUr.I. . LisL Nore !bc pn dirn.'l1on.
5. Form 11101; lipi..., 00 Ihc: tail bk>d<. Tbos bIodI
t- 3 rid,.: (It lfIU'IC ,"", li" Into !bc ~,"""'. >lot ,,,

k.,..,. thc '""" front ....b(1ng.

"''O ...

10 lOrm 1'" 5pIne. 1 """


bhct> on ,I><! .2b1c _
\li'IIh a bod<sno'. I Inmrn.,d tI><! SfJioc baei! on OI><' crttl
In~ it j .... IInt1ct 2 in<:heo lOtl{!. So .hal Ihc splne: wuulll
IIC'lIfIe 1"10 Ih., " KJOON etld of Ilie !JoI.1
lOC from
cnd oltl>c ~pioc wI. h . file.

"',,1\lIcd

Th rldge I,,'t "'IW"n Iwo ... bbl!'u Iocks InlO tn ..


1I""glll~'s "ot. kupl"'llIM tail bIock alig*. Cut
th .. r~bb..u 0tI the tabl, uw. Alt ... mikl"ll IM s ..... lIow
shouldto. n.u. ",i ., thl blad .. and adjult IM .Ip fllKe
for the bis .. cu\!. Cut so the w;o.ste f"lIs tO Ih........si6t
of th.. blid ....atM. tIMn IM!i"'ll trapped !>ttw.. .,n Ilie
blade iod the f.. lKe (whieh would I"'d to klc~b .. ck).
6. Insta.ll tile tail blucl!.. Thc bIoxk '"

I_~JI ~~~~:~~~~~]~:~:. ,. . .

o(

"'''L~ .

"dd in pbcc ... Ith "


hol' hole:. OII Iho: badt of ,t>rc
bIoL.... loc.".. "'" tJ<k'I ttnk1" of 1"" pitct.
'~h
I'ors'n~. hit. drill .. ~I>dp eoun rbon: 10 tho' 1""
bolt he"" will bc ~. Sw;.eh ." " 'Io.lndI bot,
.nd LIriII Ih" .h.nk nolc.11I" hol<: ohooIJ
IIM:
_
end o( thc sploc. 1'0 ~eadt .IM: ...".l<pIt whilc )"Ou
drill ...... il irlto IIM: "' Iltlght<"<lgt 0loi and pul hoch JWU on
.t>e <lrin praf ubk
Ori>'<: "'" arriaflt bolt in." .t>e _ . thtn inoct k
.hrotl)th 1"" >tr.d;g/>lcdp: Drop
lalll<' I"m<la.~
lII<:n .hre.d 1"" I<nob onto ,t>e c:nd

""NU'"

Improu Ih .. <ymp's irip wlth .... nd~per. Tht ""'"


coml"'ll of Ihe jig\ compress\oll ,;,mp,ng systtm i. 1IIe
laek of ... ctlon OtI...-h wood surfae." To 1<<<0 tht
~wl 'rom shppi"O OUl of pos~"", an t~t S!rl,g~I\~.
and to imp,ov. Iht j.lw. g.lp ... Iht wo<kpitct. glu.
Sind~( 10 Ihe tl>t! j.lws. IS shown.

\Vo'" "

""'' /'li<' ..

()fl"'"

8 . Nocch lhc: bloc ..... Ikllh bI<><b m...c bc:

JlR"ido etnnna lor pon. of.M ~ . . . ._


"" )'OU nIl 0iCC r""" """""bIJ' IN/" II. l'itMd' .t>rc hc:Id
10

bloc..,.. ,\>"""",,0 in tht dr.IwinllltU<lnt!l9'


IN/aU. lhe bol. Ih>I pro'icb Ihc """""'" olClIIll .hn>Ujjh

for Ilie >lap nut . an<! "'" prc:>SU'" bIock for III" bolt
TIM: _eha'rI'.t>e _
" 'iLlt/t bul <Ii""rc", dep,hs.
I CUI .he n"t~h"" on tht l2bk ..... StI II..: bbdc
10 .... Icll IM dqllh (lr I h~ """dt . St2nd Ilie: hI<>d: an
and (lui<k " '""n>SS ltu: bl>dc ",i lh II><: mia ~'.'"
re"""laI CUb 10 cint thc ...-...t"

hoIt drilkd ~ .t>e n,iddk o( "'" /JIo.Jd<t, n.., had


bIol.. tta ......... pon lI<Ik' TII" fItSIlncII b l>IltnI ,.. pilot
hole: for 1.... Ih~ Insc:n. " 'hlle III<: mll.inl"" Imgth ilo
bof't<I ., da......,., hok: ro.. "'" hoh. 11Ic hoit In ot>e prn'urc bIock .. . cInron ......, lor
bolt.
Tu cn."rc .t>e hoIai .ill bc propaty oJlgnC'd. oei up,
k:nrc and 0I0fI hluck an "'" drIII """" lIbk tO poohlon and
hoId IIM: bIock bcil1l!l <lrilkd.
1>0 It>e _
bIc)ek fi"" a ...d: It>rc bit for IIM: Inscn
pilot 00Ic In ot>e driU prt...
of bit to ...., ohouILl bc
opi1k(I on Ilie: in.cn llIt ",",nell i......... 1 """ ...q,~n:

9 . Iklve tbe Ihreaded ' .....,n. 11115 15, ;',~::;:


dkry """rotk"" bea""" 1,,",", .. hul Inln
Ihc: pilot hoIc and It>e ,;u.btt of Ihco bloo.1 ".~ C",,"
<lOII ,h'I\ w:IlI wJtj", LI'h'lnS "'" iII>en.
For ilih'cr. uS< >hon hoit .ith two ""b un
oJwtt.. Tbn:-..... ,1Ie: b<~I. \\'ith .t>rc .wo nulJ oIrndf on '
IIM: I"""'.)am onc nul "Pln>l Ilie: Irucn, lhen
nu. -.p;rt>I '1Ie: ~ Qomp Ilie:
tO lum .he In..,n an<! boiI , anLl "r1~" It Into Ilie:
Wh cn It 15 fully <Iri,..,., ....;.m Ilie: nul .... Ihr boiI

7. I>rtlllh.. :rdj""lmc:ntboh holC!< in Ihc: h e:rd


",,,d

p"""'''''''

ti,,,

(11,,, "',.,

78

Routt. l14"gl(

ASS04lLY DETAIL

'""

~")(

lKIundcd M1tboul

TaJlbIock

SI'>" curiage boiI

It" )(

2" canillgt boiI

bac"'"" It..: In,.,.. "U l of It..: hIud:.

10. AoI8emble the prc:!lS .. ..., o"",ha nbm. n... kk:I


0010 /mat Ibo< boiI Ihrouglt ,t..: P"'U'" bloci: and lrAp ,t..:
bIodt ""'~ oM bolt lw::Id.mI " ;top nUI.1lM: bolt m.....
lor& 10.".. In It..: bIock. ,.., rou ean ll>rn It..: oul opirts<

.....

1 . - l I .....rbtIC boii

,<>..,.,

h~",

' 0 .110 ... Ihc- bol'


fIIed 01( It..: CUt'1><O'"' o( Ilie !>oiI ' ,;quan: ""'blind."
fAII\pat'c" I lonK 1Icc.hc-'.... huli "'"h I arriaJlc boii <>III><:
.-, ntath.You1I .!i Ih:i' Ihe: hO" boiI h.u onIy uhon ......,.

.....,..1

_ of \hmod!; . .. hlle II><: a rrl>1I" hol... Ihro.kd "'sh' up


bnd. 1lM: t pplk... rlon I"njulm. mort" Ihlnlh lhan Ilte
... bolt ""'""'. Ikn<:c:. Ihe dJOi <>1 orriaJj< bolt.
lDm Ibo< boiI. and ' 11 ........ Ihc- ."'''' n... , .. k. A
IIOP'" ...., nyIon In,.,n 111:11 p..."""I. k rrom 1o:>oKninjr..
~. a ;top nu l is h:inllo Ih~()nco: 11w:;o,;"..,.,
....... III<" bolt"" '11 ..... <1$, )"U ,,",..,
II wllh
you can, do II ...lI h rotlr fil18Cf"S.
fii Ih<" hc;od t>k><;k onlu <h<: bol. ""'" Acid a ....,on<l
IIOP "',Ilten 1"" pl11c !<nob. Thm Ihc- knob onto thc 1..,,1t
. n ........Thcn b:Kk Ihe",,,,, nUl "1'10 Ihc knob.anll j1rn
I opln;Ill><: b loh.

,<>

""*"';

'o ,um

II . Momit Ihe h c ad bk>ck "o r.I>ec SIr:a1Ilhlwg<".

\bu CJ<'I )d\lC . nd "",..,... ,Iw: hnoJ bIock 10 IIw: ..... Ijt.h,~ .
1.... 1I<tt:"W> only.:utd Ih2l . IM-m ""tI~loty
""'Idon Ihe he-ad bIodr.. as """"'n In ,1Ie drAwl" l!>
s....... ~ ..I,h I damp wtlil<:,.,.. driA pIIo! _:utd d,h..,
ok)'nII ~.I d"",.., 1" ......,..,...., IIuou/Ih Ihc bIoek 1"'0
.... !l ... ighlodll<. thcn flipPC"d Ihc mt;, "'..". .nIl <In,,c ,,,...

Using the Straightedge


n...

rou. lnll ;tr. lglllwge I~ c.:osr " , ""' I<Q(I61 clcpIhdr>o.You .dj uSl lhe il bIod: ~Iy lor Ihc wkllh of
.t..: """'piece . ..,1 , 1Ie !igln place. lhco til!.hteo Ihc p"""
...n: hl<><:k.
Rul )"Ou do "",,. .0 meaMIn: anei 1' oul !t:i p".ltlun
vM-vtt Ilie 10",..100 <>I1hc- IOlrnckd cut. Tbe ..... ighIC(lIl"
It "QI a 1'><1"' '''' 1\ """" ., )el iucIf ~uan: '0 'M nllI" of
Ihe
Mo"""..".. Ihc ..idlh <>1 Ibo< cut ;md Ihc sitt of 1)><0
fOI>ler baliC en,.". Inlo .hc oetup. "'" as t!Yy do w;lh . "f.
or <>Ihcr """CI" gukk 11=..., In) "'v ~II"",,~

_pk<.'"

"'l""'"

" p /rQ'" I/.W "",.... II... I>{"'" rul Thl. IJ ~';r to


do Ir Ihe t.a...- wmcler o( your !OILtC\" 1 01 ruund
n" rnbcr_lil<e 6 india ".. ~ 1""""'. You h"&l1o:. Ihe cut".
uoler Ilnt. IMn """""' ~ Inchn ".. ~ "', Incllfi or ..h.,
~';cr 10 rn>", Ihc >tr.ti:ghtcdrlc lQo. ioII . R~ll" nJlCSII of
It..: widlh cllht eY.. 1ht olfSf't fn.>m thc cenlcr line ..
al .... ).. Iht samoo.
IUlalIl> ~ G"ugt$. An oIllct Pili!<' i I pM: 01 !wtJ.
bo<mJ .... Ihc 1ik.m ..idlh .. Iht """"'III .hc- "rA!jhI""
hcolllct from Ibo<~ rlIhtCUI.\'''' ~"nc""
0/ 'hc PLlf!lC . . . "" Ibo< b:youl lin(, for Iht Cd.. Iha!
lloriJW tht: ~Icdp: up ." Iht Othcr ~ 0/ tht: PLllll'
C"'~ ..... as)' \O a ....... ;...., " ()ff"o.1 ( "",. "" P"4!IC' j

". ~t

ro""

LA""'I OII' IIM 'IlO posl15oto ,eq ... rn VOI! 10


mUSII,., ,nd ~ OUIIhe (III. 1Ir.... 1Ka..w 1.... IitRlgoht
fdge
5q<U'" kHIt. VOI! nHd 10 Ulend 1.... linn
Krosl 1.... workplec:t. Theft vou nHd 10 O,,", from
III, (III 'nd ...... k 1'" ,,11(1 pOloltlon. WMn c~mpi",
III. 1I"lgIIled9f IN! 1_ 10 "!!In bolii itI .nd, ... ltlt 1....

won'

IIVOI!I """k,.

80

ItooJt~

Mo9k

Senina 1'" slRltlhledp .lIh '" offsel ........


elimin;lleS IM need 10 (~Lllt Ind IIItUlire the
ofI'HI lrom tht CIII.. kll VOU 11111 mllSI LIy oul tht ''"''
KrosS the workplec.e. lJJe the 9a .... al botll tnds of
IM SI"!!IlttedOt btfo,., ll"hltn"'9 t~t ,Iamp.

'-.ncn.
l
~

$<1"""', but lhb ~p""<: b a

lfict.t T11<:
fmm ,'''' ulooflh<' bit t" ndI ""'''' .... ur
booophtc coJw;$ " difkn:n. W"h .Iri> I:>:;uo:pb'e. ,'OU
<lfW"I tbo CUlIIIjt wId,lI o( anr ...",ipll bit In )'OU. c0l!ibi, MoI ,.,..,""te roon;c:1f tho: abiIiry 10 produce a gmllct
..,,1DUItaI """8C" o( cu",
Thio """'" bakpb.e ..... ~Iopcd br NicIc Enjder, a
proIik
of .."QO(/'<,'OfItlnJ; booIto.
!Im:'. Ilo'" II ..."OC1tS: U6c Slt:l'iP" hit and """"C p"'"
.... Ilie I>iascpIaIc' .,.".... ",de "lI"l1Ul thc: Iim<:c. TIlcn 'uni
III< ....ur .. I ~ ' . Il- !lIk l; olj3illlll ,hc "'nec. ot>d mai<t'
ltOOI\ol ~ Tbc: :odditlo.....1 !II ind> bel","", Ihc bit and lhco
net MIdI
10 II'" wkltll 01 ,,'" "'" OII",. oi<k:o o( tho:
bootpI;u odd \oM inch and & nd1lo thc le.... CUl.

"m, ...

'- Incb

nu.... \_!>il couId produec Yz-Inch._ da<k>c;,


-......:t..0I'idc ~
kk dadoes, and '\>o.lnch
riI< ~. " .. "" "mple "" 'umidtl ."" ..... 'c. ' 0
~. diII'ftrn, ~ lIgOIllUIlhc 8ukk "'nec.
l"w.. 'Hn<tI tii, wlth .his ~ iP"'" )'OU <.bdo> widtll>
ti ~ lDdl, ,~ Inci., " Ind!. and ''1\0 incI! A \'. .tnrn bol. lio'''''
nIIb> oi I, indl. .,.,. In<:h,.\t. inch. and ':.\o, inch

.......,I\-...

re}'Oll"" n!tIIIy dc\'cr, )'OU'U xc 1hI. NIci". kko '" an


.... u..... 'o undcn>i'tC<! pIp"OOd. Onr o( th<~ <1 pIywood, <Sj>a:tolly h2nhoIuod >lui!', Is
~

.Iu,

~ .. ypir:2IIy. 64,h O' a j2nd \IIldIenW:d . ...... 11I>UnCC.~ ..


inch ~ ilo moRe liI;dy "h.z lndI or '"" 1nch. 1... ttlQIln
thc <b<lo J'O" "'" ~ ... II "ilh )'OUl" ",-Inch >ir.tishl .\ lMImlns.
One :iOIu.\on ilo 'u buy Sf>C'd:II d:IdoinS !>ils 1Iu.. ,,"' I~...
Inch. !JUI k:so COOIIy !oOIueion I~ It.> ~ ,"Ct>ion of Ihl>

frocllooutU!& twqIb,c t/ul'U <allow)'OU 10 m..tI<c ,"""" uH


~led <bdoco in ,,'O p;lMC!I
~ Of '>I.Inch biI.

","11

Making the Baseplate

w"'"

In III .. sltu.ulor! '""'Y accutlUe


i> oonII..i;;d. 1IK:IlJ>iC II
b lough '0 "'" lhe Iwq>blc lrimrncd tJe:od..oo wilh )'OUr
n.... ...""'..... 1'"" 1ndU<kd tiP'" OII flnunlnfj IIx: ~pb"'.

1. Cui ",nd n lOUnl It"" bbnk. Cu. a sq....., of


xrytic OI" poIyaut>on>IC. makl"3 li . boul an Ind! ar ..,
Iart!tt
III(: f:octory b<aocpblC. I.ca,.., IIx: pn>I~", p.pcr
bonded 10 IM pbslic for now. Drili mounting~, ,",Ing
IM &ctory buq)bIC"OS '" lemplalC. For th<: """,,plalc to hc

""'o

OII ,Ix: mut.". but, ,..., itI.c tO mounl k


11.1"3 nalhcal >Cn:w'. (Sec Ihc """pl.,,. CcnIt1'~ind;'"
~ . OII ~ 8~->"'i> b<ascpLtIC Qpc<:bUy t1a'ds to
bc ""1I'-<:,",lIcri"3.'" COWM,"""nlr IM moun""3 hoIoeo.

.,lf-n terin&

MouoI 'Ile

~ hLtnlr

an III(: rQlUI:t.

FRACTlOHATlHC USEPLATE LAYOUT


For, hljlwl ukee .ou l ~.
(wrtl! I 61'1.'.(11..
1

0"

3\11.'

3. Trim lne baKpbtc. Rcm<m::.hc bbnk (rotii tii<


Me"'uro: rrom thc: anlcrpoinl In I~ Il.,. >idc: . .
nuri< It for lr1n.ntlng.( H.,,<= m.. Ix tht: ttn;> 1Itk.) 1 foond i
hdpful. n layin3 OUl II.., c<m. ,o ""ncli JII'fJl'Cfl'licl.lrs (ad
di>gQfuILs) lhrouIh ,1Ie anterpolm. In addidon, l found th:t!
~ OM Jidc and nlmli:ltd l' CUltln& ,ha! :!idt __
mllcd conft$on..,." "'" ttim a .I<k, n.. '" "'hid! oido i ..
(::l'Q, .. I.j .. ,nd "" iOnh). 1 m:odc II.., ... CU'" on ' hc l3I:Lk _
When Ihc ,rim cutS:&IT (Io:)M . 1'1 Ihc pnH""'n,<= popa'
horn thc ~pl.:tlc. As )"" do 1O. I... n!okr Ihc bhcb mpo",,' 10 Ihc pl' ''k" IbcIf 10. permanenl nu"'''', INdt ..
SanfonJ ', SIw'pk ....!II do lhc: Iob.
ruutc1.

t""

F--'."-+f-'f---"

4. Bore: 11)e: bll ol"' .. lng. Wl,h Ihc:

0 "

o ~

,"

~%o

Qty.

,"

~I.

' hc: bll opc:nlnR. ,"o.. an d.. ,hi> .mit I


I .~i'mdc, 1>11 on Ihc: driU pro:" or by "''''''''''IiIf:
Ihe b.sc:p"'c ond pI~nll " 'Irh " 1.1"JIC""<I1."".ta
'<r.Iighl bit.
Irlmmcd.

5. Tati lilc basepblc. "fh<o

proof~)"OUr

,,"ol'k b irr

LIIC IbdoInR. DO Ihe follo,,lnll. Oamp .T~""'" 10" 6-10


8-Ineh..1<Ic SOOftp. (Sa T~ ...", on pagoo 6<1
p/ani.)
WlI h .he "(Cru . . . . fi<Il"lllhl~ fenec. l'QU\ d>do :ocmoo ""

ro.

~%o

Dimenslons

MAteriAl

14')(T)(T

Plastic'

boanl. 1\rm."" 1OlJI<1' '" ro:ft:tcntt lhc: """" ...ith ""


.. 11,' .si<k. and l'QI,JI .bouL ~u:trtcn ui lhe ,,~ lICIW
thc: boaRI, " 'idcnlnM \he dodo. ltcpc:al .... llh lloc -..
lIOing .boul lu lr>o.~ F"uWI!', rotii .bour qu:rn", or,~ _'OI

It -.

w;!h ""' .. .,.>lde.

Se! \he ""lIe. asi<k . nd ""'" (':lfd"LLlIy m<2SLI'" thr


..;mM
Mur difkn:1l1 on:tiun>. DW caii""", ...m!d~
)'UU' ,,.,,. a("<'Uftle ID<'a.'>W'CDK'nI . lf)'OU h;llhc incf'CMClltl
on 'he """", p.u JOUr$df on lloc "'d. lIut i( " ' " mlooood
1ltem. do liu lt rlflNuni ....

01''''''

_ _

2. Mark lhc a:ntcrpnl"L 1010'"'' 'hc: I);loc,pbLC


bl.nk 00 L~ n)lUCI" O"..,k \'.W'"...ing bli In ' hc: lOlJIe

1.0_'" Ihc bu ,~it ,0IId>n 1"" bLmk. Thm Ihe bu ~ fcw


.Imn br luoo. marklllJl 'hc: ccuC<JlOl.nt 1'<.11" LI.., saU ~
xcurxy. kccp Ihc rrwI< as JRu.II .. ~hk.

hI.rk ti, .. baseplal" bl ... k's ""'"lerpOl", by Iow


"Ing. Vi]>OY"IiI bll 10 t he blank, Ihen lu."lng it by
hlnd. Vou ~I\~' need l>Of wlnl I Ilrlile mark. so
don~ ove.do il.

TII, proof of )'0'" lNooeplale's aU"'lICY lIes In


acl.w .111 . He.e. I'm meullLing li test .ul mlde 11$;119
eacll eclge of the b.aseplalt, and I'm joll;n\! down l/It
me.. u~menlS 00 I .In ;usen the needNl flnelunlng .
TM ZItfO edge . ..t wil! equ.llhe bll dl.mele., MI
m'lt~. wlllll. It S 'n incI! lIere . Bolh rlle .. !ILo and .. '"
edgn lre ~ Inch unde., If th ... ~ . td~ i. 1Iiso ~
Inch und,., onl)' thoc zero ed~ will lIave 10 be joInled.

....,

Fine-Tuning the Baseplate

rtATi fAllltlCAllOH SEQUlNCE

OI'

MiPwuee
IOUltI
_______
. ,_ _--.I.Mount.n
OY1!.slzfi! MlU"~
of iii" Of It uryhc
plastic 10 the

roult' NSt. (In


IIIls CUt., 7'
sqUol'" 1. used In

plac, of a 6" dl'.

5Iock bl.sepLott.1
Ike fLltM,d
I<",WS lor thols
~,d~n of 1""
style us.td 10
.Iuch It. .uxk

tuo"pl'lt.
_ _ _,.,._..,..-.., 2. Wlth the bl~k
'U.ched 10 the
.",
"",Iti but, ,"StiU
"
V-t'OOVIng billn

,"" roultl. Tum


OII 1M .oute< ....:j
adJllillhe C\ltUf'IQ
Mpt!\ MI IM M .
j"ll touchn 1""

".

--,. ______
,
t

b;tst~lt.

"

.,..~I

tlnterPOlnl.

(rom tht roule<.


Ind tfim II. uy
OUl and (ul tM
.o-~

fini

MeUI>f<! (rom

the

,.."f,poinl.
Uimmlng \oi" ffom

.:.

on:r.,.,.. ....

'ruftI ."..,.,

)",,,. lhc ~ an your .....('r talIk.

2. ~ up thc rou,tt tab le: for jolm.lng. u.: ...,


Splk I'mce p<nCIUo:<I
plIf<
'0 ~ thc <-'UU To

an

__ -

(tbc' Irft haW) .. 1\lIc ~ .Ioc inb:d


01I0Il (.t.. riIIhI haW) l<tO<'d. I ~ ~'ttd thIdt
.......o 01
paptt _
..,. dia! caliptn. .......

. . oile.

_~

~ ~ 10 ..........

(1""". ..hal , !-o.d 'o""'~

u..

llOIll'cftl ~iOn II. Inch

.."...,.. \.;. ndI fn)m an ""'"

,,, ""'"' k .0 pcrf<nloo. I applio:d "*'O ~ 01 nWoUt\Jc


IIpc 'o lhc Inl'tt<l hali oIlhc
II """"0:<1.)
'-1Ih ' hc knu: fKlnJp ~. ""Iust.""
fI'JOiIt~'" In
""",100 ,0 lloc
~
,ho;: 00tk<d >rt"I1on ollhc
"""'" '" WlI!I""l ,a t"" ~ <>fu.. bit .

"nco:

3.

nJw:. Tbc: _ ..................... rdlablt


your.......,.. il 10 ..... ~.1th tho;: ba...-- I_'"

Trlm lIwe

..~ ... _

pUte ..... thc:n _

... lh",n. 'IUttt

ono:

;"' 0 pcrfI

."'" .. a 1imIe.,\obkJe ,,,,. cut, - . - . , ."" cut .'1<11.11. """


trlm ,..., ttlW .. ~ Tbc:n tn:tl< I ta< c .. , rnn>UtO: 1""
cut wtdth, .....
u.. o:dJIt: ..
Il S "'pc1ltl\.... j'<"'I.
;ond

a N"It:

t"'"

t"""""'.

,,,,,,,,,,do

Trim 'M <Mite.


~. In IM

t"'"
ume "shion.
Tilkf \oU' ',om ,""
_ond~.W

!rom IM Ih"d
edge:. vid 0tI1y
~.Iromthe

foun". tabtol tho


""

~'

......

.,'

.,..

.....

zr

joinI ..-idI1bos ",,"-, ,..,.. ....... 10 thim ..... thc

1""
1..aIMI
,/\jo,~.
e0ge "O"

t""

bi'.In"'" ""

). - - Ilie bIAnIc

ro- ,~ an<!

1. Aslic:soI
~hu3tIon . ~n ..,. jon~ ......... oile
..'\dtlts ollhr dadu ><W"""u and """"""'''8 .hf ......., 01 oile
n,nl"ll,,,"r. ncedcd. 1':aU IIIC: ........ ,....
pIy
lI<"C'd 10 *iIII IIWcrbI
0 1 ' - ........ Bul II OM
Of ~ " - ' )'OII _
10 Itim Ihr """' cdF fInI _
....1ono I ~ .... mei MnI. r. ~ ~ """" ......
a 16th. Ibthcr.I'. ~ j2noil mei 6-kht. Sud! aQ..., , _ - .
...... 1Inoe 10 bc"'- an tbc' Iabk _
""'J"IiC,JiUII'e.. b ......
pbmotk ..., 011 IIIuNrr OII ~ knna. $o W'h:>I: 1<> ~

"nco:

INIrklng ,""

Th05 15 .hf 1~ pha>t oIlhr '"'Oft:. bkc


.."O<to; mnhol1icaD)'.

edges. IS sl'lown .
Joln.lnll On the rolitU Ulbi. II tIM ben W'~.,. tO

mJkt the fine (un n.eOt-d 'o fine-tune "!'Ou' bilKpI.tt


NOtt th~t wlth 1.. knobl 'tmowd. Iht b,a le un bt lift
on .ht b"tpl~le Whllt lht }oIntlnQ II dane .

1f)'OU:an wud.Ing wl,h ~ n.nl-b;uc rou'n", and If , h..


l ............ "" ~)'UU .huuldn ',
relJlO"-e ,1Ie
!w;o,pbtc ffUIJI thc __ 'O ulm k , JU! puii "'" __ (rum
,hr 1QUtn" """...,
Mie< ,hr first cdIIC b juot """' , , .. rn 10 'hr KCOnd nil!<'
\Ind 'W'IC i, in ' hr $O""" ""'t' tlml.", do "'" lhinl ' pIu> ~.

h,"" 'U

Using the Baseplate


Onc~

)'0 .. -,,' .. ' .... .-..1 ~nd n ...." ut>Cd II... ba..-pb'''' )"U know
how 'o U5C: il. Bul. '" n::J>nI. ro" m.~c <:ul . IIt1k1intt II...

..__, """a

r-

i
-r

ren, l1>cn )'UU tu rn tI><:

\III

lII""''' tI><: rcnc.:. anei .......

W"'" ""'y no, "" .... RI~n' 1. , h., n","er 0/ fn:d 1Iiftt
,Ion If)'UU mUc tlle n"" p;lSII .... I,h ,h~ "",.. cdj;lO >(IIIimt
II><: kIK", ,1><: S<>nd pas;lI :sIIou1d II.: f<:tl In .1>0: oppolitt
~ . TIw '. """'~, ... 'hc: dnw l"3 f'effl OIrwtIoo
s...~". aWto clcar. "'" ~ p;bO ,,"'OU1d "" eUI1Injj ..
,"" .'li<It: ul .hc: dodo oppo!oitc' 'hc: r~.
If,.....
nWtc bocit ~ In "'" """" Ilin::nltool.
bc:
)'OU ma~.. ,hc cut wl,h thc " .. . . . first. M>h .,
~"Ut .... i.h ,Ilo: !Om) cd!I< second. T1u.
toc ..........
tiI<: cu, .uwanI.1><: kne.-, ... ~ .Jun ''''>1 frum ti><: 1;t>Ct.

"'n::

""211' ,..

'"Y.,.......

FEED DIRECTION SAAVY


SECOND PA5S

FIRSTAASS
j

.. ....,

~I

ti

rout~r 5Q

(cren, baoc"pl.tc t"d1lC bc:t11o


1iC<.'Ulld cut.

'z ~,..

"'~,

FHd dl(fl:\;on

.dge Is ;tg;oins, ,100

("d dlree'lon ..

l~fI

f~lKe .

'o ngh'.

Fud d''''C100<t

'+" edg' 1. agilnst ,he fonce.


fud dlrec'lon 1. rlgh. 'o I~ft.

-,'

.'"

Fud dnK,ion ,...,.

Thls Is ~ ellmb CuI. Tht: bll winll


'o puii tho rolJI.r Ihrough ,tit cu,.
SECOND PA.SS

FIRST PASS
",.

.'~,

~d dlr~ctlon .04~

'+" KllIe s ;tg~ln~1

11It

fenee .

Fud dl",aloo Is lefl,o rlgh"

fHd dirKIion . . . . .

"Zero" edoe il a!lt,nsl,tIt 'enee.


FH<I direeuoo i. lofl 10 ri!ilhL

Cente.... Finding Baseplate


~1c.lJ

Ihou"h It seems, <II simple g.eometric


";.cip'ell the seuel be.h lnd Ihl$ fllture .
WIth It, Itle bit un usily be eent!!.ed ilCroSI
ilie workpiea.

~._.

'"II
1:"1

!._.

ID

mu:rins hule o mortis<: ~ iV"O''C ti" .he cdJlC


o{ wortpittc- ...1.... , .. 'ough. ~ .00
..mbi"8 "'yo.u Iinoi NI"' 1'01",("'" Scttin8 uP
Pk' n,n Ix ."...,..,-.".. '00 an gel thc: CUI t * - '0
mMt. tu it \o oddom rnIIJ' (JfI ttt"."..
Htlu. >implr baM'pbfc , ... , can Ix nwk In a .IMIrt
. . AnII il _in alm<loI ....pcally CUlta. CUI an ,,'on:
pi<'. TII< baoepIalC """ ,"'0 pin pl'()jc<:tln~ r""" 1. Y....,
"' .... "",,,,, .!Op ,he won:pka. with pin un oeh ;kk
T9'hI ,!te rouln 10 hri"ll bolII plns In COI1uet ,",'i' h ,,..
d , Ilie bit ",'m
ccn,crnI un 'hc:
1hr lrIck b >limpk ~ry n..:, pi"" m.... Ix rqouIolb..
. . /rom , ... bit lXiI mo.l
Ix OII :llDight ti"" ,"",
JlMtjIhrou!ll> tho: bit :lX, Tk bII ,,"il! .z...~,. Ix ~,

.u,oou'k'>lIy'"
m"'"

won:.

'rom ...

... ........ ~ oi tho: ""!II<'


hk"h )'OU nlaM'''''
,.. In :oll ""'Ilie. pn:<:ision .pparmos US<:<l ",I'h ",cii
jnCIiII JkUI ;, thc kcy 10 ~t>Ca'S:lI_ In makJng ,1", ty,u,;.

1**,1'1" mll>l

Ix: p=lo;" , LIIy OUl an'" drill aU 'hc:

.., hoIo <'1",'"U), IIdo", ",,jng 'hc: ........ p""c on JI'I<XI


wodc. ~k:c Usc 01 oile Iuoocpb'c ""lui"'" ~nc:s..
b fltml)' . IIXhN 10 Ilie """er. bul .. don.n
h .... mulro to IM """"pic' Kct;II"lI'hc: IUIlla "'I0J;In:
ehI',.'Oft and thc pin< In COtII;Io(.'I witlltlM: ..'<>It ~ Ihf

"., fU"""

.,-u"....job,

r',,. ocm

lhis .!lOt! of I>cpb'" fiII"" tu ~ fixc<l.b.oM:


but tb..., RIQR: ~, 11hInk. In UWl8 it OII a plWIlJI!
1Ollln. ''ou C21\'1 tmk~.
cUi ..,i!h il.5imply!>ta....,
bodl pios mllM bc in COr>\:ICI ,.'ill> IIM: \\I'OIk. lk"pc",Unl
up>n IIM: pin pbttm<.-nl.)"" nlll)! btWn an<! cnd ""y CUI 1
routef,

"''''''III'

IO} i,....:I"'" fA"" Ihe eII<l of IIM: .......t. Stof'""d "'"' like thc.or
ore Ihe Mulf of IIM: "'ulljIC """ a",1\<11 IIM: ftxed.b;uc rout~

Maklng the Baseplate


bdIpon ... rnlIy a okno:: M bu$hi,.. 0'VCt' bol Tlw: bol.
Into. hok In thc pI.,c. 1 klalN tIM: pim 0I11>i<k
tIM: pcrin>C"l"" of IIM: !OUl.... buc:, whk:h f"'O"idcs "'i<k'
~

"'O

ti .... ~ ~",br.; but <Ioc:,.;n 'l le. tW !OUl


dooic ...
c",l. of lh~ wortcpkc", lf )'0" ,.'O", ' 0, rou n" ....1">"
."ion .hc h<>Id clo!icr 10 .IM: 1.11 (M driU :arod "1' ~
~

,h~

p:oits of """"'),

If critlol ..,.., pin ...... m"" bc cDC\I)'


from .hc bit axif. and Ihry m.... hc (>C'<p<'ndJc.

Ac<'U/'Xy
~;>M

ubt tu iho<

J'b'"' MUbtt.

l. CO U~"C1 Ih" hardware fo r 'hc III"., ,"ou ."" !1"1


by ,,"'II t\(Iw.:ls as vins. IIuI I ~ AIIJ\~ bil's pilot :b
p .... d i!(ln; I bc.rit1jj_not 0I0IkI pIn - b pn:try much thc

"

CENTERflND'NG IAUPLATE LAYOUT

for Bosch p'unge rouler


OUII ine of rou Ie, base

.;.;.;.:.:.;.:..:..:.:. .:..:.]~t~l

-i!.:~.:.'..:.:..'.:..:.-.:.:.;..;.;..;.:..;.;.:.=i'i~:.~.~

..........,

Sc:ribe dlamele,. and


lay out pin holes
equldisL1lnt f,om
Ihe eenle,.

---f-f:..--cL-~-----

'

,
,

,.

,
Mouminllscrew holes

-;;--~.;--

3 !Il"

.. ... /
'

Q. . . . . . . . . ~.~;;:;;:
. . . ?:
......:":::
......::::::
......::::J
......='--..,

uy Oul baseplale on 8' square of acrylic.


Ihen !rim 10 Sdia. ci,tle.

Orill ' Jt..dia. hole, and eUllh,ud. fo,


pin boII wlth a W20 tap.

Cutting List
ParI

Qty.

Baseplale

PIN AS5EM81Y DETA'1.

Dimensions

Malerial

\010" )(8' )(8 '

Aerylk

Hoit. tapped

IO'~'::::::':'.:i

Hardware
2 roundhead SlOve bol ... "'20
2 hu nulS.

HU nul _ _ _ _ _ _-

2'

~ 20

2 plastic slee"... , W 1.0.

~.

0.0.

x l' lonll

Plastic sluve
!(' 1.0. X W 0.0. X l ' long

Sland:onJ lh"'" d.)"S. Sa I rn:tde plM wllh ' ,~.., b<-:Iril\jl$;


....'i"l! uddmen.. rrom 'hc local hanJw.1"C SlO"'.
o..y .. ~"(luplc o( ruundh~.. d "O\'e bollS w;,11 nul r....
"""".n.e ..,-.,,; an ~ brun"" b",hi'~ Of 'in,plc pl."lc
'P>Ccr5.lIcl"C an: Ih rcc 01'110=

1'' '>1''

I. U..- a '+lnchI.D. X Y>-iO>Ch-O.D. X Hnd.-Iong


sk<:<.., ilS ,he bc"~ril1jl. . 0.>$1 : .bou, ~'O cefii' each.
2.IJsc '4-In<:h-1.I1 X h-inch-O.ll . X 1.lnch-lon~ h,oro>.<:
I>lI>hl"l!. 0.>$1 . boul $1.20 nch,
3.U..- .. l'rinchI.D. X 'iHnch-O.D. x 1;nch-ionJI brom:"

hushing In<ido: .. Ifo.lndlU). X h .jndl.(), I>. X l ~ndI1onjc


brun"" hu _;hln~ . Co:st: .b",,, S3.W ror .,.....il palr.

2. M.. ke the baseplate. Itdi:t 10 thc eruai>1cr "'11>(:


Gcn<1ic lIa.cptllc

86

UrI p2go::

Rouler MagIC

63 for 'hc dc,aHs ur huw 'o

'W'_-----

!4" 20 X
roundhud SlOve boii

OIIlUNI; SEQUEN(.E

1. StI Ilop blOdl 101lnl' bo,h .,elou of blank. "",h bol


haIoP dirtcrly under Iht drll! brt.

1. Aflt. d,lIlinO ,rammtl.plvot hoit II blthOlt lociUon.

,It.,

movt
,Iohlhlnd stOp block. Inltn il 3'1>"",ldt
Ip;lctr ilQllnst Ihe blilnk. and 'Utl Ihe $IOP block
aoalnlll1.

liIy out hoit, on


xryIlc bli!nk'5

.owlmg piper.

Bil'hcW locillion

1. SIliti blil.nk iIgiIirlII tht righiliop bIoc:k. MId drHllM


In, pin hoit.

4. Rttu,n IIM blan. 10 11111an100 POllIOn. and reui


IIM rIolIt ~IOP. Mov. IIM Itfl ,IOp ind UM IIM lPilCe'

10 'Util!. Sl>lfI IIM bll.n. 10 IIM Itfl. i9illnSI 'M


~Iop. ind drIU IIM second PIn hcW.

Pin hoit

--_.
OI

OD
_

....

00 )'Jur """er .".j nt:.IrI< ,II(, hi'


;, One "r 'h<>sc b:lscp .... 'CIi titlu tu> '" ~<cn'cr
Dd' 00 tii<: bit u.l:i
tlo", il .. InM;dkd. '" "'" n", In
lI!iIIS 0lIl and .JriJUIllI Ihc "",,,mlnll""''''w hoIca. AI Ihe:
... 1inI<.ur 10 oriem the rou'~'" OI() 'he: plotlC ut Il", "",..
<IIs.;o bc par;tlk:I .....n nit;!: of 'h<: $<1 .... '" I);a;;<p.... lt b""'k.
AfIn' )'OU"" m:trl:c<I Ih.: <'CfIler o( Ilte bit "I",nlnll. b"1
lItPw ""'\T bo<o:d !o<'rihc: .Jilrmet"r.... ,h,,"'n In ilIe
~ (\r;N,inI!:.TIlis dio.f1\CItt m.. " hc: p" ... Utl 'o an t<;IjI<'
~ an<! mari< ,IIC pin tonlkN ... M.ke: ""'" tlle pin, an.'
~p"',e

optIIIIII!. ThIs

"'''''1'

TIlmd ntn onro ,loc: boii. bul eIon 'l lam il apinsI 1"" _ _
~. whk:h wouId ~ .hf Iknt fn:>rn ....... In&llunlJ 1"" boii !nro "'" hok. lbm "'" _
un!ll il olrnu><
!leal.>. ,hen Ilghtffl Ihc: nUf >pl~ lloc baxpbtr 'I'lk boii
o/1ou.kI !le 'Ighl. but Ihc: tJtcvc mUOl rQUlC httly

Using the Baseplate

i,.

npdi!WIl from the bit


0tiII an<! cop ,IIC holc:< ro. ,he pin>. Thc: d ..~winll
/lPtItlo $Nf......nr ...... """. jjOOd .....Y " ....lrlU Ihe: 1>0"'- .nd

___ ..... IMy "'" propcrty posI,io;mc,d. 10 cut th",.ds In


usc~h '.ioch20 lap TlIC pU'" 1><,Ic '"r lhj~
lip CItI hc 1"" Inch In dilrmne . 1\0; O:I",md)' CIlft:rul ,,,
~ tbt cop 1"'f'P01\d1c.. lar u )'OU bcKIn 10 " ul 1""
trodo.ThIo il .. he ... )'OU 8'" ,hc: hoic OUl (>/'
Tk ~ Is cod:cd pon. ,,'hkh botchcs 'he 'ccuto(')' ur

* pili boIcs. 1

.I"'"",n'

,,~~

MIM an,cr ot the ""..,pla,e. drilJ It.I""h-di."",'cr


UJ.inll ro"lc' Ind ,.. mmd.
. . "'" _pla'c .n In 1I.!ncIMJ""",.cr c lrde TIlen
. . - .... bit _for tht b'll"Sl hit ,..,.. .... likely In ......
_ilie ba>cpblc

"* lor. 1.. """,,1 piYOl

11", bastplale: ... n bc ""'" .... pl1lllgc.butr: bol<$. ro CU{ mut


lba.and 10 plu,", lI""""'". Tht upc.,il"3 ptioople!;.", 1""
"n", ror .11 .h..,.,
diITn..""", Is In ...1lc:lhcr OI"
"'.. to act ....11y ftt\I ,he n)U' cr b,,, ... IIy, and 1f)'OU do. 00'"
r". lI~",. ho", 10 do II. >lep b}' ..:ep.

dIO""'."'"

I . S":1 up tJ,~ routcr. N.", .. IIy.)'OU ncc<l '" InsuII lhc


ba5<:pl>.le. ScIo "'" bl' )'OU ",:ro 'u u,;c n<! chuek il in Ihe:
""'Icr. Set
plu. >lup.

t""

.tu.

2. LlLy o ul il", cu . M~llICmh<:r


lh" ck>oc,. )'OU
CIU1 rotii 10 Ihe "",,",p1ccc'5 cnd .. aboul 3 \'. 1nchc5. Mari<
lhr hcglnnlng .nd end o( IIoc: dc>Im:I cui. If ,IIC cui I~
.simple hok. nu.rI< i. wilh an 'X'(lamp "'" ........p;t In ..".,., .....,. tiu, p"",idCIi wtoI>>lnoctcd """'""" 10 both"""""",, lha! lloc pins mUSl n:kn:ncc.
j. Makc l1>c cut. Set lhc rou.cr In plK'C.'I'wt.t 1,

}. InsWI Ibc: plru.. SlIp '''''

*",,,,

"""r "'"

hoit.

''''' pili>

ctII1k

OI)

inlo Ilrm contacl wi,h Ihr wodp;t. Align


Ctntt,- F,nd,OO llutpbt.t

17

,Ix bit "'." .... ~31'1 .". .... ""'. S"iod! (In 'hc: ,,"", .... pI. . .
'M hII.. and m:r.kc .... cut.
Troubk4boatfng: If)<>ll <Jioroo>"r ....1 fO'" pI.I'~ ""kq
...,...,', '"' ac.:"r.II" .. )"" wouId Il:....: ~k~'tl. ;lntl ,..,... ('OI
bon'l pcrfcaly ""ntcrnl.)<>II CUI sah"!!" ,IIc "'orI<~. 1'ht
<.U wilIlx ..iI,kr ,tun "'" bit., "'" 1, ,,'m Ix "",,,~ral.
Uit ,..., ""'",. an<! "-"P""llion i, ... pim a", "" "'"
'''PJI'O<'ltc lIiIln .". 'he "'ori;-pktt ,h." 'hc~ "'cA: Ix.."..
omI ute a 5CCQr1d p>...s. Nu .... do.>', .In,ply ""'....... lIr
..u""",,1on In ... hlctl Y"u t""ISlcd the fOOlcr. lf )'tIU do """
,Ix pin, ,,111 n:m.ln On It>e $Omc sidc's"" 'ho::
~OO the bit ", llI stiU bc ofr<cn tct
Uw:.."", ~. s.
,h .. """, ', ""ori<.
, .. "~Al m).,..,lf. )'''' hltvc lu ItKI"C Ilie p..
thq' Iff.
~r<:n<:e ,Hf(cn:nt .i<Io:>"" thc: ",ootp;c:cc in ,..., orcond p-.
,II." tllC)' ilitl io "'" fin;L lluI b :aU It ~ lIuI 10 lU'titf Ib:
prublcm ~ ilie Ioog lam. """'~ )~ ~ """. ~
J"" work a linle mon: can:fully ' hc: >ttOnd timt lky. l "
,n nw.:" miM ...itt. ... _ . fttI 'ou bad if)"" do too.

'0"-.'"

"''''''pira.

t>'"

ed,.

Cot.II eIIU Of! an


clon' I'H!N i kK of "lUp fI(!
dling. Whelhef the (ut Is i hoIe. I monlse. Of i slot. Iht
nnt,, Rndlng ""nplll' w,1I positlon l equld'stant from
lhe ."'StS of Ilie WOf~plKt. Tht tride behind lhi~ magI(
is th.t Ilie posltlonlng plns il~htd 10 Ihe I>oseplil. ;1.,.
lhemHlW!s equldisl.nl'rom Ihe bil uls.
CUT 5CHU4I11TIC
Twlsl ,OUlet '"IIOTH p,ns
conli>Ct workpIK . HoId plns
Rrmly ~ lnSI tlle workpiece
as vou fHd Ihe .out., Ind
mite Ilie CUI.

!4 w,d. Cut 1 quldlsUl'"


I,om Ilie workp'.,,s edges.

'.

.'

......../ ...

'.
""

Doweling Jig
&ori"g dowel joinery

be il fulfilling
uperience. Use your plunge router with
dlis prtc:ision jlg. The jig m;aku it hud
1;....

tel 110 Wfong .

..._.
O

"."
O

join~ory """ """ of thc tl'unp IIricd cutr in


my ,,"Ol>(h<.ul'ki"l' cq><,It"Ct:. Wh,.. I bad ..~ cal'
pe"'1)' ,00I:I: but r W3:i m:akln& a ,,,,,,;'y,and I ..."",cd
1/ t:*' Ihe "'II> ~1l<J >tilc> '" a bec .... " .. l)(;no'd joWll5
_ _ h~~ Ilie ""y 1<1,11(> for mc-Iu>t buy a """"'1irlII1ill
IOd IIK Ihe pon:ahl<: UrlJI ~nd .wbt hit.; 1 aIrn", ~ .
......1. dI",ppolnl",~nlt M.)'IK It _
mc nd ",,",'bc It
...,,"" j8. bul I fl(V<"r <lld 1\l.>SIcr uuwd ,,~ncry ",i'lI driU
001. oo..'rlinjl. jis_ It 1"'" nev<:. wor1<cd for "'" 'bc W2J' I
6o:qbI ~ 5/l<.MJkl. n.c, looIQ In IIM: r~U) IU(iI woukl ,..,...,.
_ ... .,.'1111 ,h~ hoIa In IlIc SI"es,"hcy'd bc. bl! 100 far

'"" 01"100 dooIc 1<'>fI!l.~iu:'r. And Ilg o .. "''', "I~I """ of lh<c
k*> fI'(IUId bc cocl<cd .
To.mty)ftf'!l Ia.er. I'm ""01jC plun)IC roti'e< w'1I mr
ti doo<",UIIfj. rl~ ...'lth far l>c1.cr n:>l'ltS. "(ieu bil o(
...... J an kn<JCk ou. whok: oei' '" oow<:I'loh"cd ro

*'

....". willI aii ,1 ... _

.....-..u, fIOMIlOocd.

21i~Oi<IU:O"' OO fl"n~ly.nd

le:m,,"'"

",. trick II
Iha, h .. &<:"" .... 1 hol", bored
...'""'..-ori<pkttJ ...... cbmped t>enc:uh IIM:: .emp''' ''.
. . UIt I plu"jIf' routcr flun! wltll [tukk ""'.hlng In
.... _"Ci hok>. An adi_abi.. wonpi .. "OI'
cach ~piccC' ... m Ix cL.m~ in ,ho: ",..n"
,...... a.>d ,o:mp"'" odjUSl<:" help )'OU (jnoN .."" , hC'
.,..,....... 'hC' 1toIo.", dnd-anl'" on ,hC' wor1Ipkce.
1')'011""' main8' tlldil10nal fr.unC' ...ilh r2i15.....;1 Stib.

_,ha,

,I>c: StiItf ..., damjK<l hori>:ontalJy bmc h .ho.' ,crnp1.",,; 'hc


l3iIo. ,....,1aIIy A '''I!8k damp ....1<0 w""'pIce .. dlalljl<'Q\-u
fo!C md

nJf.,..,. II. hokIs .hC' work


a paei

,Iu, nuI<a k

"C'I')' 0"\11'<"1),

.0

~.o

An 1........ww: lOt"", ",.hb Ji;g. ....","ioo.I'II by frnl


M.a'bd< '" RocWc:. l)c::sjpl Sbop. S .b'" ;odjuoublc: WU<i:.
piftt "op 1 """"\ono:d. YOll """'" It {rom ono: <:nil '" II><
JiR 'O ,...,
~ upon ...11Idl mii '" (ram ..
""""bC'r b bdfI8 " ...... mQnc" adjllMN br. job. )'OI' .... kc
...... oi ,hC' 5:ImC 5cI,inI!; a' both p06IOfIS.
"Thc: lis is not InfUlitdy \'aI"iIbIc:. "Thc: , ..... pIa.<: tu. fow"
""""Ir >pacnI hoIes. II )'OU al'<" ~ I \ :.-Inch-..-i<kbr eumpk. you wouId ....,
01 ,..., hok:!I. Ind

"'bn.

..odr..

"''O
xcommocl:I'"

)'OU, <lQ..,'d hok$ ..'OUId br: 1'. ind! "pu'I (CCft'<:~"").


I{."" ~ .. odI ............ :and an
.hI'C"C'
hok::i on .hC' I'..u.rn cnu.....w-cm,,,,. ~. Ihcn t......,J ......

,hm: oi" ,..., ',-"IOpIlo'" "'*'<. and J<) ono

,."0,'' ' ' ' '

Ru. "'" Ps an:and m .... Ix ,unnj


A h!teh wltll ati)' "'""" cJoooodIltI! liII b tiu. )'OII an',
ofiC'm III<' wor1<pIcco J<) ,"" oamc btt '" nch ]o IpruI
,Iw: jis. It r.... pIatt .Iw: .m~ fa<:C' '" .I>c: Mila! In
(ag>.1ru.t .ho: Jig), ,1"", ,II" ...,,-., ......... fatt '" tIIC' raU. ....... Ix
OI".'"lm .lu",
y It
Ilg m.... bc adj'l>Iahk In

,hc: ......

->

l bc elamp . .

"'Iti ohe '-ilImp.


posIion 10 accommoda' .. cIIIkn:n, oi>:<:o '" workpit>.

II;

".s...hc:

,'lIC" ......y .h.. 'h" dowd holn Cln bc pIa<:c\l prttbdy.


ArMl ' hls IIjj 1< ,1"" .dl..... bIe:

DOWEUN(; J I(; EXPt.ODED VIEW

F ac~

Q/

.-...,o
C

-:t

Q/

1bc u.-rnpLale <-.an 1><: ohi/icd In .......... un '1 ... 11....1)'. ond
LrroRlft:Jlrd,_ 1nIInI'c$n;al ~
_
Q/Iho: ''''''f'ble.TM .wnr li uu.. Q/Ihc wortpi1: >1"1'.
..1II<h .. ..,ro ro """,Ion II><: ~ It b ~
MII"",....
~ adjU>tctS all"w

".:n:w

Making the Jig


1bc do",ell"l.l lItc Is " n'lx......nedi. anlion 1 w.aJ piulic
..... ..,.=1 of Ilte p"m.n.c dcar pI ....ic w.cd ~ ... 'he ,."...
pb.e lct6 )'OU SIX .Il<' wort, whI<:h .... ke< "",up muci!
c:as;cr; llIc pb>tic <MljU>ter pble< OII loc thtcaded. >O yuu

dan', ~"IO fl<kllc wi.lt1'nu15 OI' Imcm.


0."",11. 1 .hink lhe phscic ~ It 1. ,hc rillh' >tuff Ibr
,his appli<;:o'lon. antl 1, lt>uIl5 oIid:. ~bu nil ...'Ori< . he .. uIT
wltll YUU' WUO(I"''''1''''1I tool< n ....ppcndllt ha> """",...1
Informatlon <>fi buylng an<! """"'In thc pb>Ilco ti"" an:
...it:tblo: ..... 'hl~ jlll.

1. Makoc .h" bod y. r


""Ulli

madc thc jljc bOOy by I. n,~

,'"' O 12)""" o( \ ..Inclt 11,11,;,: 1lin.1l p ll'....ood. ",hlell

odd .. p'O a IhlclmcM j ......nda I ~, ~.''hl. nu.k""

unl. """'" .t.bIe .... n If I hali ....:d a doi .......,., ..........


ami J!.1\lcl.ml"'ll~ pl)'WOOd lOr ilie: f.uc. 11_.
'op . hen ttim 'Item 10 the ~ )MXifi ..... br
CUtlinlt 1.bI
Gl"" up th~ p.n:l. as Indic:oted br thr EnJ I1I'W 0/
f'Ia .. l'fat" dr;twlflll;>' Chcck thc: ..-mbly ~1)':tS
damp i' 10 cnsurtc
it i:s ~..an:. Mi.,.. thc: [41""
"""""''' thc: damps an<! """""" oIl' ""Y "'I1>tt".t.N>Ut
,...., cn<b:. an<! .and ' he top omoodt and
to tI><
Uy ou. ""d roUl tll<' dMIoc5 ...... he """"'pic
...,... Itlc:oIIy. yuu .h"ukl do 'ltb un a .......:r ,.bk. but
.< .... Cu.

,tu,

"'1""'"

caii ...., l't)U,e. rqulppc<l 1'1'1,11 ... edftr II~ You n<I
"op 'o bc rquklblant {rom thc: ttntc:r o( tll<' ~g. "'II"
of...nld1 md 1. Is Ofl. "" yuu mlbt poNtlon thr dod"",
cmun: .IIM It ,,mIx.

.inalIy. I:ry

OU' and drill ,"'" _

lOr mount.in8

wtXtpkttolOp .mltl",.~ d.mp. Doa kw p",lIm


hoIo ......... hen :adtJ Olite.... dict:ued br .hr ...
.ions lha. """'" up.

DOWlUH(; JI(; PLAN VIEWS

1'------;

' . . / Tomplate adJuSter

'-1

~.I==:=;:::::;;;::====;i=~
,l

,-

h" dear aerylk:

FROHTVlfW

.O

ENOV1EW

,,-

:E

--."
O

o o

o'-o--JJc

"

T09!II~

...-

Qty. Dimension5

x 9" x 16"
x 3" x 16'

IW

"",

-.tinO ~d

IW

<"-mp 0..5Ia<0 ,tTC22HI

&altle: Bireh plywood

x 6" x 16"

Jqo>lff pilit

Il" x

2~'

li" x

1~'x8lo1'

,.,Iy<Q""".", OM

'Ao)ol/<.
IM ojOll/k.t"",

Baltic: Blrel'l plywood

H.rdwood

M' x 1W" 211" hlti< lire" plywood

Il'

~te

Hardware
Material

1" x 211" x]"

!""!)LItt

Stop

...

H~

Cutting Ust

'

..

x 16"

C~a'

i>CryllC

PI.ostl<"

Threaeled rod.

1 tiu nUl .

x IZ"

~"20

1 pb.,II, knobs, W dia. with \(,"20 In,en; Ilem


,tOK 42I,om Reld Tool Supply Co. (800'253~21)
3 compresslon sprlngs, \(,"1.0.)( !"Ion;

8 oanl'lud scre"',. _6 x)"


1 carriage botu. W-20 X ]"
2 flal wasll"" iii" 1.0.
2

.... ." ...., _ {M

~"20

wl~

nUIS. \(,"'20

TO'l!jI. 'tamp, DtSta'Co ITC22SU


4 panhud se,",,,,,, _8 X j(,"

TUIPLATl LAYOUT

"._ - - - - - - - - - ,

,.

Mounting se.t"
slot; lIt.m1"
Idjullmtnt of
Itmpl." ~~

IT:
1 4~. 4'

,.

..-t
C

-.
~
C

........

.. .
._......._...:._.. :':::::000
. .

L:~I~~'"~.,.,.~~~~[r
.. .

2. Cui and by oul ltIe tempble. Clnr X'lYIC il;


tlle be>t nut<:rtll for <he lemplal~. ' ''''' "'" """ l/>roudllt
'o llelp l""'ncl( alipi aMp;cca. YOlO ~ nch ..itP'I.........
Ur>eS n it "ith .. se",.d! aw1 ot a LIIili.y blIfr And M Ioab
$Iwp. ldnd:a ltJ&IH'"<:h CUI Ilie le",pbl~ bIanIc 10 si.., an Ilie
ubk ",,'"
~ 0101 Ilie Iu>es~" in tlle n",',,",I~ ~ d"'''''l1lI
right on tlle nuskbtg popct .... t proICCU Ihor ocryIic.
Prtti>ion
l. ,itai..11lr allwunmt line and ItIc <:allcrtinc
mUSl hc p"".UC'l. lhc cro6Slulrl
'M 1>010:> n 'cnJy spoo.'1I<I.
'M,h .. S<'r.Itch . "', or ",m'r knlfc. LICUr<: dlC ~ roIlln$!
riglll .hruugh Ihe n,Nlnjl. ""per .n<! etchllll IIM: pl.:Lstic.

""r<:

ro.

AIso nu", tIM: Ioc;LtiOn:l oI ' M mountlnjl.""'~ """",

U".5 .Iched '''10 Ih. l.mpl. l. hllp yOU .~, up Ind


uoe IIM J;.g. lIKlus. I""y li' KO~ In.o 1"" su.f"t.
t.1\nl!le wom 0' Kufftd otl. USI. sou....nd.
ullllty kn ife 10 K.ibe .IM IIMI. II lhown. cUltlng rlght
hrough tIM pro!ltClM! mUk'ng ~ptr.

t"'"

_ _ _ __ _ _~.::::~ce"tt'I''''''
of Itmplllt hoIn

Unt. Kortd Into ICrylk

3 . Ron: Ihc: tK>ks. Set up ,..,... driU

.hJ.

rmo

fencc .0 dn th.., and ~c .tIc Iimc 10 "'"


fint hok
t'olt' ~ _
Ihor bit bffltr; bortn8 It.

To msute ttw Ilie


>paCe'" MiU. Jlri!> oi ~ Jlock.
.hltt pleca. Uno: up thc .~.e

aviIuC .hc:

'

rmce. B"" 1"" thIft

".

bIanIc .....". o.g>lnM ti",

Re.....,.,. anothcr >p;><:eI'. """


Ihor Ihln! hoIe Itcm<ft'c thc ,..., >JI"Ctt. ano! sliock thc
...."'" ..pin>< ttlc ",up bIud<. l>riIl the l)unh hoIe.

80rln, th. I~mplll~ holn should be done On .itt


d.ill prIn, usi", il feoci Ind snetr blocks 10 tUm~
nl'e v,,'ablts ," pl.ctment of tlte holu. Tlte fenee
InSu"S tltil IUtite holu wlll bl an equJI dlst~nCt
lrom Ilte lempelate td,e. Tlte block . un in I.ont.
PO.itton tlte template in "I.dcn
tit. stop block .

'o

.o.ojUSTER DETAILS
IDIPlATE AOjUST(R PlATI

,.

....(oile

OIi. 'ko6I,. hok , ne! I'p for \01;"20 tll. ud .

\.

- ,. -

"~o.

...

r ....

Olill moullung 'Klliw "<>Ie I .

".

AOJIlIST AII.( WORKPlK E STOI'

AOjU5TER AS5Et.18LV (typ.)

Ofin '14.0.-<1.... hok. ' nd


liP for \01; 20 III.tad.

....
~.

ml>UnulIgboh

]J.
,. t-O

0 .1 11 mountlng.
K'~W holu.

0+-,

...

."

1" h..dwood

_....

... Ibt Sk>Ilcd I~IOI '''mpl.", "" 1"'8" .. 10 !ou' 'IM:

10 d!tso "p ,ne ~l'f'Cl'r~11CI: o( Ihc ,.. mp""". "",n,fe.


.. !barp ~ Qr1 'hc ro",,,", lIbk. nw.1l ...., ablnct
...... to mno<I" ...... m ...... ForWJr. fbmc.poIi>h Ih"""
..... 'IiIlbcy MI""

4. Mm tJ>t. ..q1lS1er plai", Any n"""""of dI""",nl


acNb ao bc ......J lOr ilie adju>Ia plai" "rnaIC"riaIlIw
... an CUI Ihrn\J!. nto ils beii. ,,'hidl mnno yuu C2J1 ~
'1Irinr ~ pLw:b Of mtt2b. If )'OU ...., ""'" comfon~bIt
""" .."01)(1, ."... <h~ 1mcrU. 1 ......J ~ phmoIlc
(.uI tlt" 1'1.>1" 10 :li4". and br oul Ihc ....... mlna hokI
.-1 thr boIcs fur 'h .. ~dl"'lcrs. as """"'n In ,1Ie dl"2Wintc
htpI<oIr ~II'. lIorc 'hc lIoIcr.
"ni> "'" JdjU>la hale!; """'1 .1"11<: [m ......",.,. l_ <kuilcd in
.. _
"Culling Th"",dsln It..: ~r>[1Cndj" .
ro...nu.tt ilie .ppeat2J>C<: o( ,1.., ~It , If )"uu won, II ,,,
.... ~. ddmfcr ,1Ic ~ JIbI m<>lIfIh 10 ... fle" IMir
""bine! ....... p...- 10 """"'" ..,.. ""'",5.

..,..,...t:ot

S. M2U tJ>t. ,,"Orkplecc SlOP. 111'-' il ......,00 ",,<1


~""""""'lh3Il> boIlcd 10 It..: liJI body ~ mUillJl
bf dIrdina out 1"" byoul dr...Inr.. Cui 1"" pbsIk plat ..

1""

ot>d
1wU......,oo bkw:::k 10 Ihc di~ spc:c:on..d by Ihc
ColII"" Ust.
Lar out antl drill ilie _
In rlw:tto pulS.1k adJU>I,,",
hale In ilie pIale
bc t:appc:d 1O'/Ih 14-;ncft.20 lhrcad .
"lIuJr Ihc cdga of Ihc WJP pIa'". ''' 1"'" did ilie ~ of
'hc 'cmllll'c ot>d ,1Ie adlU'l.a pilIt, br ~ .....
cdp ot>d ocr.IpIng oIf 5;lw nwb.
Sc,", Ih .. stop p llic 10 Ihe "'OJI IJIoc:k.

Dt"'"

6. "-"-""tnblc ti ... Ils- Thb b Wst=1J" m:lUa of


.O\"'inlllIIe , ..........
ot>d ~1>I1c!! 10 Ihc ii!! body.
Mount ilie IO'I1pl:.. c ot>d adjUSlcr pL>lt On 'hc li~ body
..-;,n pallhatl ~ 1nluU ,t>c worI<pio:o::
f.~
by fiui"ll ilie ...... pIa,t In,o ilie d:ulo. lhcn boIlIlJIlh., stop
bod)' ' o 'hc PIlI body. (IlIt ..op mU>l bc: ......""" 2nd ",,,,,,,w
olt"": yuu ....... 10 Uk a "'""- "III OI" o ..UIIdrtl pb>tlt
knolllMl<:Od 010" .. ..., k doQn'l tatr ........,.,m 10 mounl
.nd di.>n1OWl1 II.)
No'" "",ke up 1..... odjllMe. ocrn.""5. Cut \hn't: pic>. of
14-1.-.;h 'hrndcd rod. 1"-0 ,lui. ..-.: 2', ir>dIcI ..... lOr tlle
'''OIpt:ue ><Ij..,;I .. ..,. """ ,h .. ilo ~ h lnchc:!I ..... lOr ilie ...-ortr.
pic .. o[> ><I1,,"cr. U.....cry!-m>lI fi1c. li" 2n o"lfC"bil
rtk:. '0 ",n""'C hum rrom Ihe Cut cr\<I:j of,hc th~.l\Im
a hC1! " '" and pt."ic I<.nob 011'0 01"1<: eoo o( nclt rod. !In!

""ru

"'''1' ,,, ,.....

Oo,,"e l,ng jlg

93

TOG&lE

CLA~P ~OUNTIHG ~AO

LAYOlTT

I'iloU ro< tovgle (timp


mounU"II sc:reW5 ~~ff

".
,

.-....,

..

". plywood - -

OI

,..

"'" knob, .lM:n lam .h~ nUL '1P' 1n>l Il \'ft'}" lshlly 10 kcq> il
W>tlu'c:>dinr.,
JI\SblI thco;~:an<I "'rmon >fIrinp ""'" mk-0I .1M:
~ b lO keo>p IIM: """"". r",m nmlln, nu. ,>fllle 1""'d",.. )'OU >CI_\ 1>iI ,he
>lor.: aod ~ 'hf\loLl&h "'"
..,..,.,...",,, 01 com~ .pri l1jlO "" 1~ )'OU IInd :i M)ir
.h:i.'~ IIM: c:om:c:I In>kk dbme"_', ,IM: C<l<nx, kn,gLh, _
>fi
ar.p.."pri.'c >liff_

C rrom

-il
OI

Iunl"'.""

.0.

7 . Mounl the ,oggIe d aJ'lp, A$ fI{)I<:d, thc '<#k


damp ;, Oludltd
plod. .. hIdl 1. In LUm I>ol'<:d <O oM ~ .
TIII> ........ ljII<fI.".lL _ . " ... <O "],in Ihe 10AAk' cbmp pooilJ011 mon: o:<ISily Wn if 1 lud <O .... i.hdto.,, :ind d ,h.., lOwMO""'inS .."..,..,.". I ...ro lk-S",-eo cbmp-thc _
1
IIUllokr .. In thc 1bRtw:ttc lliI-... ILh :i
01.""", 2
10 21'> inc:hcs.1b mc. ICIdl ... 1M: disunc~ from.he cbm,,'.
rtIOUII'UIg f1angr.o oM cnd 0I,IM: b.:IrlO ... lIlm IIM: opIlkIk

...,...od1.

l5 :i1 tac11ftl " ... don', ...":UIt.o 1I!C,00 ~m.lI" domp, 1f)'OU
do"'" ..idc: (........,.. LI>(" " IatjIo:r o;tamp. and ohm IIM: k.ln.Ions oIthc in>cruo.., IIM: damp <Ioon'l m llflkl ,,I.h 1....
lcnl]ltile
1.)'00' d .. wInJt
CUI 'hc '-'10 thc tIupc """"'n In
Ck. n up IIM: cdjto.. .s.:...,... .he damp '0 .he pod . hen
nK)unl 'he.OIIIIk OII ,IM:,..

'"e

TIlc liS! J. ""act).

ro..

J<)R1oe

Th. 1""111. dlmp 1, ulr 10 poslllon .. MI rtpo.


lIuon lH!uuse II 15 screwed 10. 5..... 11 pood lhal ~
~P,""Le rrom .ht jlg. Cltcll tlle pood~ mountln\l .Iot
on .. elIrrlaOt boli Insened Ihrouo" lht :l.pproprl.llit
hoit. In tllt )10 bodV. then tigllltn tlle wlng "'" to
!Kurt Iht cI:l.mp. Orltnt lM c~mp $O IlS spiMiIt
"p~lts prtssurt dlre<:tlV on Iht worI<pit<:t, just IH!Iow
IIIt Itmpl .. lt MlltS.

1. Set up Ihc JIg. Clamp IL 10thc ......... bmdt 10~.


Noa !Ict Ilte IC1Ilpl.ue. l<x<:n III( >CI '""'"'-o AIqcp III<
o:td>o:d ~"" Olt ,empl.' ... ,,'JIII IIM: b ....... 01 jIJI. Lhm
1'CIi&hL<'I1 IIK:
Sel the ... ju ........ lIpln>t tIM: C<JsI: vi
.1Ie .cmpLue.
\ Ioun, thc 1"IijIk Cl.",p """1. Thc",', onc fI'l"/LD
lhan ",1iI2hk~ .. l'IoLh .. li ",181110, fI""'idnI Ih<"y "",,'1
100 ..idc:. lf f'ltl . ,., Wt>I"kJ"tI job ,,"11 f......., mnnlIn> tIuI
'"'" } lnchd wklor, )'Qtl wlll probIbIy h;.,... 10 .....i lrn III<
touk d,mp />;ock.nd ~l rl h hct"'t'CI12 puo;.ion 'lui , , _
for ,1Ie ,.ik:f:ind ono: 1Il0l' ..'orl<s for ,he ..u..(1'Iw: ....iu:toin(!
il M111ctomc during ."" CU,", bul ""'" .....-hen )'OU "'"

li'''''''''.

thc ""'u:Jl job,)


FinalIy. mowtt lt... worI<ple stop.

dowelmg,

2. Set up the router. 1& jit:;s ~ 'o bc UJrd

Using the Jig


Tlle IiM I.n' . difllcult ' o 1I!C.1>uL i. rruy ,.ke hit of tim.10 tun" ,"" OiCt .. p,QPIIJ1r Lhc: r".,.. . lm~)'Ou o"" It. 801
lf)'Ou" "" do"'d inS:l. bolch o(bec r.. InClo, tlle.pd :ind
:iceu .."1 "'ilh " 'hieh j"OU nil plunllC"bO"" ,h" dO"'el
hoks m.k~'S this c .... """1' ti_ a ",0n.1I " 1I11,, In"''''' I'
men,. lf )'0" u... Ilie J13 prlnurilr for \4.incll >lock, alld If
)'O" worl< ,..;,11 COIU" ... n'lr lhl(I<no:Mo:d m.." . I.1. ,tocn
~ ,he IIB 1 ...,' up, ''''' adl"""""'1 rrom ~Ih 1" )<Ib wlll
"" n.lnln,.1

....ith. h-Inch """pI:i'~ tLuKk, ... in",.11 tll,n tLukIr I>u:>hlni


on thc l'OlI'et". Sclc<:t It... co ~ blI Jiu for thc den"el> )'OII
"'" ~ ond elIUd: it In thc rolle, .

A...llp,cl thc: plO"ll" ""pl h.11, .... 1111>, cbmp ~ 0C"'f'


In .hc II!;, ~ thc I'OlIIU on .he Iil!, :ind bouQnt Ihc: biL
:lfI;linsI ..... """p Orop ''''' &rop nxI omo ,IM: '''ITCL, d~"
..1,.., II <Il ..."""" cqualL<> tIM: tkpIII of.1M: "'...'d hok l"'"
.... nI ' o bo:Jn, .... ' J'pk:&I ""plh 1> 1 ll'l(h ,

'Ql' """"".

3. Makc
y"" necd <O ,..url< .... ;.11 OCT:a[l> vi
'he "",u;oI .............. -Mod:. 01 C~ nd )'OU m .... m:C'

on llnI .....,_

joiJIl JO ,.,.. <2n a" albit I ;uId l<"2hu1c thr


'O . . . of IM p>ru:.
Uf OUl II.., 1"" pics ~nd ....1\ ..''''"''' thr ' ni!' inI.".
iim 1"" ' 5I,Ie' IIc2ri"ll In .....,.. 'M Icmpbl,,'. hoIc
~L>y0\ll 'hc dowd po$k1onJ on
piQ Fb\;Il/y.
MI< III<' ",re",n.,., rau of boIh pIt<u (u.., ..,~ I!o
ln'Ilhr 0I>r Ih.I '5 UP")'OO' "'y ""1 LI.., ,,*,1),
Cbmp II.., LeM ' Mile' In I hc ~ori"mlnlll"""'~
lKt OOIl:o\li&II thc Iryoo' "",010: ....lt h ,"" U..... nchro Imo
.. ......., Thm opin IiM: ......tI....'" 8Iljuot"" ..... U 10
~- 1aL> ~ lhc nil!
' M l ot pica

""ti.

<.,

Xl W

!'OUl ... on

minorfInNlIftIng "ilt hI: _

1""

..,"iCon

- Il thr hoIar '"'" doocf 10 thr


txt, llv lnIIo
pbc.. ~ 'o hc pooIwd 1dI:,
If lhty '"'" doIn" 'o ,Iv ldI: (;on,. 1hc ICDIplalf .... UM hc
puoho<d ro...-.nI,

""')'OU ..

':'."~':"::.:.:-~....: and C\'lIlIuat" Iht Ir'fl, jolnL .....,..


jllur. 0I ClIU<"C.'- 1nlo thr lot ........ _ ,.,..,mbIr
oIbolh ...,.,. ~ hc up,
~ thr joiJIl, /U'f ,,,,,-, '"""" Ouoh1 Do thc a!6O.-d
~ ....... n:. ....-bct1ll Il ...'tft.'. compl<1e bec ll'2mt,
.oLlotr ......... "'OUkl'hal ba: rn...., "" /laI>/U'f thr "'..
lKt
IIlNl!gnNI /U'f Ihc nIItc> propaty aIignc'(ll

7k ~ _111... wp,' l ltc woricpic MOJI ....... hc


adjIJ ..n!1n

...,. ,m,,,,,..., ,.,."

"*"

" f1nc.IUnc lhe JIa M.'tup. Oi' """""'-'. 11' thr


"""', ... Ihlo llr5I u.,., P'" JUUf'Odf on thr had; anii . ,
" ... Ihrml .. ortp;c(Q ~ """"' m..lil<dr;apc:d.dI)'

OI' OUl.

If thc cdF oi thr r.>II ~ ,hc moi 01 thr M", ,hr


odjtbIc .."...... """" hc "-"fI\CIN,
Il Ilie >IJlco <Wrrlu"8' Ihc r.tdI. 'hc ad/U5I'" ~ _
hc "",,"'''''N,

runc.

.u "'"

"""1_,

,"" l""'pIrI'" " 'lIh ." 8'~ hushltl(lia

_ellbr ltoIo. PI~ IM """'-'. ~ ..... " ,"" f'OlMC1' 10


.. ~ Idr, >nd plWIfII'-"bo'" ~ hok ~p 1011'\8 unt~ aii
ill hc h<>rillll an: donC'
""","';'d! teg p;.:.;c:J,l l1l, . 1..." , oric:m Ih" ,de",,,,,,,
IKt. IM' \M cnd 0I111c ICIi! ' nllI ' IKjUil"'I)' .gainot tlle
......" ~ lIIdr Il Icft un'il ll ~""'L""'~ lhc "op,CWllP II,
... dor JIo6n"

,l'oll aur

ha"" ,,, ......... IIM: ''''''ploI'' in OI' IlOII, OI' adjUII tM ..m ,
pion: "op ''011 nun 'hco<' adjuMmmu buc'd ''" r anaty,it 01 IIM: JoIn. ~t In trlIlion
""'y In
..-tridt Ihc pati, "''tft.' cb./IIpN In
IIg.
n.. "'"' Il,.. . . .-...t,' n.., I"n.plale 15 I."OCk<'CI SIIKIy
'hc hoIar In 11Ie."SI pittn. tJelcmlinc ....1Ii<.il <>ne l. olt ilie
anii od;u.t 'hc appropri1,e cnd oi 'hI: 'cn'I''''lf
n.. fi-s _ 1 JI- 'Ibu ncftI 10 ....,..., 'h<' cnU",
.~ in 00' OUL lo<* Ilw 'eM pio .. tMy .. 'tft.'
dampnlln IM JC.

,II.

".nI

''''''paie

Iknu,"" ...f

.'"

dn.Iil'\8 ,,'lIh lwo .."""~, ,1..,

lm~,

01 ach ' C'D'IpQle """"""'-'1 ...;U bc.' ....... "Ied, TIIu'!


In _
lIi'UiI'I(Jf\< ,"U "";11 " .. n I It) mO\'c tIIc ,empl~,,, ~
""'''' frx'Ilun 0I2111ndo, ..'bIdt lnruJ.al<:> In LO' """'" lnoe-

,rI. 'UnI

,Ion
"1,h ,hI: lO-tJunob..,.....lndt (l!>l adIU.IC ....
q ..................'iI! - . .... Ihc tip
Inch
n.., ""_ .. truc oi Ilw """""pic .op \'"Y ,;mall
odi...cmca~ 01 thc",-"",,, aiI)idd .... tiIIc .... ..tw/b 01 'hr

01,,,,,..,..,... ...

....,-..

6 , Rou. thc do....,1 hokIIln Ihc WOt'iIp~ lbu


<:an MIow " 'ha,"",, /IIlIIM '" _
productM.' III' <'<Jmr
fo .. ~,*
~ 'hc dr........ I>oo.>rllltff!iftw~ A.
,he Ilie """" b 0Cl up. rou '-"'II " " ' " 'hc ....'d hoko In.....,
cnd of nc.il ,,!lor >nd ~ I r 'fu do Ihr OIIIn molo, S'IOitdllhc
"''O<'I<pktt _op ' 0 thr OI"'" poMIlOR ~ 01 oo1torft
Ihc "m,*"" !otOp 10 pooItiOl'M'd. ,toc ....., _ orknIcd ......
b",,,,~1Iy ..ilh Ihcir """"""'" ~ OUl, IIM: raih \'C1tkaIy

ro.. ,.....,

..'hit

,Iod. """""""'".,." In

""'cr

tIR, lIId Ilie comp.uslon IP""'91 kHP Ilie Krellll's


even wlli!n lhe roult. Vlbflles Ihl Ji9,

""""9.

..-...
:E

AII "j,1;>tr (WQt ..,' I)n! .... "h 1"" problcm5 OrI<:
,i"", O
Sq ...", Ihc lempl.le ti .... , I"C" 11'-" II adlLlSlnl In ." "'"', ; '
F1NIIy. odjtbIlhc wuriirk"-'<-' 'Iop
tD
Tu adj"" thc ,cmp"'e. )"" mLLOl finl Ioooicn IM .,
""""'WIfI "-"""'" 01 """"'" Tu """,'(' il. bad, l "" Il00(1< '<
boIh ~"'" -'3)' rrom Ihc r<W 0I1hc.' tnnpbIc .. cqual
_
, ' bm puth IhI: ,cmplate: ldI: ~ ,hMl, 11>
"""'"' I font,'atd. )'OII
hulh ~cn l<> 'heT pn.<h

........ Ilw

. . . tll .... 1'" ' .... pl." poeIlllon Il usy w!th thfl4,
"""' adjuUlrs, Thf!o JJI;IsUc knobs ~ .oIY Of! tM Iln'

cO

:rJI Ihc """'5 al 'hc endo of tM ......tpKca ~


ltoc ....""pIc<\" Mop"")'011 <2n <10
.hc mi oIlhc !<>Ina Th<:>c have la "" aUtpICd WIdn' IIM:
.......,. ,..... <:an "'1tIOW'

,em pLale h<~o bre)'c 11"1 If Ihe La).....1 m."'Jon Ilie "m
pia:o .", I>C(Ul'>le , )'OU ohouldn 1 I\;&,'C "Il)' diflkulty

aowtling jog

95

DOWEL ING stQUENCE

./OintAO I

- Stllt C

Stllf A

./OInt CI

.
......
-

>'1lT'''''':''''''--

OI

Stolel
for jolnu AO Ind CB
510p on Ilie left
Rtft~nee face OUT

FUI .... orkpiec. h"'ndUng III mi,/or benefir of lire


roul" dOINeling jig. A raills pcHllloned vertlcally. OI)
the holes eln be bored Inlo Ihe end It Is IJ'9ned by
squlflng Ihe bUII encl agll",r rh, under.lde oltlle
lemplat then sUd Ing il &l}IIln" the .... "'kplece .top.
T'" IC9IIlt e~mp Snljli horne 10 hold 11 In p"ce.

OI

it

O
Q

StUtS
lor jolnU AB and CD
5top On right
Rtferenu face OUT

A 11. b , pos l.loned hOt"I.r.o"urlly benn"' .....

template. Wh,Jt Ihe elamp wlll "cure mosi sud!


very long sUI mlV ~ a tempJllt
IlMIge, tO suppO rt Ihem. 1. shown he't. AII vov nttd
1. il thln block cllmlMd 10 Ihe jlg bodV. where II ....111
.uppon t .... wo,kpltce wlthout Interfnlng wlt1"l
wO<l<pIt(:e neN"",t.
wOfkpl~e

Raii,
for jOin!s AD Ind CI
Stop on tlle leit
Referenu face IN

bils
for jo,nt, AB and CO
StOP on Ihe rlghr
Referenu lace IN

96

Routtr MIg ic

NOI .very do ..... 1 joi". 1. iti Iht end of 1.... "Ime


member. To ba .... Ihose dowel holts, VOV have.o
"mov, the .... o'kplece .rop Ind ""Ign ..... workplect
unde. rhe tem pilit holu u.lng IIV""t ma,h Ind Iht
liMs tlched In Ilie template. Tlle logglt e~mp Cln bt
rtpcHitioned II INr helps hole! tlle wO'kpleet.

Dowelnis simple, shop-m.de


.~r.lltus . de ftly 1"."
lIy il rouler ma gicia n

)"<HIn. turns

squ a", blank5

tnla round s . Yu, il's ,. tfiek ,


IMII ;"'.iI ,.ick ,."11 [iln

".rl'.,

<\

:~;,;""~;n~.~:,~,. .
:;::i~i:~,
It.,

11 th il
g!zmu?
1oQuM<:
~Ick
In,o

ou. ,""

hooIt in ,. Wb!:1I
COfIInI
Md hq1 .. .. noi a r:.ocy...rnltl.1.l1Cf
ltJd: <:1 ~ pWtJc OI" Dollc 8;l/tic 8irdl rll........:xl.
t"o ~ >II onJina<y tunt .."OOd bIod.
So ..tu. d!(, (2JI il 1)0:, _ ..,....., of lhal rouIn" .... gIcl
OII, I I<wt Ihn flxtu"" jUOl bc<::o ...... il /f SO oIm ..... SO
prxIIaI..o dh"tlvc le i> wtw ~ ~ A ..... pk- pk'<:r <il
war>!us, dd\1y ~puL1lo:d bf practIccd maJdebn 10
~..,
~IU>ion. And )-nh. It OI a
! 'm
~ 10 ,.U ,ou "'MIII b .
Tbc trick 1. ,hol ,he hokb In ,IIe 'ppa",us .'" 1"'"
<iIIr'piu;.,l and p"'cl,dy plxtd In ",I:otion 10 <>ne lfIQIhc
0I>t OI tbt Inf.,.,d I>ok Il .11"'''5 WlOy 10 ,he ou,f<ll><J.lr.
.l1li inlCf'>"fI"ll "1OC ,wQ " tlle bi' hole. (Q( COlI"""

adIeo )lele,

tOII1UI!

".,..1tln8

.rid!.

dom',. rooMr' 1n,'QIw:dI)


0IIIdI

m. approp,tllc bit -whcn

.I>c: ti"", con\(:>, "O


0JIIIIIa wbat bII b .pp...pl'tllc ,and "m goinll '" 11"1 ." wh:11

III il >ppiOjH ;:'le in mlnUlt_1n ...........1OUD'cd


~,.ou ta

m. 6~.Uft "'..". tbr bil

roti,.,..

arni cbmp k. Set thc


bllIdIIho ju>I 00, 01 rounc. s.,itd! on Ihc: ......
and poIo:c
. . lIid In tIM: lnJttd h<>k
Lct . . uplaln bow ,,, nW<C lM fWwc,thm 111 dcuil
lIoor 10 \Il1O: II """ how 10 ad!~ tl>c bat ~

,et.

f"""

lk'l I>t:~ 1 do. 1ct. IIK """"..".


quodon. "XI
""" 1"""" own do""", wl>t:n )'UU 0<:n1 w.olnut """'"da. OI"
o:.ok .Jov.' ~"'. or chcny (Iu,>.. ~ V".. r",," 1"""" ()Wn """'n
C""'OM"'pbcc bin:h d ...wo:b. n:oll:lbk: lOr dlCal' oi :any Iwn- IL.._~
l>cry2td """ m:any hlInJw;' R: >1 ........ "",,,,'t do. And <>n)'UU
~ how cur ~ i 10 MJ1 )'OUr own,!"XI n",y ~ 10
pm;um, thb !;Iti< on>g:io< an ................ )'UU ~ a 00..."'.

M.klng the JIII


Tb< iii consi>u ol a ba.>iC and a bIod:. V.... lK:Cd 10 make o
dLfkn....1 bIod: lOr nch di~I diamncr uI do:wo'" }'OU
" ....11 .........' V.... _
tho:
lOr aii ,I>c bIocb.T"
d"'nw: rrom """ ~ t" a""",,"- just undo tM f.btcrorn
,1"" ....... . '" "'" bIod: <XI 'loc _ . an.J "wilch bIoc~

son>t""'"

1. l'kk lloe hole "Izes. A> 1 MId.th<."n: "'" Ih"", l>oIa


In .hc bIocIt. Two . n:." Slonc t imple tu "i<C . Th~ ..... tfoft/ bok
nm>l M Ih" .. noe dianoe,cr as 'he do,,'cl Y"" ..-anI 10 .......
d""". n.c bit boIe is RO

mot!."

lIwt

lIt bllIII'"

In dun"'I"..

Ihm ,10<" bO'}"'" wilI....,.


111<." thln.I _
'" tloc
bok. hs ..... m... ler mU$<
""'tell tM dUgO<UI ~ ... nl 01 u..,
.......,1
bbnIt. Fur <:nmplc. 1f Y""
10 rotii a \'HnclHltlmcler
\Io'fI,,1. Y""'d elA a bbnk 1""1". ~. Inch ,;q....,.., ( ooo ~.

,"fted

"""t

o;q""'"

"

OOWElMAKIN(; FIXTURE EXPLODED \/IEW

V---Wing nul

....

!
Cunlng Llsi
Part

Qty.

..

81ock'
~

Oime nsion s

Malerlill

I " . )( 3" )( 6'

H1.dwood

Wx]"x36" j

"~..,

Hardware
1 f1atl.ud "o"" bQlts.

~.

)( 2"

..... 1I~r ' ~bk 101' (from sWc 10 sl~). CUI Ih~ JIIt'.."OOd lhI
""mc "'kJlh '" thc hk,d,. :Ind CIOS$CU! il 10 n\:tldllbr
I'OU1cr 101~~ ..'id'h.
3. Drlll thc f~-.:d hoks. n.c",..:. hoIc:s mllM ~b<m
on ,lIe ."llIe
sIIown In thc dr.wirtg Do:>oofo'.ll....,
Fumrw I,aJ'Oms. Ifs \n,ponaR' tO drW tM>c I>0Io bdort ..
bl, holc..., lh;J.t thc bit 00'1 ddlcac:d br Ilie biI hoIe.
Hy 011 mnru.. driU thc hok an ttM: </riU prUI$.Sa lip do<

".us. '"

2 washers. ". 1.0.


2 wlog

nUl~. j,I"

Cu. """ ..",It blod! for ...,It

""f/'" a.

""" ,.,1." ,,. """


lAII .. riie N'O

dlf(u.~'

d,,""f'.. o( _1

""raUl')' 'o fi. ""'" ""'t... '8&10 .

_ _ >l<:osh ",,:r th:u). IIm

)"OU ....oukln ', "" .bIe to ''''''' ,I\;It


srick ,n,o ~Mnd,.(li>m~".r hok. Iuld 111.'.
be<... ust, mn";,"",, OII d dIafton:al from COfII<O' 10 ~r.
;t's 1, ind! XTOS6. So 1/K infced ""'" mU!>l "'*<:il ,"" d<l(lO<U! rnc-.surnn<:n' 01 ,1><: bI:lnI<.

"'lu~n::

Rdo:r 10 ,"" "()oy,..,J lIIant.II'n.'d nllk Sizin(t" dw1 on


dnnmine how bqI: 'he iorenl :Ind IIUIknl
hoIes sbouloJ Ix.
p>jIr 100 10

2. Cut It... p<>rU. n... fixtun:: C'Ofbbb 01. Il>nJwood


bIod: . .....idl bas tbc ,,=,, hoIo. and plp"'OOd bax
..'hIdI pooiIiooo< :u>d $C<.'W't:$ tI'w: bIod: on 'he ..,..,." "'bie:.
'Il'hlk )'OU an ..,., """" aR)' ,","'od. Ilanl . . 00II. lOr .hotbloc. , ""1\100-.-1 ,,-iU bc more dur.obk in (/", 10"8 run.
1\' ~ maI<~ ""'~ l:>IodlI tigh. fTom .1><: j1:C11t<).
... )'OU an _
more Uun """ ...., of _ ' doSun wlth
61~ (ou'<!lWt ....) Iw"d.....oo boud :UIou1 18 in<hes lung
fbnrn """ 1:><:0: on thc jomta , 5qU:U'<' .., cdI!I" 10
r:..:.:,
... d piafIc oM boonl ' " !hc tIlId:nos spcrilil by t h ....
CutUIIjC u.. 1bm cmMCUt tbr boanl Imo ,h..,.. blocI<:<.
~h .bouI 6 illC!>o lOfltt.
Fur the p/)', ,,,ood btio:. ~,.., 111.0: width of )'Uur

,110,

Drilllnii Iwo holu On Ih. SilIm. ul, 11 U,IV witll


eorrKI IfIUP, USI a fenee on Ihe d'lII press 10
Cenler I~ workpleee unde. 1111 bll. Crank up Ilie Llblo
i i close 10 t~ bll i i \'OU can befOff m ,mng !O drll!:
vau need 10 USI n mllcb llroke a$ VO"' d.1I1 pren n.u
10 bore a 3lncbdeep holl. Bun a stOp bloek agoln.!
Ihll"d of Ihl wo,kp,tCf. and clamp It 10 !he fenct.
D'llllhl Infud segmenl of Ihe hole IIm. OO,lnll ab'M
."" Inc~s detp. To chinge bit!. (emove Ilie work
frnm !h~ d.1I1 p,." The "CIP block and fenel ""III
en~blt vou rl"',n il 10 u aCllv t he Urne poll tion for
contlnulng tht hoit wllll tht smalltrdlamt!tr bit.
I~

DOWtlNAKIHC; FUfTURE LAYOUTS

TCW'VItW, BlOCK

,.I

,- ", 'b
,ii
"
<.\
-,
)- 1

I
o

r(W
r~""""T"'--j
,.-

BaTTOM

!4"-dia.

for

lIol~

mo~nlll'9

bolt

c-1

f~OHTVlEW

InfHd hok ')


to~

VlEW. SASE

,,- ,,-

1 W-dla. bit _nlng

for

m"" .. tJ"5I boiI


y,- plywood

~ """ ""'" ond .. ofl bIock .0 pooillon ,h" ,,"Olt.


pktt DriIIIhc: ~I~n>ct .... hok: ~. ht .... fljI allC<u 1h

....,. d<qo.lbC1I swl'ch b,ts arid fini'" .,'" hok "",,h th<
II"" mi of tllc ,,~ thlOU(lh
_I:b:l. Tbt fcnL"c and ,",op bIock ollo,,' )'OU 10 ~ th<
"'lfoke< 001 ofl~ ".,.,. ... het! yoo cll~n,," bi .... }"el rMI, ....
. . ,.,.. nn ""um h tO COctIJ' th~ Slmc poaOtion.l "h>' 1,
....w It "'" """o _ "'" 10 .1",,,, iti<" .."'" ui<.

_<lilmct.... bit. bQri"ll

oi. s.,kct. b ll a OO bon.' thc b it hok. Yoo

tlt"ctl

'0

dcn tii< bII I>OW. ..""" II ",IIM fllth< bOI hol<. In t~ hIoc:k
ilbOUI rIc:I... "",,_
\ou an ..... a bl'JlC-<lI~mc:tct"~" (o. round""",,)
1It.. ~g hl. , a I1\tIf"tbr1!l bl! , ...... doo """u

*""" ...

""

1'"" ~ Ihem au. arid r h:"",, '1 lIiKuncd mlKh <liffe~


in Ihc ftow...d prod ........ ~ICSII o( w bit ..... d. I'd qgol you . , 'III"Ith ""ble""""r o( Ihoc" bit.- you tu...,.
TI>c biI hoIc Is ""pped hok. as you C"~n :c fn"" lhc
dr......m.g. It il th< ~n'" dlanlt"tct" ... "'" hi, }'lIl> ...iI ..,.,
1'1""'1100 thc ""'" ,..
10 Che d.-.w;ng, arid boIT jlbl
<kq) a>outCh .0 b"'ak "'1OU(Ih 'he .... LI uf the outkcd hok.

""""'n

""'ctId

Routing Dowels

1 t~ ..... kifljl oo...'d o OUl o( oaIo:. aob. d>ct"1y. :ooft RL:l.I''''.


poplar. ..... ln.n nd~. Alllhcx """"'<lsrun ,h"'-"'tlh
the oo...cI'ma!dna Iixt~ wlt houl a hIIeb. "" lon{I: "-" the

bbnk Is "'toJtchCPncd. Any t...;.c~ dlpo.. OI" ....." . . le3d 10


<."hlf><JU1 arid ."Ilntnlng. F.nminc your .."ck co.""fuLly. and
M ,.,lecth-c lor bol "" ... Ies

1. Cui che 00.-..,1 hlanluo. Cheek theoo...-clchan ror


you ....,,1. Ril' a IeSI hbnk 10 IM
~ )1"-"CiJk-d ror 'ht d<;jln:d dowd dWnc1er_No""
chcd! M. ni In lhe I ..fred boIc. It nl\l,., hc """8- buc not..,
""'-'II tha'}"" C2J1"t
by hand.
f/ II Is 100 1/gbI. "'""1' U", blank . .... k!1lIJ 1 Iltehcl)
&mo.Ikr.
lhc

>peC5 o( th~ ~' d

.um"

l'H 1.. llrlKt lon of th, fI.t .. r,' , IhrU holl'


(JII bt '>HII ,",r . Tlle bll 1I01~ should Ju", bruk Inlo
.... oulleed hole. Vou dan' nud 10 dflU any dNPI'
..... 11111.

J:

...
II

S. Mounl Ihc: hlocl< an th c has<. Uy OUl I~ bIock ; '


pa.llion OI' tit<- ~. and <nrukr .m. Iocauon o( tit<- block 's CI
bk hok la thc b:o>c: . At lha, .pot. boft, :an ~1.1 hnIc ""
th< bi. C2JI
llI"""l1h th" ~ iluo w bIock.
Drill mouruiflttbol' II""'". .. """"'" In IIt<- bJ"Ul
d ... ",ln", in bQth thc hlod< and th< ...... Counlero.ink Ihc
1>1.>1.,. In thc """" IIl.!ct"t flalhnd...,..., bolts .hrough 1""" 1_..1
""'c. iiI .hc bIock 0I"ct" tllcnt, add wWM:n, and lhet! thn::ad

f/ II

Is 100 _

. r1p "OOIher bIaok. m:tklnj: It )lIghU)'

I, <!F'".
DoooelM tng FIKlu,e

99

DOWEl BLANI(/ FEEO HOlE SIZING DIAGRAM

OoW~O;iagonal

dia. +Yu"

1-.

......) Oowel
dia . +Yl.."

SLANK DIMENSIONS

OOWH

Dowel Blank/ FeecI Hole Sizing


Dowel
Size
Wdla.

Bl ill nk

Infeed

Outfeed

Size

Hole
'y,," dia.

Hole

1,\" dia.

""'" "1.
' ~," "1 .

,.," dia.

\'. " dia.

~"

dia.

1,\" dia.

'~",q.

dia.

~"

' ~,"

I ~ ."

..
,
..-...
Cl\:..dl.

al

W d'a.

.q.

dia.

dia.

~" dla.

:." dia.

J4" dia.

W dla.

,"",," .q.

I y"," dia.

W dia.

1" dia.

sq.

Iv.." dia .

1" dia .

II

:r

II

~
O

Whc:n }"uu "..., c;lll bl ;"h ~-d ,he.,.,..,..,." bI>nk .i>:<: , tip ali
111<: blanks y.... n""..... plus . fcw "fW"'S, <O th .. .>1..,. H'1lJj: on
10 Ihc: COI"I"eClly.>ll.ed Iesi bI.nk, '00. 50 )"OU <"lin lISC il 10
'une . nIl r.nc:tune the fix'urt Sctup.
I!c: )Cn.<!hle ,'''''', Ilie kllJj:lh of II'" bl.lnb. t ""\It them
~ 'u 6 lneh", M'l>I<'< II .. " ....'h.' 1 . hsol"'dy nee.!. n",...,">
us".I!,.. an .. n"sable seaion
en.J tiut J!Cl5 chud<e.! In
Ilie "puv;cr fttdo::r." 11 .. , I 000 c""""'-""" 'o kttp Ihem as
1M>rt,., pu>Slble. n,'lng ,u rolll .. )C,,,r.lruutlo"lI \\.-ltlch
di.mc,.'f dowd i. OV<:m<achi n~ .

.,'hc:

2 . Se1 up Ih c fu"un:, ChLld: <hc bll In (1", ,ablemoumcd "","e<. and r;t1)C i, JlISl cnou!lh ' o <"lIP'u"" ,he

INFEED HOLE DIAMITER

..

~.

OUTFE(D HOLE DlAMrnlI

,,,,,<

(1", bit, CC11lCf ll."


clamp 1, 'o Ihc: rou' ....
" djU>! 'OC bi, bcigh, by sigII,i,,!! Ihrougb 'bc ()Ijl/tll
1>uIc. I12isc thc: bit un<ll IlS <Ip '" nU>.h ,..Ith tbc bonOQl_
r.cr of lhe oUltd bok.

11001""" on li. Noa , ... t 'hc: fixlu",

,.bk-

3. Fln" 'une Ih" <!IC'tUp. Rom a SCCt~'" 01 ~ l1li


bl. llk 'o chn:k Ihe bit bcigh' "'Uing. Swilch un ,"" l'OIII
. nd r<:ed ,Ile blmk Into the rue,,, ..,. 1\5)'OU <lu 'hiS,
blank by lurul. \'ou'U find tiu, il "lhn::tds" t"",1f Ih~ ta
fix,u...,. In utller ..... ords, )'OU """', 1"" ,, tO pU>l' i" twa.
"")"01> lUm Ihc blank , 1t will fd i,sdf.
\l'hcn ,he k:ldin~ cnd of Ihe bw.k cm<:rgt:S!rom
o",rn:d hok , ~w;td> off thc mula. PuII tbc hI.lnk 0lII ei
Ilx,u..,. Don ', bc <n'~' ~"""""mcd "';,h ,h" ,"'" doood'I
fiolsh ~, ,his [>Oio', sinee ~ lund-rcd duwd 1cnd5 ro ~
rou!!-h. 11;1.111<:1", focus un huw II fits Ille outf~"C<J 1Mlk. llI:
ligii"" ,he <luw,,!'s fiI In Ihc outfcctJ hok, the bct.....
flni,h }'ou"lIget.
'/ /be bkmk 1:,,,, '/ be fr<1/bro" /;b /be
bll is ' 00 Iuw. II ;"n', fnILK'1ng Ihc bb""', dbmetct la <qII
tlui of II'" oulro:cd hulc.
1/11x> bk"'k bl"d 1" IIx> o"tfte</ boIe, ,Ile bi, is
IIIw. ~ the bit
.Iighlly. ( Rcmcmbcr, the",
bUng dT~"Ct ~, " ... rk heI"<'. lr )'<Iu ni>c ,he bi, ~ 11l1i1,,..
fnIucc ,he duw cl's dume,,,, bl' L,.. ineb.)
1/11x> douw 1, Ins /h<m '''ug In //)e .."tfr<'d b<o/P, dor
bll Is ''''' hl!ll>. 1, Is ..,fDIl\lng '00 mll<h n""erW. A
dh;p;r.rity bcrv."cn 'he dowd "s ;md ,Ile hoIc's ,,~W

"n.

fix/'''''''' ""' ...

'''1)'

TUNING THE SETUP

BIT TOO lOW


The bit 15 not removlng
malerlal rrom the blan~;
the blan ~ un"t Ollmo
,he ou,feO<! hole.

100

Rou'" Magic

BITTOO HIGH
The bit Is removlng '00
much ma terial; ,he dowel
Is smalle, than Ihe
outfeed hole.

PERfECT SETUP
The bit Is removlng JuSl
,he rlghl amoun, 01
materoal, sa the dowel
is Ihe samt diameler;li
,he outleed hole .

......,.", ti>< do.....,. j,Uru '1) duucr an<! .... bI". "".. JPit:I.I
_
01 ti>< 00.", ', .....&ce lI"l' IDOl'<' roaN<" " ,,.....
dItct> .... ~, ....-cr llte bi'
k<dt 'he >ctup. An(! kttp 'CStinB an<! odju>IiIlJl UPt~
fOI'" ~ .h:lI II ...., fI'IOII "" )'OU an rm"" II. AIkl
..."1 ftd " """"n lhe lOl'tllp II lil!bl.lbc bI1nk "'II ..,..",
.dWppa.r In.n 'hc: fi~ ' u"'. 1>0 ch:lun, ,...., hirl<ling

oi, kt up thc powc:r feedc:r." 1'hc: bbl finbl, 1.


--..d br 'nc:",~...'n8 'he:.pced IIJ.tI lhe """k IIIrn. "" II
- . . pUt tht: hit. lbc ...,. '0 do lhis .. tu cttuct. Iht bI.nk
.pln MII 600 10 800 rpoI.
I ...., \-).Ind! porubk: Ihill lOr this. 11 p""kJcoo, n....
_eliud< npxll) an<! IlS opcal is ~""'nl-.'w,,JiIlll'O
.. 'P<'" pUt" Oft Il- I O HOO rpoI. SmaII 110....<""1 bI1n~- > fiI
"""......, tht: dtudr. IMII" """" mU>l he ,,-hiu"'" do ...." 10
.. You onlj' nn"J 10 ,,-III"'" shon 5ttIion un ,>fi<' mtl ol
lbobbnk. AfIc. '"e 00.-.:1 i51Onnnl. )'OI.I ltin, ,,.... 1" off.

. ' jIIN"tt driII, anei

R",, ' just tht . .. cI btfO<t chuck,ng tlle blank In vou.


powu 1Hd.,: You'l lIIen bt .ble 10 gft \tie dOwtl
... nfil mon .. Si .... II \'OII Shape juSt about t!lt ""9lh
shown M,e . Tu.n 1!It bl.lnk by ~nd 10 do II>IS.

,. Roul II.., do..-c:l, Il gon qllkkly,<.>n<:<: )"" 1J.t,,~ IIt"


laIft ICI up
fine-Iuncd. Il"",, '"" tl.iI! ;

an"

f....

A.0aId:. _ I n lhe driII.


1.S.'cb OII Ilte mut ....
C.IMM ti>< md ol ' he _
in.u ,.... Infd 1,,*
n Squtt..., , .... lItiII ' ..... :and >imuitann.>U>ly I'enllhe
hIml< into lhe hule.
l'l"hm )'00\'" fnl as mudt of 'hc bIank IIIIWtIh .he
ftl,U11: as )'Ou CUI, CU' .he !,O""c. '0 .he
,hen '"

li:

fI)U,,,r.

""~

f f.IllXl the do,,-d rrom Ihc-

fi~",,,,

::1

G. rut " .><,. of tIIc (/riU cll""k an" fi new blllnk In",
"'" dt\ldt. Rnum tuA.
Thc 1Ut\lJl: ol'hl5 !OulI"" ilo sud! d~. b:M~..-lIc1t IH>
. . ......,. 10 bir. pI ..... Vou gtl ' M driII ..ilh "'" bbnk aii
Dto.IbnI "tJI .... tb< pc<bl. AneI..tom)'OII alt' md)' 10
ni tbc powc:r, )'OU don 'l 1J.t,.., 10 ici 110 olthe driU h.. do it.

CI
v.s, '1'5 magld Swltch On Ihe !Ouler, Ind In.tM Ihe
bl.nk\ tip In
Infetd hole , Q"'ckly I"gge. Ihe d.llilo
.pln t'" blank, .nd .lmultlneou.1y pUlh the bl.nk inlo
Ilie hoit. Wilh I I~tle experience, you'lI dtvtlop I ftel

1'"

for tht

bUl

fef<! ,.'e.

TlN fl n"re's powu reed e . Is vou. elec"'c d,'II .


SpiMI"iI,IIe dow.1 blo.nk with Ihe drill U Ihe bll CulS
'l'"'Iduo'~< , h.. M<I finl.h nn the dowtl , To fit . '''<;Ie
dowtI blilnk In Ilie drill <huek, VOI> h ..... 10 whlllle

......

To ketp . lo nll, s lt nde . dowel 'ro m wh lpping,


fud its On,shed end Inlo I SIUdy "SI bJock cI.mped
10 Ihe IHck of lht fOul., IIble tOp. The tleady rul 1.
no mOn l~n. bJock with I hole ,he dilmtter of Ihe
dowtl drillfil Ihrough It

Here's " turn"bout an the woodworkl",


c:onvention. Turn Ihe wo.kpiec:e by h.M
in Ihis jig while using your ,oule. q
sh.pe It .ound ilnd smOOl1l.

:U do....ds. 5implc roun<.l "'pc.,;, .nd c,..,n nM>tk""Y

, _-'

om. men,<:d spi ndl"" co" t>c I'n><l'K'<"! ",',h fOI,R.,.


.nd 1111. priml*~ "'the. li OI "mplc !<, m,kc (as ,11
good jil\S arc). p,t it tus. lui uf pOlenti.!.
,.,.., e>Jlcd il a {/""",I-tuml"l' jl!! l>eco"-",, ,har. ,,ltal ,II<woodworl<~r

",ho told "'"

,1>0;"

it ust:d ;, f<)f';

oper.",,,,

m. ~in !l

dow&. ArnJ Il /s. wminll


,"nu Imn 'he spindk
t.t.nk as 'hc Culler mu,',,", olon~ i~< uis ll,~, ma~~. II
ruund Af,e. I rn:uk LI'" 1'!i1O II) "ul,1 n,.lilt~IIh;l1 il cOI,1d
"" cUSlomlzcd for 5I>mC ol he. Ol><""''';on>'' "''eli.
This jig J!OI IlS >1= ",hen Sa" .. r.'I<."!....,.' ""k><lwotl:r
Yrung Olan n=k1.l a 4-lnclHll:onlC1<1" """"d for. !Oble b:oS<'
~"'" hc coulc.I,n nnd ,,'11:0, ".. "".:.10.-.1 ...-Ml}' .... <k. anoJ
bcc;o">c hc didn', h:"" .. I:ithe.Oun tunlCtl '" hi> mut<1'. 11,~
....-nion of Ilie jig >hown is IU)' Im~'1>"'I.tlo" of CII.,,", lig.
In brid. ",h.1 he <lid
l<> ...-n:w ,,,,,.;thn fI,ur_
sid"d (>1)-..'00<1 b<>~. ln ,I>c ""nte' "r c.d. c"d. Ch ." drl1ln1
.. I,,"h hule. lle moun'ed hl"n~ for tllo dowcl 'n"d"
.h~ box b)' drlvi"" I"n~'hs of Ih",.d,' ~ ro<! .hro,,~h 'Ile
Ilolcs an<llmo Ilie ends of 'Ile bI.nk , II,' .1,., ",,,,,n.ed.n
imp",,'i"-'tI handl" on OlIe ro<! so II.. ~~'uld .um II", bI.n~ .
11,,,,, Chon m.<k a new plp"'>OtJ bas<'pl.'" for IIi.
1'OU1<'l', One ,,-Id .... nough 10 sp." Ihe ",id.h of 'Ile bo" .

w>.

,.,

'1'0 fix .lIe rum". owr .h..


'bI."k. Il ...11_
lI."i<.l<" >lrlpS ro Ih" plywood l.~l'l,''''
l I> lurn .he dow"; . aII h .. lud 10 <10 ".." .s<1 up tbl
ruu'e' ,,'i.h. Slr.igh' bil . .....,.eh it on, .n<1 ' -c' r >10,,'1)' """
It alon~ III<' top of the box ,,-hllc h... Im<ll,.noou.ty ~
'he hbnk .ru"nd .nd ' '001''1.
Chan'. iis, i, "-,,,nlS. '" JoI><;pcdfle oolu. lon .0 an _
d;"e l'n.>lllcm , Ilul " holds ~ ..ml.1 lOr a """,~' h., . . .
floibk' iig, <.>r>C 111>" , a Jiule Icss imp""iscd,one tIu!"1
kccjX' Af,c' nooll1inlC wi.1l .11<' basic doign ond U)ing'
("", kka,; ,h., dldn ', 1"'" OU" J ""nI<' 10 tiI<' c:oncluslon 1Iw
)"'<1 ...
=111' dcMWl" do.... ck"rning i'l!.
" ill ~
mOtb,,, '-"''t:ry jo/>. \"" an: goinB
h..." .0 """.., lhc ...
piece> '" ......'UIl'mow.. " diffcl't:fll >{limite lcng.hS, YOII d
"';' nI la dril1ll>c e!lod plcs opcc:iflC>Jty ro. l>pcring job4.
In mile. ,..unls. keep
lig, hUl fi!!"",, on doinS a Iitdr
""" ,nI!. drillililC .<Iopt II la tiI<' tob" hand,

n,

o,

'0

'o

,ba,

.h"

Bulldlng the Jig

it,..

111<' ;111 I'''-'>enlt:d h"", ",ill t>kc:o. bl.:mk "1' la ~2 inda


long, Jf )'OU "'ani' iig ,h w;U do .kJ<1w::t bI;onk, o.

know .h., 32 Inchn b ",uch .00 ~>nl! for .hl: nttds)tll

DOwnTURN ING J IG U PlOI)(O VIEW

~.
.,.,... {It

llle:n m<llIil)" tlle: tlint~n"""" nuk,nst t"" jIg


.ohonn.

CuUinG List

,,"

1. Cut ltot p;lrtJI. I n..de onY!lA mooolf rrom plp'"OOII


""""'"-Tht ditnorn:Iions of .hc
.pirocd 1' ,1><"
ClIaas UsI. Cu! thc bu<:. !<i<k:i. an<! cnd, lOt .hc: bo . >
5dI.Ik.....,pIa.c fo, . h~ mu.e. 1 ........ pItu "'''''11'lk
lot .... baoq>IaIc

Oim en si on s
" . X 6" X 44"

(XI""'''''

2. Bon: .hc ~p l od Jc hoJes 10 .he c:n4I. :)(utly 'hc


...... 0.. ... il,).,,,I. IIJI>tI<' eoch cnd p..: ..... h. ",rie>
....... "'="" 110 ' lut "",.." ..1<llfk""". di'm<"Ic",,.( "",,,,,'1
aa lot """"""'" IIIIlthlM ~If ~i"", .1Ie cnd
poM>.l'or tIM; Ilg tn ,.-o rl< pl'QP<'ffy, thc: ull of c..rn h..", In
_ .... pIt mtIM "",.cIt Ihc: .110 of Ilie: ........." I"'''''I;nll
" " ia Ihc Olttc:. ""ti piccr
t.zr OUt <hc _ . an<! tIriIl . _ OII 1"" drill pn'''.

Qty.
2

SidH

,,,,"

3:

W X6" x34

_.

II

~ X6"x6

:" x6xI !t"

lU.eplltte

H dwocxl ~

(lant pI.lte

\1" dl . X~ "

C.~nk ~ndle

Cuodt SI"P5

'lfjxltix6

Oowel

It" dl . X 2'

Oowel

locklng'p,n shank

:"dt. X2"

Oowel

Hardware
3. M5c:n.bk Ihc ben:. This;" as >imp"'~' Iln'OJt up
.. pam.tlriUiIIlj piloo _
. an<! dti>i llll ...-rcw . I .1l;lchcd

21-.- drywall St' .... s. '6 X 2

.. ""'" '" Ih~ ~. lhen final Ihc: cnds bc:"H-':" .iI...... \1;1.1:. su"" II><" i(Ia: :and ftMb .'" nu,h .round

I ""n\lt' boiI, ~20 X )"

.. _.

,hol.

4. Muc the cnnk. SlutIy Ihc: drAwl"l! c,,"'. 1.4)""'-

T"ttr mru: pbl~ II ' oOndt har\I.., ><JtI. II I~ bo-<k'.IIr ~ .


lItough Ihc ...'idlh of.1Ie
koo: .,.." .1Ie: <I/.It. .
<iti 01 "'" drdo.- I NIIlcU. Thc ...... "k .. mll"nt"" OII ' ..
m K ~ ""'w:r boii usU>1I' 'f.nu. ~nd
op nUl>.

""'.p , ......, "'...

t"'''' ..

Ta lOCOItltIIOd:I.c both Ihc c ..... k pt.:tIC . nd t ...'U n,,11 "" 1....


~ >tlon of tI><" h:oltJtC'. b.,lt . "'" h:o-,,,, tu
tii. ' iHn<'I>dcqI <'UWIICfbo<c. "" "",-""" '" .hc """"'1 '111.
ArId suiubI< ""'p. al>otl. 4', 1,1dIcs wi<lc . and .........
.. murpoInI "'"" HncIt 1'ur~.t\C1" bit. <lri1l <hc coun-

1<,.

~ (101 thc ttfI.trpQlnl. S...1.cll


'.-Incit bi. and drill
. . . . W ""'"''''''..... m:tklntc "I.'IX hoIc: l.;Jy "", and

2 IIOp nun.

~20

I TnuI. " ,20

~ 5<ft'w. ~.

Xr

4-8 flal w.shus. ".


II..... II><" ' .. lnch-d"'m(1<'r ""'" for thc cr."k t.. n""'.
Set "1' tll"Tnn,md IIbcpbl" (~II" ~9) to eul. 2 \ ..
Inc hr.dtu> .n.- :.ct th .. Iram_r. pi''''' In the ~..,n.c . 1>oIc,
.mI ."U' tiI<' 'Mf'<' uf .hc: <nnIt: pl.,~ . llo"lnS """'" III ...
",01,111 .h.. ph'Ol """" ,,,. ... Ineh dl.n'''tc. 10 .omrr>od ~ tc th,,'f.nu. Il.hc 'hc T-nu. In pl. c ~ . Ghtc Ihe h.ndlc
In ploce

Oowel-Tum">oJill

CI

H.It,dwood .\

Lock.J"9-1)1n gtip

:o

10)

~_ _

DOWEl-TURNINC:; JIC:; PLAN VIEWS


SECTIQN

TOPVlEW

Hanging-up hole
ENDVlEW

ENO V1EW

SIOE VIEW

c:J

.-...

Maximum dimen, lons for a blank

6"

--- -

--- ------- -

...

5"

Tiil end

-----

}4"

al

Crank .ocI

IIOTrOM V1EW

II

L -_ _

~~

_ __ _ _ _ _ _

Il

~.

CRAHK LAYOUT

FRONTVIEW

BACK VIEW

SECTION VIEW

)4" o1la . X ~ d" p counterbo

durance hol.

,-~-:'-20

stop nut

,,;;;;;;;;;;;;;r-;;;~ Handl.
........., W -dTa. x

104

Router Magic

4' dO"-.1

IASlI'l.A TE tAVOllT
I Wdia. bit hol~

''''I'-__ Culdt mlp

Hlrdwood -~

Sow boiI t:>""Y'lti"ll I~ Thtnd a .1001' nUl 0'''0


!I'd.....,. bolt. )",,'U .~ 10 I"P llK- 1>011 In wpal. o( VbcGIip anei lum llK- nul ... illt a ~h . 1\tm .IK- nUl ... &r
8 ...iII 110. Now .um thc cnnk ..... 0 thc 1>011 lahtmlna 1.
...... """ "OI' ou. Add llK-lOI1d otop nUII.

S. Make ilie bastl ) I:I1~. TlIc I>asq>Wc iti ~ for


Il!' tIM<:t ..1Ih b...qlboc di;y,lder unda 7 Incho. .. hldt
U'''f,dIm norftW}'rou.er. lt ~ Ihc """eron .....
"'" cdIa 01 tbc 00.. ..iri, Ihc bit dirlJy " , t t tbo:: bbnI<'t
DiI- Tbt JIIidc>' 81u.td W ..., bo>q>b.r ....ap lM I:wcptac.
PinlllU be.;tid rrom moi 10 md but oot ..... 10 .....
Cu! lhc b:ucpb!r rrom \o.indI _<:tiaI. I ..sed a p;ttt
t/1ICI'J1k': ... I coukl _ lbt bll "'.........,1). n>iIy, but pIywwd
WOIIld>bo bc 5Ultablc. (I don'l thlflit k'l ncc~.o bur.
piott d 0I<T)1ic ~ for 'Ilis "ppllc::1l1on ")'OU
""'II' d pIJ...'OQd.} U"", lhc ..........n fIctory b:ucpbLc as
,...... for driIIina lhc mounUng~ hoIct ond 11", bI.
. . . . . AlIK1> thc bucpIlI.c 10 "'" tOIl.er
1<1 posibon tho:: g<k Oltips. ,,'Iuch an bc t...hloncd

Iu,.., """*

"!CnP

rippiotgS. dlud: "......tkIiaJncter Slr.tigh! bI. ar


f1fOD'irlI bir in lhc ooIIn. So:l .hc: rQUIler .... tho:: pg,_
lip it dim:tIr mc...., "'" _
in ...... mei. AppIy ~n""
"101ht 1IJIcIr:I.:aod .ppIy thcm 10 thc ~ of lM
~.1Igh. :qpinsl .hc: ~ 0/ "'" bo>1. Oamp ,I1Cm

......... dornp. {To oruch tho:: >ll"ipo m my Kf)'11c t....cf-r.1 dn;n.., _


~ Ihrou(!h llK- buc-platc Inl" 1""
.... Ilripo.}

Using the Jig


",..,una1O thc $pCrifi<:$ of n>ul.er.. uming " du,.d. le!

.......... 11'5raj:Qdllc:!.
Tht liI..no..lI in 111C pb .....ill OCCO<nn>od:;J1c, bw.k

tha! 1I.t indtc:o "'I1W"1f. Unda Utc: bot rondltlonl;. lhls ... in
)"idIl " ~

cIo<o."d. Ir )"OU .tim bUnI< '0 ;In


ocup I>dl:>rt R>OUIlI'1n/!: It in !It<: 118. )'OU an prOOllC"C
_"Ci .round ~ lnocho In d~m"'er. max. (Of rounoc. )'U'U
an mb.., tho: 118 If )"OU nea! an c''''' la..,. round.)
To , ....... OIrIIaIIcrdl.1.mcl dowd. )"OU 5houId ..
urnlno!I ...... ll1C bir an 'l "" Dtcn<kd ''''ry r bclow thc
ba>cpLl1c; 10 thc doK. 'O ,bc 11(1'- 'OJI ~ ll1c bbnk I~.
."" ""tler A IelJ()rI.lObk tulc o( .humb 15 luIf ,1><: dbgon:ol
u1.!lIc "'1""'" bI:anI<.and dtup rhc 10C>d and ...iI ."indlc looko
llut: di..una: rrom 1"" lup .,..., of ,1><: en"->.
TlIc lonIIOI bLanit .11C ~ wiU accommod;!lC 15 j2
ind!Q. By o..cndlng thc I'i<k!l (and, lf ~ry. thc

be:.""

bonom). )'OU an n..... n 1on@I"T IIbnk. of COI'rIC To


1uno.IIc ~er bbnk ( ,..try .um mOl'e ./LJn )"Ou nd1).
lI"I<IVI:.hc.>.II rnll do!cr'o lI,t c ..... k cnd. AII)'Vu
10
do b puIllh 1CTt'W.'>10 r= 111C rntI plc. "'1IICn>bcr
llcar In minii
)'OU ClI/1 '. ruu he emil'<" Icng.h. lf)9U
....00 doK 10 II><: blall"', tneb. roo oUl< goojtlnll.I><: JiIC'1
md piccn. So you wIll II ....,. bit of "......'1c 10 ulm rrom 11><:

Iu,."

.Iu.

complelcd dowci.
1. Set u p . h c 11g. 1"ht: dlam~"'r ami ""ng1h of 11><:
<k>vo"d roo '""". mus. 1><: ronsi<krcd 1><: '!<Usa.
,1><: J:inh ami Icng.1I or .1", bbnk n=IN. IklCrmInc lhc
MoI """I'1on for lhc ~plndlc holes In lh~ ~R' I mtl pIccco.
Oomp 11><: JIII.o.1><: ,,urkh<:n<:h .l"ht: JII! _ ~
... lth ;In o ....loog ~ sptelnc:ally for ciamplrta. M:d<r 0UI"t
."" dan,p .. Il", cr.nk ~nd doa;n', Im~oi~.., Mth 'bc a;onk.
Ir IICCai6;Iry. n"nu'~ tit" cntl pleca ond drill \+.ind>d.i:.omcte< spintllc
Sandwldt .1><: cn<b _
dI"iIl tJw:
Iook:o in boIh .. onc dmc.
Il~ tbc wds. lf lhI: bbnk wiII bo; .v.oncr !han ~
lndIcs.oh.ift thI: llIlI mtl doocr 10 "'" cranIt tnd., 0fJPI'0IWIlI"

Cokul:o."

""Ia.

Oow~I .Tl.l m, ng

J'II

105

_.

:::1

I __~

ROUTEIITURN INC A DOWEL

1. Turn tlte "~nk (wlllcitever d,rectlon you prdtr)


10 spln lhe bl~ n k .
slo",..,. rrom Ont end of rlte j 'g 10
Ilie olher.
1. Tht brt,..;11 eul Ilte sqlJl.re bl.onk. transform,ng It
10 II rwnd .

2. Cut a nd mount the blank. e .. <ht bbnk(.) 10


sizc loo c<", "".., sorn~ tuming ,im<.- to,. ripr>inllthc bIanII
10 .n OC'~I!OIl . lIut fr;tnklf. you'U tus> tot ttaWng tiRIt OII
On~ m:ICh;n~ ro, time on anothtr. sult you...,lf. Tht "".,
n:uon fur doing .III:! Is 10
S' l"iMh "'1""""0 IIM: NI
Scrib<: <Ilo~ on thc bbnk's mds. """ <!riU ~
dia",,,,,,,, pIIob ;"'0 'hc OKI:! fur ,IM: ",,,,,,uing >pindit .
1'hc IDO'" """,,""e"" you <:an aJitIn u.n.. hoIor'.It.. 00,.,..
I lIli" ,,-..;ho:n; 'o oIt"'t LIM: bbnk from IIM: lilr;', crn.b.
Slkk Iho: ~T~nk >Pi ..... k: ,hl'O&'Sh 'IM: hol<: in 'hc lil!'s cnd,

fi,.

IWIJI ...'llShCr an ,t.. ~ 'il'. ,hen fi' thc bIank .


ri<lrI. TUrn It.. (nnlI: anei d,h.., ,t.. tpondk inIo ,hc
Ihc bW>k. 0riYr ,hc b~ KInI' ,~ 'M 1iI!' "' ....
lnIo thccnd of 'hc hbnk.

,.U

Adjusi 1"" jl, 10 KCOmmocll.." Iht blank. To rDYtll smaJlod'lImelef dowel or splndlt, as l t lefl. Ilie bl.onk mun
pOShlontd " 'gh in tlle! jlg , A IlIlrly "-roeodlll""ler bIlnk ... ,11 be SUSP'!'ndrd lrom the m,ddle of ttlt enO p,e{t!. fOf /1
!hotI bIaIIk, tlle .. ~ end elin slmply be m~ c~er 10 Ihe Clllnk end. n ~I rtght.

106

louter ,,"goc

pup..dieul .. ,o ,m, bit n j ~ Ca> oppoKd to one p . ... lld


lIu, ' Ile CU tlin" nllI<"S U e ... ~iu."<Cd .,
tIonr mmniu"" ... 'he horlwn,.1 . u rf:u.: ~ of ,1.., cu,
lIIa>do inLo ,"" ,,,nl<."l. .... II." tlun ,""IJR ~ ~ h.rp. "ilhi'
..... du,.. In ~ . 'h.is bi, Kem) 'o 1e. ,"C smoo. ht:t.
.... " .... surf:>tt.
~ or ~ bi .... st ... igh' bi ... bonom
drairC ~:IAd tnOt"ti!oing bi .. an aii bc oKd. I n."Com
..... tIw )"OU .,. ..i1ic:t1c>..". 01 ,hcs<: hilS yuu ,,"'"C. I( 1.....
~ """" :oLuy Ihcm alL T1I<1I usc .he <>ne II",. J>ro<lucn
II tbo bi, nis).

",_...uc...

"""''ci

1"" ..""'- R c""'~ ttw }'OU ,.,.,


""II." of Ihc:
'hen l"OU al, ..... "" bi,
cx,clUio<>. Thc: dlam." .... II t..-l Ib. ...al.... 11M: tlWnc:t.".
of 'hc
" iU hc ml""nI by lu-lff tho; ol..an }'OU
",o"" 'hr 1>1 ..
Ta n ........ ..,
<lWncIer of 'hc:
,,-hile It b >tiU In
tlle diirnc .,.. of

clwtWl\I< ,""

"""''ci ..

"""''ci

u...

.).., 1111. ~ cal/pers.


Wht:n }"U .n:

"""''ci

olt_. """", '~ lhc ol<J,.d rfOlll .... jijI,

1"00'''''

..-td! Iltc biI n , .... n>UtCT. 5<1 ,""


un ' .... Iill and

tlIc biI almsion. 1b Start. turn ."" b1.nk .... fu ........


!tu il up. :;.:. thc """.". In poo;itIorI ond u'e,1d ,1... bl. 'U1
I botIt::mo an thc bbnk. At ,his ..... "llJI.l"OU' li,,", po.s.< ...ill
iot ..-.y ,"" o:omns oi. "" hbnk.

4. Rou, .M bbnk.. Thc flIll ,.....

'*'

)"OU
,hr Iil\.
01 ,"" opc13'ion. Cnnk Ilie
lIIaoI< ",xhile ond koI .hc: """.". II> lhc: Id\ T1I<1I f<.l
I to th< riah<- Tbm cranl< ,t... bbnI< <'OUfI.crdocl<..-bt; Ind
f,l dIt """rr from rljtIM to Ic,. and Irft 'o r\chU'",,'1 pIl...
II' Olt . 'bm tt... l"OO,a b ..dfkoNing. ...hidt """ , <bItahie
\...,- Iltc n,r 01 )"ti"!" ~, ,..,... cIoc:s Ihc: ipd o(
iIn~""''''' ~ and ~ o(.hc: ~....
l\1If;II .\Ir upnlcncc b ,h;o, ,"" r.c~, 1"" cranl< hr

upc_.' to drvdop

..mIC

.....

-""'", .....<ba
I ....t flUm 'hr ....'
.hc: Idi, aonIi:lng ....
iIInIc dod...;,c.To b<tdn, tip .... """era l"tIe.., Ihc: bit '"
<bI o...... ......n:. S"'~ch II ono,ht.... "'-1 M b;ock on '''''

,o.."'"

'III.

!wt CIIIIklnt! ,hc: hlank. """ >tadi", """.., 1""

1"00'''''., "OU

...., fIC<"d 10 """" .... l'OUter ""'Y.


M C1 )"OU'" ck:IlM'<I 'hc: C'Of1I<n from .1Ie bbn
fIIIIII!inIl il tii. roun<!. ""1..... hc: biI ato:mion ,o :ochii:>"

A"'" fini pUI wlll clun off ,he cornen of the


~ u '/OU Un
Mt,fYrn round .

iti .

1. won ~ nKenarll y produce a

The finl.hfll doweJ's surface m~y no, bo Pl'rfK'.


f ... ,h~ bo... urf~c~ fin/sh pOu/b le. ma ke a ve..,. IIgh'

Cui on ,tit finill PilSS. movlng Ihe (oultr Clul.e slowly


but ,,,,nklng th~ bl.nk fur!>U.ly. A IIgh. und,ng
should clun off ItIt mlnu,e ridges and ImPl'rlKlIons.
(Of cou'.e, ,tit ch.. ocler of Ihe wood you Uit wlll
""~ a 101'0 do wlth ,h~ qUlli'y of , he final'urflct.)

Sand Ihe dowel . A IU'M' .... nd. hi. lurned .pindle


whil<! il ....111 moun,td In ,tit li'tIt. Ind r found Ih;o,
I .... 'S ttlt taS"," WIY to .... nd a .......... , '00. HoId ..
.... ndlng bIo<k aglin .. ttlt ~I. and , um ItIt ,,"nk. k
worJts wlth .. PIlI .... nOe lhough a beII .... ntitr II 100
crude aOO a random-orb" ......0.. i. 100 err~.ic .

TAPERING
TAPEIIl)I,yotJT

: ~.
RotJTINC TAPER
SKtOn vWW

Cflnk Is mllunt.d
Of! s_lld l"mfW
lnd of tht WOrl<piKf.

SPlndlt! ""'" is d rilled


on ,ngl~ Wt~n from Ioyout.

-...
:1
-

Tapering

RouI!n& I tapc1'<'d splndk" attOnlplishcd ~unply by likm.


Ihc u;,s of thc bIanI< In thc Iii>Onc CAd i> hiflh, thc Olhtr
Iow. T1M: ...... ,~ r """..". baeI; and fonb In thc - . . k\"d
p!>.ne, but Ma..... Ihc bIanIc i> :mgIW. Ihc ro.uh Ilo
tapercd .pindlc.
TIlI, Is noi<: ... h~..., you nttd to ",,",oml.., Ihc n><l
pi~ for the pro/<'<:I for thc blank '" bc roI.ted whhoul
bindi"S Or jiAAlill3.lhc r>ivot
In II><: lill e"<b muuld Ix
~ngJcd . So:o ImI Ih~ cnnk ~ ' I bind Orllhc cnd plc , ~
;,. bcol lo I.. ,~ il an Ilie hlgh end of the bLutk .... ..J1U",n In
thc d"",1113 TtI{J<'rl'IJl.
. ._ . .
On plIpcr Of 1\(",1' boonJ. dr\lw thc 1'11"" full~wl

"'*'

10101101109 <II bl,o~ for uperl09 requl.es the I~I


slIlndlt! 'o "" hlQhe. In IlS IIQ 'nd ' .... n ,"" u,nl;
slllndlt!. The splndlt hoIts In 1"" bl"nk .ft stlllloc~ltd
dud"<fnlff. boWl!"'o'ff.

SII"'ch In thc rIIA an<! Ihc tpIndk boIu. Dctnminr


frorn thc top ~ '" Ihc "- cnd510 II", p;YOII
IfIIIIr oIlhc: opindlcs.M)"OU ........ out t
Ihc
oIlhc ~ bIanIc In
bIanIc Of! tbc tablr _ or joInln bd::, ",

li3. )"OU1I .. ~"""",

....u 1_) pai", 01 ph"01


<>ne CAd '" ,1><: bbnk Slkkin up OUl
..,u"" moi b II tbc lIrnIts 01 thc
h<>Id Illows you 10 ""'SIt. tbc blank 10
KCO<Id X1 '" hoIo:t ""JIO'il\on$ Ihc
redU<! 10 IInbhr<l 01 ....
1<)

)"OU

bit.

In Inr cu.. by OUl 1"" ""~:~ ''''.~'':~''''''


."hc propc:r IIlglc,Thm Iruull thc md5 In "'" jiI..

)4ouru "'" bIan~ In

Ihc: jig, >C1

""

Iht ""III ...., anii IUUI

"'1fIindk as )01.1 would in makRg a >!""glll oo.."C'I.


Simple Turning

0In )'OUw IIIa>InN Ihc proceoo 0I1IIminI!. blanh in>


..... and tapao:d rounds. you'U Iitt Ih:d, .,.;u, 1"" . . . .1
_ JVU (;1.11 pn;;><Iucc _
""'limn"Ml' nnbdll>luntnt>.
~ rinp arod 00'.....
la...... !.han rq>Ol a loc oIlnform,a,;"" . In mc: ",k.
_10 lht dupl .... OI> _ing arod .... ng "'" It(..n~.
(jIIIr 169). That. <lot. Ia l<I more tn."OIvcd ,o build and " 'IIJ
. . .h lIII:ft oophiS!ialcd lumingl;. bul ,"" bilS arod
..,. ollhc: KdlnIQue!l I.*d .:an bt Cltficd OVe. 10 "'..

U,""

.......pk;;w.

Fluting
_lut> round, )OII nccd an Ind<:xlng whccJ.This is a disk
..ud otr In rqub. IocrtmclllS. whieh )'OU .. \Xh 10 tbt
bIoJIt!ol pU 01 "'~ er.lnk. Thc iR<k:1l whttl allowli )'OU
_
lhc: bLonk a Spcclnc nun>oo of d<'ltl"C"$. ,hen iod< il.
bt an lhal m..kc a SU". IJ;h' CUII"" kngth 01
bIanl<.
1t)'OU UIIC " Slr.llJIhl. mvnbling, Of botton><k2ning bit .
)!OU <"Olt ""'''e """.. gun.I , hal8O'w. Of """'JO'W bilkt .
"-ah ron:-box, )",u ..... n mul uadillonal, dp n u to:$ in..,
lpbJlI: Wilh <:O\'lnll bit, )OII '''''' etnIe bro<od, >IWJow
...... With plun~-poInl """"""U hil, )"tIU OII roul
lnIo "';"'('1 "",",.11' lhc liJ is kI up lOr u pc:t'in&,}"tIU <211
raiIy porfornt thQ<: CU" OI> ..po:rcd pitI<Iko.

'o

Indor", nwb.bu! >implo. II hc:U..... IO mr mind, rd m:oo..

mcnd makirt ....'htd wilh ontr tbo nurt<s yuo'lJ nt:nI fur
11>0: job :oi hand. \\ben" new ptojcct <kman<b IUffen:nt ""It
"",tIt:Il;"". hn:k_rn:Ike a II<"W " 'httl.lt ~n 'l l:lke Iort!!.

1. Lay 0tJ 1 Ihe ",hcdo U.., -Inch plywood ti<


mnIIIIIlHIcruilY lIbtmu.ro ( MI)F); ro. 1. )'OU1 pUI"J>OI'CS,.. an
,,1. h a 12lnch .... ......, Locale Ihc Cenle. of ~ he oquarc; \bin~
a rum~. sctibc 6-lnch-di.mC1cr ci""" ,
You.:an dlvklc up lhc ci""" In" , .. li<1y 0I"'.. ys. [)on't
II"~ orrfcd ~way .00 ma'" 100 many
though. PicI<
rn ..t ....... lIII"men l and folkrw ,b( "pproptWc OCUC1KC
lhown In II'" d ra",1np. Oncc )'OU'"" >!cppcd oIf Iht ""'lI"
men'", I.bel IlKm " 'Il h <k-gn...,.. """, Iabk OI> Iim pIiIIe
convcu IIK n .. moo of JCjU11CfIlJ In!o dcgn:u for )'OU.

KgmcrI".

2. ROUI OUl Ihc dt~k. Wllh lhc byout ...'Ori! done.


\ot.Inch ph'Ull hoIc: OI> W call cnn:ut. St1 "1'1 }.,..
""" .... and tranuncI. and NI 1"" dbk.

driU a

t""

Ml.king the Inde;1ling Wheel

.... b lhc: bige>I pan 01 tbt job. """, .....ing Indu


IIJffI Utyovl l'Hc: ......-u how 10 ...... cornpoo 10 ~
_ tbr _+ood ,.. )'OU ...,. h OUl. I ....,.,.- )'OU coukI U5C
(IIOUItIOr and 111)' ..... ,,htd with a lvupk 01 dottn

. . . . . of

...-

Setm.nu

S ~ments
,

~mfn\S

72' fi;" ;.....


60' Uell

~ments

45 ' uell

12

)0' uch

~mfnls

"=',----,

24 U9t!'fnts

15' eO

r'

"'" .....

f\

Th e Ind ... ln, w heel r.pl:lus tlll ",.nk for fllll ing
Ind bUdlnQ. Thls one Is IlIld OUl with 12 posillons.
tach with I locklngpln hule. Iv Ins.nlng 1'" kxklng
pin Ihmugh a hult In lne whte lln~o li hale lft lne JIojI
.nd. liS shown. you lock the bbnk.

INOUWHEEl LAYOUT

SIIi"dIA,

-It-l\4"'20 ilOp nul

HlInger bolt

1oi"20 X)"
C,ank pl:ue
Dowel-Turnlng )Ig

109

INDEX WMEH LAYOOT TRICKS

:'--1 '

."

"'
SI,O

6112 segment.

"9m~nt~

@
A. O.IW ~

clrcl~

and ,wo

A.. Scribe a titei". ilHI! the

dlame''''';1( rlghl anglu to

compus set to tlle cllcte'.

uell 01M., rind Ilie mldpolnt


of a ... d l\ll, n shown .. , M.

,"d lus lh,oulll>oul Ilie IIVaU!

pfocen.

.-...r
fi

8. Set i compus 10 radlus AM.


Wlth the compo.u polnt on M.
wih an arc. local11\O P.

8.

Maf~

a polnhllny polnt-on Ilie

ci.,,,m',,.,,n,,,. t.aboel it II. Siep


off fi~ mOte polnts ",.ound tlle
eircumf"."nce .

A. Slart wltll il squa.e.

~<ttf

II.

Illen scrlbe dla!jOnills, A , ..de


scribed In tlle squa ... w,1I how
II! c"cumfe.enct divide<! InlO
elllht equal seo~nls,

8. To get 16 .'gmenlS. S~tl


compa .. 10 lIalf Ilie leroglll of
a d'agonaL Settht comp;ilSS
00 uch coro~, arod m k t~h
ad]ololng slde .

C. ReStlln" corn"".. 10 radiu. AP.


Stati al A. ind slep off fout

addnlonal polnls a.oum:! Ine


circi,,', ci,cumfe,elKe.

C. SpIn Ihe a" t.t. l w~.m Iwo


poIOIS. WlIII Ilie compus 00
poIol II 1, strlke In I.e oulslde
Ilie cl.cle. !.!ave Ilie comp.ou 10
poInl '2 , Ind slflkt iln il"
I(fOU Ilie fi.51 . Uu.
str.lllllttdlJlllO eoonltlle
Ircs'lolersKllon 10 III, ci.cI,'s
cente.pOinl.

C. Br tllis p.ocen, each Sldt ... ~


lIel tWO new m.rh, brlnlllr'lg
Ilie 101"lto 16.

$'
O. Ta dOllbl" tne number of

polnt., set tne compo.ss on Z.


whkh evenlv dIvide. one of the

five segment . Siep off fou.


addl tlonll poinu around tlle
(Irtle', elrcumference. uuend a
radiui "om the cente' to eaell
mark an Ilie perlmett .

an pO'nlll7.
.nd SlIp off fi~
pO,nts
a.aun<! Ilie c'fCumfe~oce. rau
un now scnlH! d,; f.om Ilie
eMIt. 10 IlIt 12 d"umftf~ntial
m,uk$.

O, !'ulille comp;ilSS

mo.,

O. Scflbe il cl.cle. hltn'; a rad lUI


from tlle cenl~. 10 eacl! ma,k.

IPQI>.' drtllN a !.Hnrn hok .1vuugh u.. dI>k

I abo drlIlnl
Idr la ."" Pl', md pIooa " ......"C1 .h..... Ihrutoah d~
"III Ihir "bed Imo ' hc md 1'1"" Ihc ,,'bed and prn.:n..

........inIl .. ......

IlriIIhir ~ OII ..., dnD PftS. Cb.mp ""'~I' 10 "'"


~ 0..:. Ihc ......."'" LaIc hit In ~ p.,..;N ......
... k 1'1' Ihc WI< bt thc drilllnt!: oi IM
hok. n."n
_ .."..... u.n....p. ,"" dj,k'5 pA'OC hoIr "'10 ..., """~p
~ 0rilI1t.. finot hok Thm ,tic ... hcd .0 line up ,hc'
eal
and driQ ~ . Kcql lJ>UlII un, U oii 1"" hooIeJ .""

. . pooo

ar..

"'*.

4. MUe the klocklng p In . 1 ..... pin ...,;o, " . . frum


' " pi<"tt> oi """d I driIIrd ...0J>IIrd ...... In,o 1"" mii
fii ~Mnch ......d Ibm JIucd ..,.,.. fii ..........
'*-1 IIIO thC'
I uimoocd Ihc Jpip .... I Ind! ......h.

""1nIi!Ilb

"'*

............ 10' I~ 1I:r\pII.


, . Mounl . he _ h H I. 'tbC' Indo:h Mri
- . 1 thc ....... -'IIf u .h(: ~ OfilI .Iw ~
~. MII """" up Ihc ......a ...- loo6e for IIw

lw1Fr boii.
A.lomIbk Iltc h;mI...... ,..,.,.. did Ih(: cnnt 1\;lnk'atC".
-.1 ...... il In ,"" ... bed.
~

Usng Ihe IndeJtng Whefll


kbt )UU a('IUllly "'" ,t.. 1'8 lut n"'lna. )'W ""'" 10
. .<it OUl """". , IM: flnl.t..d pu1 ohould Iuok Illcc 1......

'*

manr .wocolb! '&'hal "II JOIi ....,1 1...,.. dftp"""'*l


tIM: aM bel 'I1th thctc 1Il*k1l"" In hmd. ,.... .,., .... lip
ano,!

'*' ,"" ~

1. IotOUnl the bbnJt In tho: Ils- ThcICt:hnlq ... i51hr


....., ... b mo..ne'll3' !!bn. b
fIIlltc
cranI<. _ lbe Indesl"ll " 'ho:d.
, '011 do 10..", 10 drul Ihc ~. p1n hol!:: In tM III',

..,...,.,....Insteod

enll. 1"" p".111on ofllol> hoIc ~OII It.. hci8ht fIIthc


bLlnk In Ihe JilI,. 1k51 appmaclo; ,\Iuunl Ihc bbn hen w;c:
ono: of III" Io<:klnHpln 10"",. In L1,,-" ...11""-"1 :os lJu klc In
drillln8 IIM: c:nd.OII"\ousIy. tlle h olc: .hol>ld roIncldc ... itll an
.ppn",""te allSllIne,.. poIIIl ()f'I . he md
2 . Sec "1' the rou .er. Mount thc b>t<'J)blc on .hc
"""cr Sdea ~ ~ppn:If'filo.c III. for .tIc cut )'<>lI ...,ne 10
make<- ~ li:wn..~foroampk). -' dllI(i; il in
tbr rvutcr. AdjlBc rhc
OI<rn1on. CllIllon ~ OUl 01'

'*

Ioojluk"", Ma 4S k~ tbc: fini . - cuu ohaIIow


AIIa JOIi lIa.... kd ilo" tIM: OjIU ...... ,.... proIbIy an FI
Iht drplh fii cu .... COi ond)' al Iht ......... ano,! _
""""

cu In ....... ~

f'OU'' '

3. Mue thc finit p-. TIp tbr


uP ... Iht biI.
Itdnrflllht W<Wtpkct TryIJppinR il ...... ltIc IlXiool'thc
tob ....... "'hul )"OU 11>-..". It, 'hc bil ..-\lI F<I"CqI Into .hc <.'Ul
... Iii<: CO<'f'tCt 1Ine. "thcr .Iult ""i'OiIf i ,
Swttch on thc """.". """ Iowrr thc '*- SIkk rhc """'.".
u,.. thc 118. m:tkInc thc aM. M ,.... mod! .hc mod fii rhc
"", ... ilch <JIf thc rouIcr arod lift tIM: bit dnr fii thc W<Wt.
pkn. 5cl1hc """"" dnt 01 tIM: _VtI<.
PuII IIM: lodinfI; pin. """ NWc .toc ""hed to IIM: Dat
p<Wi1nn. lcimm ltoc pln.1ockirII tllc b1W. PIrI thc l"OUICr
tack Of! Ihr II8.IQ bit dnt 01' tbc WOtlplttc SoriI~ il ....
ud totii. Kcql ttpe:2lint thio ~ ... 1l1)'OU""_~
flN.-.. on """" qmcnt 01.110: ......

4. Makc adelldona! paoiIIaI. A-...h(: ~ fii


thr ,,"Ori<pie. [( )'CIUr iim cu .. ""0'1: .mao..., odjlbI ttlc
RIUl.".', deplll o( cut. localC .tIc l>IoInlI .0 .hc Mut ..... ""'III
~nd lod: It In P""1, jon ... 1111 1"" pin. M;ik~ a occon<!. and If
n<:C'OI>ary Lhinl .... m of p""""'" In II~ ",noe ",:",n~ r ali tloc
fi"" ~
Sqll~ring

1u;.olr.lrlF u

an Irregular Workplece

iI~'

"OiI

""'"''*"

'unt..

".out nullS or bucls hoto sph.dl., UH lhe


_>1/111 wt.t,1 to dlwtbutt tt.. cut, """ty. wtM.,

""'It.

\O ttle workplKI . fHCI th<!


from onl 'ud O,
'III JI\I .0 , ... otht m.kln.g tII, cu,. Hote the ilO!'
~ 10 tlle 'Id, of tii, J~.

.hI,

sean, )'OU CIIIlbo """


",mllllllijf
10 pbnc! n:oo-l Oi" inqubr
flat ond MI~.
Ikf,r' an cxampIe:
III"' ,..,.., .......... ......., ~
oM'""VI" .... tiu! )'<>U "'.,.... to .um Into Iumbcr
1Jm,'1 how- J'OU do il. DftII JCIIn* ~ la thc 1otI.
~ II. In Ihr dowck....... "" bul lud II. ... It
1km<I'''' Ihr lJUidr . . frooa ltoc """'.". bouq>blr 00
duc )'OU can """'" thc ..,...". ..... 10 oioit OU Ihr jIl .. ....,.
OI md ." c:nd. RouI a fht ~ on ,toc ....
llnlud; Ihc WOtlpoe ano,! ruIatr 90 ~ Itdod;
il Now """ a 5ccoO>d fb o ... 1..... woc1<pku. Ih .. """ al ~
tipi. ~ 10 .ne ...... tlfll>/l "1' ,ne .....
""m::dnlnfl tWO _
In the o:amc iIWI.....

_o

Dy . . -....

oile:

r~

-...
::1

el

Joinery
drilwer j o ints with one set"p of_
, "",. Two simple jigs help y~' ."

T::~:'~~~'~~;~:::~=S~
in!!,

,",.,.".

","'h I'>!nc:II $Iod:. YOIl can

llM' Ihld<cr >locI; fur

Ihc ~

bul Ilie oIdo mU>l hc ~.-Inch lhict,no..-., IOd no 1a6.~

pn:wJuca. nU>h tIn,,'a" Ir)'OU

"""':m ",,-nbppiQ(lm..

tri.:d ..... ' - ' IL


11'1 ~ >lron,IC joIn! bc>c'''1M: the cwo pan.. Int~nock. n...
<1 ....",,. ffOl" Is gi>'Cn a I':lbbd willl a Jink 1~UC: w\ Ilts
In", . >loc in Iho: dr>.",t .kk. UnIiI<c. pbin nI:II:w:I joInl . ~

faJ.c from m .... thc dra..-.;r uz,3 _


,....,mbInl. 0tI u.. 1..... .>I<k,,..,.. .... """ "'~ .~...;..~ I
ctlc Ick ~rId Mda. ......,U al bcf..,..,.... ctlc r",m :ond iIIb.

p;ut ....... """"N IOFIM' mcch.:inlally, "'"C1l """'" you

Maklng the Jiu'

Uu.L

you\'~ IK'I ....

dri,'c n:1ib ..... bnds im<> Ihc join . le <!oeon '1

Iook...,. bcu....

tl'Ic fron, o( Ut:>"",,,r (/un ..... bbn joi"'. Tbt


dr.l,,-b:tck lor _ ha> 1l"'2)'S bn
II ~ to
lot oi 50"1'5.
TIIn! 00I"rIc0<1C $hoovnI "'" an .pproach 11' 5Uddcnly
made ,,~ dN,",'" Iod toin' _ _ o. .....,.., .."'ac",,,,l'h:ol's bcc>~ ..;,11 lhi> ...rup. it is. "'''''''' loc r:l>kr.noI
.... "'''''''' OI

"""".1.

in,.,!."

bstn- tQ ..w.:c_
T'hoo joInny .. CUI w1th "Hoch...,. """.,... ""ud.... In
uI:>INnounlcd RIUl ..... ''ou 5CI 1"'" bII, poMIlon tl'Ic rn.c.,.
anii bw<t thcm. l'.adl joint S CUI n bar p;WoC$.aU willl thc
boi' and ""'" in Ihc: """" po<>iuon. Tu nW:c tl'Ic )""'"
"'"",, )'OU nccd ,....., ClI~1y .unpk ji8>. an .uxlliuy
f.ocill.ll lOr thc ..:Ma table knI:e :u>d " booM .... okd.
AIlhough ,""
lod: foin, nil bc CUSI(>mi:tt<l ' "
work ..'1111 aU IOIU 0/ ..od: lhlcI<tIos<:s an<! <ir.I.."r conrlfl'

dra,.,,,,

ur.,,,n., tllis p:UtCUbr 5ClUP <loc!; ha,,,, llml'a'loni. II ,,'Ofb


112

)'OII ..'"'.., 10 add "

0nIy. lCw "'-""'IlS 01 ..-ood ond 00<nc coonmonpbtt


wvc: b Dftdnl 'o buikl "'" CWO ~ jIp. N>d .
...udy ,tic dr:owlnR:>.,..,.. Im)" find W3)"S !O .... ,pUfy cht
evm IOIOI"C Uun I ha,,,.

~:::::

hmI
-ood:and
hcdnalI
' o ctlc
Uot. ..
Glucc
IIIC' dimcrulons
hcd 10 ciM: Jpedt\<"d
..:>Ic. using
(Stt u.. drawi"ll /JQoI1" SIN I'fan.) M;d;c
~K MUlk nWlh . 1iO ch<y """,, c tlr.ojj Ofl ctlc "'Ulcr
... hen ctlc likd CI hci"ll uscd..

,~ bk

10051"[1. ruD PLAN

IOOSTtR SlED

...

Cunlng lisl
Qty Dlmenslons
~")(

""

~.,

)1,")(

M;II"rl .. 1

8" )( 10"

Hardboilrd

2Y.t" )( 10"

H~rdwood

Hardware
1" brads

IM: obout" ind!c5 10 (ro." I h~ ~ ..... an<! .bou! ~ tnch up


(rom ,IM: bouom nlgc . hl.>ugh ,Ilo: 5piIIc tocu"-",,,...., 11<>1
alt that Unpo<Ul\!. Drh.., ,.,., T........ 1"11tead !hc <":Irriolt"
boIb,....,.j .. ct.mp bolb,In!O 'MT........ lll1.,.tt.I. h~.. nu'
on e>ch boll . hcn a pbo6oc _
el, thc knob. Ih~n jam
,ht helI nu, .gaJ.... !hc tnob. Pfn""'1ng II (rom Ioooorn,p.rr.younn

re.I;Iw

>Ioel< an ,"" table !Ilw.


'(> !hc <Iimc:ruIoou ~>cd

inlIlo 'ISC.

. . -.I~' ,1", pan5


~ .... CIIning UoI.

3. l".taU thc cbmp ~1U<b.. lbc damping "Y..nn b


...." In !hc: Ikwt
dn ...... AuxllI",,. Fe"CfI ffld'W

oi,,,,,

"""- 0riII bob ibr!hc T-nuu In !hc b;oek.ll><= hok:s.t>ould

lne

4. Asscmbtc
f~ fadn8- lbc ~ and !hc
bad<...., gIu<d anr..l ~~ to ,.,., o:<l8cI ol!hc lOp. aslho-orn
In Awdl/ary _
Fad''JIl'Ian. ~ ...... 10 .......... rninII !hc
.ano... 00 lMy WOO'I Impcdc ,M......-cmem 01 ,.,., dn"'cr
~ aIor>8 thc I\::nce whm )'OU .., CUIll1!! ti>< jointry.

ii:

.
::Ii

.....IUAI. ... rENCE FACINe PLAN

It

_.

tie_ nul

"

AUXIUARY FENCE FACINe;;

CUnlng ~L~I'~';...-:~-:~
p,"

Q",. Dimenslons

*" x.11" X 20"

fllCl1I\I

ClAMP A55EMIl'" OfTAiL

'"

."

... ili/Y ~l"Kt ('(lng.

",. X 2" )( 20'

lif,rdwood

",. X 3W X 20"

Hl.dwood

Hilrdwilre
2 TnulS. \4"20
~

11I'ud bo~ In,o Tnu'


llfORE lSl-tmbllng 1'"

M;ateri...

.. nu,

~.~

J'1uuc knob wilh


blind Inun
(bld fOK.2)

2 curll9l! boIIs. \10"20 X ]"


2 hu nuls. \10'20

d".

2 knurled plnlk ltnobs. ",.


wl,h \10',20 X )1,'
blInd bran InSUl; fDK.2 from Rtld Tool SuPpl"f
Co. (8OQ..2S10.21)

Drywall scn.ws. #6 X l '

'"

Cutting a Drawer Lock Joint


.. oM prtnctp;al appnl 01 lJU.j<>inI 1"" """" ..... tI .. hictl ~

b . . . .1 Or b I 1"" Mrawh 01 "'" _mbkd joIm1 "''h1k


,...., . - ..","*-}'OU" bc' pkawd .. how '1u1dly 1........ ..t<
po .... ..-.. !lui ~ "'" 0. "",.- ___ ....., 1""'1 ""
iII\pftMcd ...tI "'- otrotoa Ihq.- :00 ,..,..,.. ~ bolii.
1. SrI "I' .M "",Ier I<lble. 01,,<;1. ,"" ',..j""h .....
e,,"er In ,"" tai*'
roulcr. lodj_ 'M biI u.n>......... thr lOJI ..... oI'M
,mh It ' illnch:aboo..-

1l0000NG SEQtJEN(.E

arr ,.
MU~ IM Ii,s. p,illSS ... uh ,he
ci."... " fron' n'l 00 Ih. 'OUl"
l.lbIe IOp. Tl!e ... orkplec.
,tf<!'ef'lCtS Ilie fenet. P,US!nQ
belo ... lhe a""mary "'nce.

""ed

.......,.

cut,...,

Or ....., "001

lIrIrlII ItIr Jmcc into """"... ;uQund ,hot: (uU.". ""'"


typlnl ..... ""'la m;dtQ' ';tnch4ttp oIooI, ..twm b " 'N '
,....,.--. 50 potirIon oM fr1t,c., 00 It ....in JIC"l""ii thi> ...".tI
,,~

2. 1..,u.U the aUIillary r:.dnIJ u n lhe rence. 1)Iup

ttw: :atUJIluy

~ "'..... 1.... I'cnn"'J ,=101

btt llIc p.p

,.bkwp

""'....,.,.. 1.... f..dnlf' "'........ ct4tr= and tlk


iii
,"'...,....",. It "'.... "" ~ 10 " inch ltI""I.". 'Nn , .... lhi<tc
".,.. oi 1.... dr.,..er fronl . 0In IIM: fronl "''''' fU"" bcno:2lIt
'1 00 1"" Il"" IW<' pitSllO, "<>lI <':In ~ ,"" ~
.,. ,,I,tI. n'Icr.<>tcl>hhk "Iu COlII'''' ofopxeno In eIIht:r~.
C odlU>l ,.'" tlot..1' ljI; ~11on . ,'" IljjJllrn Ih~ cWnpS 10 ~
._ "'" ."xlhuy r.clOljl

.;
.

3. Col ' h" J<>lnt. IU oho..", In 'hc d ... ..;nll Roull-W


s,,1,..mu. e.>Ch joIn! 1. cut In four ~.llIc dr:Iwcr front
b ... 111 Il".. , ...... Ihm: ~.- ""1'*"<1 ' u rompin ... u..
~ry ..... ......., e"" l. OII ..... A>unb ...... ItIr dr."..... >ido: b
..... lrd_ l~ ~ ItIr faur JWOOI:
I 'llh 1"" olr.o""" f...... tl:at on ,,,", NUIa ...... I<>p. ils
n~ fiIcr up. """ ,1 ........
l. 10 ....... ''''' 0I'Uftpitn" fur on'O<MI r-s. .... it on ,""
000M(1' oIc'd. lhe OI'knuUon ~ u.. Am<' Thit
r- wiII wIdrn ,.... >lot 10 " 1ndI.
) :!Ia 1"" okd ..... """ ound ,"" 0I'Uftpi<" on md ",ith
thc np<M\l rac.. <lUI. Qidr u.. wort ........ :alonjt ,tir
aux-,. bclnjLand um ItIr >lot 1 ..... TlIisco->pIw:$
u.. ..",....... i'Tonl.
" SIot "'" ..",....... >ido: ~ ,"" ............... on nod. and
fted It ....... u.. IIWIiuy Irnce 10 IlUkr ,hb cu_

--

,un
Place Ilie ci" .." fron, OII lop
of lhe h1,dboIo,cI boott< sltd
and ...... lhe _ond ~'U.
-'91''''. IM wor1cp,.u IS
Igllnsl lM ftnce. btto.. Ilie
aUJI,lilry ftnc .

0<.1"''' "ont

arr , .
Stand ,1Ie drl_' ',om OII
end. and.1Ick II M>ng It..
au"ihry "'nc Onc. boIh
ends of 'M _rkple<t irI
tUI. ,III! "om (s tomplo'ed.

Or.I_, "<>nl

"'lIm ........... fW\' ."" ................ ,..,.. ......, I d .......".

"'tom m"l<l.... ClIK I\JU 01 d ....."'.... It 1, """" ""1""lI'

10 rn>kc ,tic fi ... piO on btMh cnd> o( n<:h dr;o"""


ftun, (a ..... h..,:. ) Thcn ..... ' lor .In! OII II", I.N..Op and
n...1c , .... ...cond put on ~II ,IM' pl..... :>ci ,tir okd :a.ick
...... comple'e oi", ftunt, (.nd
s,,'IMm ~-'dc Ind do
'OUIi

,"" .....
""
TlII. >l'f"'OKh

"""k

~ .... po

IM ..'OII< ano.! ItIr """Ine

~.

nil..!. and n,lnl",,~ Ilie num"", o( Iln\O 1"'" ""d! ...... ,....
..""" '''''-''<-'ti

CUT .
SIot IM dr,,", sld. wlIh tlot
WOf\.pleu: on end Ind ",,,.
lhe all"ililry

.""Ing

f,,,,, .

Offset Baseplate
Are yau on tha "ge7 Tens. ilRd
10001.1ing. teeteri .. " . slipp lnlll'

1'1111 oUlrigger Inse.pliue milkes


tdge-rouling mo~ troublefree
Iry htlplng you mai"laln il
router's Dlanu.

...
",

III

"
.s .

'Y rou,cr """r~,1uru, In ........., shapin,j( :In cdg<:.


\"ou I'<'fdIlhc mldtl"" 'on Ilie: ..."(Id;. but ""'"' Ih:l"
lWf 0111 b Wl>Uppo<tcd. Oby. lIU!'bo; )"" kC<'p ,Ilo:
1taIIa:obgJ>ro ,,-hll ,he rol!" ul ,"" CUC 11m ~. olicR .. not.
""'W FI ..... h.ndl" "'..". lhc ..'Oft . ,lIe Q1h,,, .,.. rnc,.., in
lerrilOl')". Il', a ""1:md!1Jl.1KI
So e i1.""y "'OI1<1<1')'OU occaion;>lly boIlbIc. llppin" tI><:
. . . ond ,nlP!"lI II,.. cd:iP:l
,In 0"", ~tc IIkc ,hit cm hei!, yuu pl'CV<'nt
...... boIlbIa. II. obIofltl .11>1"" dtm.,. a rou td~ b.:ow.a
_ bas.1Idty tnoII "' 1.. W1bc;.t ot:>dJ , 8(J )'OU an ou,

.. ; ,ed

~,Mbobblc.

1lIr ~1.o1c is f.oIoty 5mpk fl'Oit. I( )'OU .n: 001


... pa'tlrubrol>oul lhc ......l1Ing.)"tJU an c .. ro ,1Ie dla>c.
~ of p",""k IQ 5h2pc, driU ,he nn:n"'Y b<JIo,"'" mounl " OII YOU' """e . 8uI ,,, prod,,",

.""pIy "'"

prodsion oII>ct boa!q)I. tc. onc )'OU an u"" for 'n"pb1 ...
..,m. lot aampk. }'Ou >I>ould out" ,. '''",p'',e, ,hen mak"
.. ...."..c from Ihc ' cmpl:.nc.
A bmdi, of ,IIe:
.pproarn b
)'OU an
cdI!' ..kc mon: clan onc b;o""pl>!c ''ou an .... kc .......

'=p':n"

Iootpb"

ronfIscwN w

,r..,

thto\.ofth tll" tcmplal,,;t.ppro;ICh. 1( l..... c:I>oo>c to oIcip.hr


" ''''I>I:uc. IlO ngtM ohod.J"" 10). OUt tbc t:o:ucpbtc drtttIJ"
on tll" p1u15C'5 ItPSkInll p::lpc1". and """'" fn.on, Ih"", 11)"00
.""'~ rompIt1dY"'R: oltbc 1"""'ftI""",.1 wouId ~I!I'
)"OU '0 rad .hlUU8h thr dup "Thc Gmcrit: l\a!qltttc
OII 1"'# 63. II pn.nidc> a fIIOtc .I>OIOU/Ih and 1k..11cd
~ lOr mh1l anei lIuing ~ 10 a routa
llIc d """Ing> """'" tWO <.Ill'f<:ttnt <i:.oI:s o( (lff"" bak(>b.e . FJtoo ooc <.":In Ix- m.uk rrom tbc nomln,l fooo->qtAt1'
p~ .... plu:1c (:IC1)'lIc, poIycubon:ttc, and pI.......:>tic)
.'" ",..ibhk rrom moik>rdrr ,,'OOd ....'OI'k:i1lJl """~ llIc
"""'" bticplalC )"00 ~ OUt 011 a dl:qjonaJ. 1IS }'OU <""~n occ In
IhrllmYintl. w hlk Ihc omaIkr OM 1< O<tmt<d OII.he_
pic from .si<k tO otkIo:

.Iu.

Make the Baseplate


iIJ.h<>usb

insI:alllnl( ,'''' b>Ob b .he t..SI .hln& )'Oll 00


ordt"ri"llit '" ti", ''''ry II... !h1n,)'OII)houId do. Wllh Ihc
""n./w;I", n hand.,.,.. """ mok" anei eumpktc th" off>Ct
h1wpbtc In J....... _ r Of ',,"D.

a.,<-"" ,,, lempl;n" lIul<lc . an(!

..c..r tO Xttpt falrlt' 1a'1lC"<l1.uncl proflk bilt.

iII lIIc foI~ Slcp-by-Q"p, III quk:k'r 111~ )"OU

1. C UI I lie .e m p La.e b l:.o" L I """" ">nIlw _ .... 'J


fib<:rboln:l (.'.11)1') tor .he .cm(>b.e t..:..... ",.,. h ' ..",oo!h an<!

'"

Ei

_.

~
~

._~

OFFSET ..... SEI't..ATE LAYOUT VERSKHt 1.0

bid ''''1'8-6 pW,ic: knob


EDCEVlEW

...

BDTTOM VIEW

,
,
,

-----,

\."

Tw,' bit open 'ng ,.bbtttd for templiltt guldtl

CUllla, Llst

fb . . ..11h o ronsistC1U. vo;a.frtt COft: ond o rcloti,..:1y Iow


prict' ,,"" an ..... pl}'wood. !IO Iong .. 1. III frtt o( voids.
Of P;lrtldcbootrd, Cut ,iM: bbnk III ,iM: illrn<ru!on; .plfled
..,. ,iM: Cut'lng Lbt ,

Pl rt
Templl't
BOIep l.,e

2. L:ay out tho: ~plat" on the bbnk. 1'0110",


Ihc: oppruptUtc O/f$d ~If Uzyoul dr:twin.I!: . ,,1'J'f'Q"
.,.u.c mea/'" u.e, ,"nlIion t O '" ,iM: ......Ucr ~p L:"c.

Olmt nslons
W X

MiltlriaI

.'"

14W

PIIStlc'

h' Xll }j,' X I I}j,'

Hardware

,.......... 1.0 '" IiM: b..,....


\Ii "Il ~"""p.1SS. 5Crihc ~ndKIi.mclcr d,dc ;LI " " "
C1Id o( W bbnIo:. o i -inch-di2mncr circk ., ,iM: uthcr nJd.
Uk Slr.ligl"",*
luide
""rthlnl o( W1gIrnI> con"""""1 ,iM: ...... cin:ks. Ik >u'" !"" clt:lrt) mari< IiM:
c...nC1'Jl<'ln'" vi w drdc:s.

'o

Qt)'.

I mush,oom-5Nptd DllIstlc knob.

dl._ .. I,h ",. thruded in,,";


'1011'8-6 f,om II:tld Tool SUPDly Co. (80025) 04ln
2~, '

'o

I fT"hud SIOVi! bolt. It d ...

Ar,.,w, /II1IJIC~_", _

X~

"""""",,,"~<III ,~Ir_

LA YOUT OPTIOHS

.".

.. ..

SmaU

b.~ ~pl&UL

"

...

'"

"
",
",

",

'-

116

ROU,t,

M~lc

..

,"

CWfS(f IASEPl..ATE LAYOUT VERSIOM 2.0

x~

flilhud SlCM! boii

.......
o

....
3. C",t UtIl II", ""mp"'I.,. U600

~ $1 ....

or hilnd

MAMDLE ORIEHTATtOM

.... 10 ("III .... tbc: baxptllt JIul)(


I\lr IK bat I ppn ... ....., of II,., flnbhcd basc-pbl~ , tbc:
DfIIut......" mUSt bc srnooth ...... bir. l"w roun.J IIut
..adi IDo It ..... fill In flir1n3 Ihc: ~ . II ponIbk: bel.

. . , B hII 1(!IVQ6i'" IOd B'fficull 1" romrollor oomc... ~ thi:i.llhInk. buL


M~ 10"}' 1f )"OlJ ""aM, Micr liIint
. . . . . _h.ho:m ..llh. r.,M.k:In><><bit OI" pod .. n<kr.

sn-.:

4. IIore d ><e
Io*l,IIft tbc:

II

1.-

boia!. T... lor oul 1"" """,nU,,"oK"'''

routt,. b"-,,,pllo.c Stkk .wo Dt

,h~....,.. 1

0/ Orpe! "P" on Ihc mul.,.... fx ....rr ~pI>'r


. . .., (iri ..., Icmpblc . lhaI pn::so It Rnniy In pIlocr It
_
bt cool, of CO ....... , .0
.1 .., bIt ..... i> .... Ic h <hc
.-.poin. of
ci",.., . hltllh>l .Iiwlmcnl .... r bc
Iti lIlRI 10 achlc>.., In .hc Itll " "Ork1,
m ..,h Is

1"" 10,.,.-

ha..,

.ha.

- . i. 1.
" "ilai iI~' .. Ihc otknt.>uo n oI"lM mu.e' , It.:an.... lbr dDwlnjj fla ,,,/", Oritomatk;m .tIow. .t.. 1......
prIIcipoI......,.",u 1 like .hc:'''fI """. bul )"OU suit ,..,......
!III.)8t iIIiIIn Ih<- "'.. plnc ... tbc: len.p!;"" "" Ilie lw"L<Ic>
"\I(..-ben:}'Uu .."", Ihcm.
DIa """'" for thc moonolnJl ""..,-ws,MIrkIrd 17)' 'M bas<:,... Coonlcnink Ihoc hoIo. Orill " ' ~cr hole
tbt ("tdt<"tpDin. 01 tbc: ~H ""'. Thls Ij lot .1Ie kn.ob.

_....

s. u y ou. !Ind bute the bit o pc:nlng. A \'.


poooi:lI bit in tbc: ""'tcr', coIkl. Moun. tlo., IcmpblC 0tI
.. ...". Dan't c'..... "',. "'" mutcr in. IIrin8 "'" .ip ul
.. Iti in )nt3(.1 .... ith "'" bclxpbtc. 3nd lum l!tc hit
......., 01
kll JOII' hiI"" 10 nuI<c .!tc C1;ntc< of
bit mact IKa:mcrpoinl .
kJrt,oo.., l!tc rempl:ttc frum .!tc n)Utn". arni bon:
I~n" hoIc though IiM: tm>pblc Ik >li'" ,t..
W. il <mteml OII .hc ..... rit nude I>y thc bil .

",""utions ..

Dffsel

~sep~le

111

6. Makc rJ>t ~pla~. IM co"""" "'1'" 'u bon" ,1 ...


"'1""" 01 (JIa>ri<" ,..,..., .....kx!<-.l ~". ,""

,rm"l:ll~ tu ,""

ha,..pLlle. (fl>c" '1'f'M'I"JI~ Il;&> ~'''''' un 'k ""Il.hl<plelio 'h:u rmr ""II' ,..,.. <kdok "hKh h> ..... )
UrW "'" _
fini. 00 ,"" _ ' ...""''"'
ono,!
,"" k ... Jb.mounlll'ls hoit
Cnun,~""k 011 ,"" ho>lno.
_ , ''''' hI' ~ -... a ........... bit """ I"mpI;o'"
JILIItk TII " .. kr a bit ~ b" tuIW1u\I I\wt......uIIIM'l'"
!COOIpb'"
I 1' ........
,ltn..... ,t....
"""""~ pb'r, ...... I ' Hnd! ...... ho' PI> ' .. in<IH.).I>
InIIplotr I"klr "Thm JWilch 10 I ~..- ..n.,jIh' .... In "'"
......... templotc , ...... ano! r.obbr1 , ........ \\<":bun"
n..., lin Sukk hu.hi,.. ano! ..... , .... _
'lui <kpth.
It. ~1Ir'1touI 'Il \ndI, 1u rhtrt.
II,..,.. .... RI I bII opmInJt 01. <lofkrnot ..................ith
OI"'" 1IIt/btJ>h1"ll """,Iton:o,..-. 'Ibu (":In _
....",. u
bent "ZCS 01 hola . ...,;i,.. INot I ',.onm
In LI ... ,rm","I"

..,."iow. ....... is In """"'" nIII<s." "'~o:<J . I I M _


k.,.,..
a"xJIiaoy tnob "'..". Ihr
h>nd .... It .. J"U .............". ''''' rouIc-r

t""

"'*'

"'*

"'* . . . . . .

,,,kb., .....

1""

"'*

oU

jL:lIi<k"

FifWI); .... IljII. pa1l,,", hi' .... nlhlHtIo,,,,,,, .. bot In )'UtIl"


......,... Imn 1"" ....
pU,r 10...". I"r) , ........ pbI .. anol
tit(" ~ pU'" 0p"n . 1,,11 lI .. hm ti ............ p.>per
roIIOO otrl"" """'tnl' nll ptol" " , ....,., tlle- pbI .. 'OI , ........... .".

>UII,,'"

. . ._ ,

..

T'Gub!llr. . 1td<;l,",utl"<;1 h whl' Ihr Glfnt b",.,pl~le vln,,"11v \IUA1."'HL /UlIlllIJht,ouch OII ,III!
INLSlpl~,e\ knob CG"nlerleU 1'" fOIIltr'lltndlntYlO

tappll afl Iltl worl< .

Offset Baseplate on a
O-Hand led Router

r-

If yo" are PJon,,1 tOI O-hltlelltd routlfl . ., 1..may appreCIIl' th,~ 1011" I'P. MII'" '" 01f,,1
pIote wilhaul'n ,,,.,Ii.lry knob. h,~nd ,1Ie 0111..,
"nder fhl o.h.uldll. lI's I t"A"""'~ ....,.j,IOUIiOA
Ihe roIIlt. In moll "F"mILlnUI-'YOU jul' dori)
)'OU

'UlIU iI\ 1h1'.


lut "'hin you lIftd Wt 1.'" ..,~""...... ,.;
,,,nply ,h,1i. \~.
of 'ile _If. PlAI'''iI1III

!IO""""

VIU .. s"rf". whlre

Usi ... a ,_pLala aIIow~ you 10 m'~1 mulupill


quOC:kl'f itiel
Sto<k IM INLII~II II\I.lffliJ 101 Ihe
IIIIIfIIIII. anei fHd le lround I n",htrlmmlng bit OII
1'" _ f f abIoI. You U/1 ltW"n IdlPlI Ilmpllll 10
II\OA! Ihin _
model of fOIIl". Ind 101 bcxh opall .....

,..,IIy.

...cIdur_~ .

7. IMWIIM

o~

knoh. 1 ... irt"l.n1 ..._

l1li)"\0" ",""k btob (rom "'" Idd Toul ~"rM ""....1br


""""" rumlorubIy """"""
jrip (n .... oile- ~e An)'
n .......... 01 .."",
..-.,..Id ,,'Ot'I<. Ind >uit.bir .. ,"10 .....

_,iD 1""

COA""""

Ix Ii>ond In......,. ~ ...",,1)


""'" pMtlcubr knob I mo...- """ ' .. ind1 'b..-k<!
in..,n .... 1"" knob io ",...,hn1 ... "It o ' ,.in"'~NIj( flIlhncl
.. OI........ '

Using the Offset Baseplate


, ..... prublhl) ........, ha .... I

\10" 1 "f !.l,flkul,y fiMurilljll


"''' 1...... In ...... ,....... """,.., m:a<lr ,oIT""l 11;0""1'1'1' 1lK ""'''''

III

lI.ou,,, 1011<;10<

II; w~1

do

t'" _t lJOOd

Flush-Trimming
Baseplate
lllUe In old stilndilrd OUl
_temporary. h igh-IKh
IIIlIril ls. 11'5; ulr.. s li ck .
utl'1 lough.

-,..
."

'"

TI

Is

bule

Iixt~

In

o' u\d;, ",..[ )'OII ...., b ............olullut ..ry ,,,....'


1hIgn, hul CUfl''''''P''''rr
or ... 'okl .un.... , ~ 1\,< Ik>nc b ...nkw ,h~ """WO ro CXI~nd , ho;

,-cnioo,

ado ot tt... rouIa" hit an<! u.-aI high-qu:d il}' m;II,""" llw
....... lin"", ~r.nlnlt .ntl Ioolg-b '''I\j!;
n.rn,..., fIWIY 'ppruKh<'" 10 nu>lHrimmin{c foboo. hul
.. 1ta!<pbIc il 1110' ICncr.d -pu""",," lixIu ... 1Joo:oa..... II

'1',

_ Ibt ...ma uporl whkh h n:>ioI


tbc _pLu" I
... for =mploo. Ia lrim ""O<lOIkn ~nW"" OI" 1,lull'
....... ~ 11>(, <kIgn >II;"'" "'f'C'CU11y briW"1y
_1IOIIklf! In", nJI'I'"-b:ln<kd~ . ...""... <lIher n",,,"
......~ """",,,Ilr fali..,.
TlIt Irld: " ,h(, , ~~ <lcsIjvI. 111e ruu'<T Is
-tIttl W III<- uppa 1;0)""', " 'hlch I aII'.... SOl" A"..rnnr
D Ih< """",
5U~ S 5I>ortn bl""', ..-hk:h I 011
acbtd.Tht 1Ift! ....." "'" " ....,n '. ind!
...,..., ~ C3n dn. """ru,lom,111" bit
1'>I1IwIac 1OI.Uf. ... ju>I da. uf lhe ...ori< >Wbtt. ..-~ it
..... tlIooir~ nJ .he.r> , _ ",r.IIra..... "'"
lai I..,p;d b:>d:: ....rpl}, In"" thc bit. l"" . . """ II" n",
_
M )'DU "'"Ori:. the IY ..
OrI oi..,., ""10 ,II<'
""rfK<' . nd )'OU a.,""" II"" lrimn"'" ...,.

hoI",,"

,110\., ,1.., .."",


"",mU.

_......

"""1IIIIl1ICd

pLa'"

la'" d,f';;",,,, 1>;I....,pLalc ........... "",,","TI. Qn., 10 ~ ....


lamm:.o." 'rin'mtr, clIC "' heT lOr. ~ Ii.cd-"",", n>ue~.,.

Maklng the Baseplate


Ahl" '''lIh ehe e".., tusq>bfa ar<: Nljln!) d!fftrme in conf....
ur.,Ion . "" nu ,~-rUb ...col:u>d .IIC C<)JI!IIruct<>n k"Quo:nce
~nd pnK"nluon "'" ""'" ""'''' for bQlh .

p"",.,,..

my._

1. Cu, e"" hcd and ,..,Ie


I ma<k
n ...... 'rimml... """"pU.... (00<" fOr. bmlnl>'e enm....".. """
lOr full.oUnl ....... C1") of

p~k .

for .IIe bmiruee Inn>",Cr

""..-pbtr. l .....d e"" 1.)"", o( '"Hnch pbtnoIlI: 1kaU!<' uf


' Ile

<bitIn nf ."" ,rin.nl<Ts ....... uoing dnr X'lll<: ""' ''''1

"""ng 10 1'A"Id. .n)'

moft

vi.a.llny. (kM aC"f).1I<: <lua1PI"Q-

un eh<: fui ........., rou.C1"'. fl>scopb.c.oo 1


ditl "'" i. for ,"" ook pIlI'e for elu' 1"OU1C1"
fl1h", """"pl..... o( ..........,. nn "" """'" U>iJt1l- oerflic
,1< "'>I)...... rhon.>.ec. it
~ fO'J' "",r.:...,,,,,e. ar C"\"C1I pir......" d. n....... ''''''......Il,.;,) Ilbnbu;aru (MIl!'). ar 1wtI>o>nl.
If )"0\1
mnd "'..... il1ll
,II '11''''810 o( .""
pl.:l1<: "'0<1<. C" , ...... pKCn ,"" ...,,'" oi~ . '~ ~
di" ............ o( ,IIe .,,'" pl ..... An) of ,"" nu,rriab d,n! nn
bo: cu' "" ,"" ul>lc ,," ... Tu lrim ehe "..,... oi ,"" beci pIlI.e.
, .j"k """" 'bi bill,)'

.tu,

oi",,,

"""p'"

,""

".

~
_.

3
3

_.

tE

FlUSH-TRIMMIHG IASEttLATE FOR LAMINATE TRIMMER

LAMINATE TRIMMER BASEPLATE


Cunlnl USI

EOCE Vlrw

M... I'I.oo"H.'(It knob

''p ~~;
80nOM VlEW

".

PlI.rt

110")( lW)( Il

Hetlpl.te

Hr.")(3W)(IO~

Millerlill

..."....;;;;,~ I
I'hellolic

HArdwAre
(; flltI.ud machlttt SCftws. IO-l4 x)l'

1 m.. sl'lroomstyle plasUc knob.


2S'J,' d,a. wnh ~. I h,u~ instrt;
'Mf>B-(; from R~1d Tool Suwl'f Co. (800-lH-()4llj

e . ]"
KffcWS

Dlmenslons

SoIe plate

Knob moun!lr>g boiI

.l

Baseplal~ mountlr>g

Qly.

2 pI.oslIC opact . W 0.0. )(

~.

1.0. )(

101. thld<

1 fhlhtead JlO'It bolt. h dl .. )( I W

A.. ~mblv sc.ews

PLATE LAyoun FOR lAMINATE TRIMMER


SOl[ PLATE

HUL PlATE

MOUnlln!l' ICftW I'IOIu:


un f'ttory 1uo,.pll"

PlIuern .

.-'"
C

-....

clu.,"" hoIts
for

~. ph~nollc

E
.-E

..,~.

Counttnunk \<1

u~mbly

o.nw,

..,--, ,..

10 ~

,,,,o

AsStmbty.K'tw
holts. tIpped
for 10-24
mK~lnt .c,tW

Counltrsunk k hoit
lor knobmoumlr>g boiI

"""II<'

"'"' II'I.,.;....~ mite,


10 1"" .1lJdor opn:rocd In ,'''' b)"OO1
dr.rwInjp'. an.d "". " 10 .h<: krlgtll """""n.

2. Mouot IIM: !IOto: On thc router ba!ic.


~

nu. ...

dclllilnl in thc """pter""" Coftlc1'ic lla.;q>bte:

,,1I1e1l ~ on p. ge 61. Bosically. roo ..... Ih<: (aelOl")'


b;uorpble ." a ""Ilem (or dliJUIljI mo..m;~ hoIa r1
thc bbnk lor th<: new b.:I,;ep"'u". Ir.t :aii po:>SIoibIc, o fut
_
5Cft"Wll ro .t""'" th~ new ~. t e 10 thc rotIler.
, 'ou ~ ..... m 10 .lim the pbtc 10 <:OrIfonrt to thot stup'"
01 thc rotile' ~. The om.1I plne "..a. madc lor. tk\\~11
lamlna'e 1J1Inmcr. wllleh ha.'! ""uare Iw.c; ,"" pbn rrlkct.
conr",w:.tion.l1lc
pb.e _.........xd tO .......:h

,hal

Il""".

.he ",,"pc 01. lle\t'alt I)W 610 lixeclba.., rotita". To shapo


J"'" """"plate. roo (211 radiu it ..,;th
and ..........t
or u im 1. witb ~ n...tHtmmi~ bi .. .... Ing th" faaory .......
pl:o." a.'! a pallem.
y"" (211 moun. thc lIOk [>bte on th" .outer ~
chcc:k your worl<.but thm mnoYC tIH: pble from liH: t-.
\'ou c;m driU .he bil opcning now. or ""'It until tlle: lintI
"""P. ,,'hich b " ......1 I dif.1 il rou do it 11OW. }'OU wiU b'e''''''''
'o .rtn'lhot tip front ..., hcd [>bIe

n)U'' '

3. !.ar ou, .ocl drlll ohc IlS>ICmbly.sc:n:... ho ....


,,,'" Is kq SlCfI .'lina' .hot , .... pb.c5 an: IoIncd 0I'Id0
nuchlnc
drIll thc hok< ('i<l
wtll lin<: ..

"",..,.....10

'''''r

flUSHTRIMMIN(; 'AS(PLAT( fOR FUllSIZ(O ROUT(R

FlXEI).BASE ROUTER BASEPLATE

Cuning List
I'ln

Qty.

looIt pl.ot~

Oimensions
)6'

X 6' X II W

SIOE VlEW

Cle<ir uryl"

)6' X 6' X 'Ilo'

Htd pl,tlf

,,-

Millterlilll
f'Mnol"

BOnOM VlEW

.-1

Hiillrdwiillre
, I'IIr"uod mKlurw KrI!WS. 10-24 X ~.

1 ...... h,ooIfHrylt plasl'c knob.


lI\,' d~ \.,,111 ", Ihrt.dI!d InStrt;

ft1P1-6 from Rtld TooI Supply CD. (800-253-0421)


1 pWIK SPI<trs. y,.- 0.0. x

li' 1.0.

I ~j!I\ud Slove bolt. lot ci.,. X

)( }! .. thkk

I~'

e,

"-ATE lAYOUTS FOR FUllSIZ(O ROUTEI!.

--3~
"TI

seu PLATE

HEEl Pl.ATE

eo."ws~nk ~ .' IIDln


IDflfKlunl;ng Seft"'S

In

:r

,lot clufAR<I hoII


faf mountlng Sefi'"
COUnlfrlUnk ~~. holn
for I . .~mbtv .,,...,,,.

<>j --

-,
h

,......,,-

~ o
o

''''1''' IIDIes.

llWtd lor

10-24 """dllrw KII .....

...

p~nollc

'""

pnftttly

for~. j " "

m ..... driU IlIem in boch pblD


Stk:k."" I"~' 1''''''''' "'I!,.'.I"" ... llh a (OIJpk
>ntlIl1 ",...,," '" nrpct I~""
Uy oul Ihc ioooIlun. u( Ihe IOCIT'W lIola. If )'UIl an:
usinl! hbd: phcnoIlc. ntUIt ,hI; ~~ ,mll;l puneh or . ... i.
f)riU ,"" lIoInI wjU>. -15 drill. wllkh i> Ihe COrtn"l.ac for
, applnc Il).l4 ,1Irn<h OrIUI"" hol.,. "" ,1Ie driU p~ ti<)
'hcy ... 111 II<: ><iU:O'"
lr IhI: hcc:1 pLue CO>~ H1J' MOW1Iing~"I'CW _
In
Ihc !iOk pLtIC. }'O<l wjl nttd to dnU ck~r."'Cl" hoic" Ihro"w.
Ilie hed
b 1"" ti ..... 10 Ioc::ole ' ho:sc lIoIc<. Guiokd
by ,h" ",uuntltlJt>Crcw hoks in loc """' pb'c. drill 'hmugh
IhI: ,,,,,,1 plale
oimul~.

O:unp Ihc pLt,e on .op of "'-""1'. S... itch "" .... 10111.... II1II
...::d: the "",,,Ins """'II ""1U>tn,e,u nltwliMn 10 p/unfIr
and rrtnCI.hc bit .IIIUS "",,,,,,,,,Ilie opnti ....
An alI""'"I;...... pp~ , Iln" 1"'" 1 ....:d. b 10 bon: tbt
upcnillll ..ilh. Fon.Iroc. hit <1" IKIk "" ...

1'''''''' _

4 . Ta p tII", boieo> In t h",!I<)1c pl:ll"'- lac. I ()'l~ 1.1'


proc~u",. il )"QU\" " .......:r doo>c ' Ilu ~ . Is <k1:IJkd
In "'" r.,..cun: "Cuning11unds" in the appcndu: Omd: 1""
tap in.
n:n,,11 App!)' the appropriale lubri.:anl 10 Ilie
"'1'. ut.<cn . h", tap ', 'II' In Ilie bok. and turn Ilie "'-lnIClllo

n.c,

"1' ...

MarI

II\c Ihmd:i. ",;u;e.un: thc Up b

q~

19'hcc

pIl'".

E:och coujllc or lums. ~k .tIe "1' up. qwnet' '0 lWf~um


10 b<nk up Ihe (1111" .1111' .U <il .tIe -.-mbIy hoIo In IIle'
,;ok: pblc

t""

S. Roo riU a nd counlc .... lnk the bok:3 ln


h ,..,1
pl:lte. n.c, hol"" In .Ilc h~'Cl pbol'" ..... too ......u for Ihc
aoocmbIr iICrI."O"". [)rin IlIem witll , ho bit. lhm COI.U1lCnink
'hem. 1Ic OII'" 10 hore II", countcrsinh ""O Ihc surf.occ u(
.hc plate Ih......,.. aposcd ,,"hen j'UIJ olrilkd ,II<: hoIo In
C SI''P ~ .(lrJOU ""'~e Ihc roun.en;lnb In Ihe .......... lIidc. thc
Ilok:s p<t>babIy ...unt line up "'hen)'UIJ Iry to.-mbk Ihc
f>b'es.) Iloo: ,"" rou"w~n~, ....'CI' c"""l;lt 11..1 Ihc JCIT'W
hnd, ..iU,..,.... hdow 1"" pLtlc sutfocc.
._
lf l'OU hue ~c Ilok:s 'o dJiU fur fUU'C"","'lIIllns
t.. ""n:..-. do
'1.,...,.., 1"" oeI'CW h"..u. and hore
.hglllly Ltrgct hok '" Ihc hc'Cl pbte

c:n

E
E

-.'".."

bie.

Using the Baseplate

.11>, ........ .

t:"

.c

Ot"us up th ough .... uplat. RgU . llound Ihe


$qua~ cQ,nt'~ wlth a round~, bit in 1 , .. bie
mounted ,Ouler. StIInd Ihe bllsepliue Ofl edgo. IInd
II up ..."h 1 ScrllP pushe'. To make 1100 cut. fetd
11 llonglM renet and Icron Ihe bit .

6.

A.'i/lCmblc Ibe baKpbu:.. lllb b ....",pic .. dn.


,'Ins fo:y; ".,...,.... Pbcc 1"" lwo pl.le._ log<:lhcr. ,nsen
' .. I"d'1onJI 1().24 fb,hcad m.chine !CIC,," I"w ".ch
~on~IC'"
and lighlC1l it wj' h """",,dri>"c1"..

10.,..,.

7. Mou n t tM k.noh. 1 . - . mU>hroon.~.pcd knob


... i,lt. '.Inch l"""n. It OI mounled ,,"Ihc b3s<:pb'" ... i,lI.
' ''nch-dl.n,no:r. I ~Hnch-Ion:tI: f b _ .."'" hol. To e"'
.,.te Ihe knob frutn tlte pblt . I lbftl eouplc of
'1 ...lnch-thick plastic ~ bouJd>l .. tbc Ioall""u"... 1C

..o'"

[)riU thl; moomln",-boIt h<>k. lhen ('OWIl<n</Ik 11. A


'>o-inch ot",,, boii It... Ibm big hnd..... a ... counl...... nk
is n-quirct1 \u..o n.. y bc- abk 10 IoIIbotllllle a wtIc V"fIIOO'ill3

bit in , plw'JIC fUIlte r tor thl> job. AlPin. tIM: rounlcninl<


m .... IN: <kcp """"!Ih tlt'l Ihc boh hnd 5C3U bdow 'hc

f>bte ..,rbcc
8. 80,.., thc bit n pclllllg. o"P'""tlill.ll <>II thc fUIl,o:r,
an . ...lth caUIIOI"I. bon: ,1Ie bit 0(lC"rliI\lI "";lh iL ehud:
Ihc bolt In 1"" NUICT. then k'rcw .hc pl:lle lu tM fUIlICT.

)"OU

I ZZ

lloule.

""~'C

\\"hktI ba>qob,e '" ti,,", 11", un,' 1""1 ro" )'OUl" ,."..,ff. o(
cout>C. 1IW iI)'UU
laml ... te lrimmcr. l d ~
1""1 """er lUr ,ltis "..,.,.. It 113h' and nt:llYU\.... rabk. Eil ....
,,~.1atJ!o= or _
. 11 ... b;oocpblN an: u>CU In 1"" .."'" "'"1'.

h.'.....

1 . Set IIp Ihe: r<>tlle r. 1!cIl\O\'C t he f.n<>ry b3s<:pI;IIc.


and replocc: 1, "ilh the nlJl.h~ri m mlng buc:pb~
xlo:cl ... Ippn;opri>'t
and chuck II In 1"" rouIcr.
o.:""ndllI3 upon 1"" "",t.... )"OU <= usc: a botl~
boli . " <lod<H:""'nup bit disii ""'tler. Of' muni'lns bi, . ....
of
arc daip>cd fur ohnring thc 5uruce "' thc birt
III" You <= abo U>C ot~1 bIl.
Adi .... 'bc cutlin8 drpth br botlomltg Ilie hl. OII
.>I1Cl"I .,1' p;tpn'. Th;ot mcant j"OUt biI ...ill bc: re ... ,looo
smd,h.. sby <il ,1Ie "'OAin!I>tIrbcc. (M1' dW nllpc:rs Idl "'"
'beci of ')'p;a/ copIc:r ,,",pc:t" Is o.~ Ineh 'hkk.l
111", ""Ui"l.l ...ill ~ecp thc bit rrom _~ Of " . ..,,(IIn~,
>llgh'ly w,e'"C1l .urbe<:. ~ aI_ i , 10 p;ttc ,"" =1 1'1'01""
...000.. ,\f!cr fU" lrim ... ilh .h..... up, ' h~ ...uh . . . ndn>houkl bJinsll ...... r(""" dnd flu.Jo.

bi,.

1""""

1"'" "

2. Trino II. e n onn",h stutr. Ik""-' ....jjchlng ""


IIle' "'''ICT. take n.... e of 'Ile nud\inc'. balancc:. "Il>oup

.... pbsIic

bascpb~c:5

Sttm ~o

bc prntr ",eli b;oL1rw:;w

.. lI<fICRI tcn<Icrw:y witl> "...,.. 1u>cpl1..cs l. for "'"


~ 'o lip 011'<> "'" biI. . .\1)' p<>In. iim:' I:i II"" )'OU n~
III ~ tlK mUie. LLpriAht br plOllilljl 00..'11 OII Ih, 1>:0....,.
plllti 0/1'''''' k....... 0I1L<:rwbc:. ,iL<: !>it ...iII 11"\.119" ,IL<:

.......

"-uh OM iund p"",,,lnjt (kno'n QoI "'" knoh. 5WI.eh QoI


.\1"'''' Ihe rome ......u d the protru.kln

.. lI)<"""'

I)qJendmg upon wh'l ",-'<'ds 10 IL<: 'rirruJlC'd.)'OU ""'f >iiUc


and b.''''pi;L.c .<IdnI"'l'" ot)'OU ~ ju!.t .-..vin
IK I'OIMItI' in In In:: around .IK knob Ib!lic'all)', )"" """n, 10
" ......" 1"" """n~"""'. off
...m~ 1)00', .tk,w ,""
bit 1" <t>o",U
k"'tl1n ~nr <InC "PIC
"'L1h a linie pnak:c. )0011 ""''dop a ~ and. Ii.:el
lOt "'" mIIIunc:n.. ,lut ct~L1t1bu1c 10 ~ and tcaN>UI.
" ' " ...... 1tI'

'o"

,Ioc

_Ith Ih. flu5h' lrlmmlnlil bau'""'t.. ..


......" trirnme. '~n work pl~,es Ih~, piloled Oush
_"'\1 biL , .. n' ruell. TII .. ,'5 becauS4! Ihe m.. ,hlne
tih OII I~ wo.klngIU""" ... nd IU bit pa.u away
~ ho]h ~pao:s ar .16gu. T1I11 5. wllen Iflmmlng edCJf:'
bItId.cl8. u shown. II un '''linia bolII InslOl! and

ouuo6e tomI!'S.

"TI

~1weoI

To aYold 1I011111nll Ih , work, vou mUSI hoId II><!


routtr uprigll! by p.uslng down firmty wllh OIle h,tnd
al Ilie elld of ,I><! bastplatt nlens~n. Use YOU' Olher
lIand 10 slldt Iht I'Olllt' atong Ihe rld~t of mauffi"llo
bt .0"Led aw~,

III

:r

~
_.

3
3

_.

:s

'"

Monising Jig
Monlsln" wlth rOUler JUli
"0I il whole 101 euler. Tllil
jl" seu up qulckly, holds
the work St(urely, .. noi
ensures Ih .. t mortlsu .. ,..
consislently .nd .ccur.lely
siz~ .nd positio ned.

j
c:

OI

'~ biggc>.I .l"lIIe dJ>Jlcnge in moniMrIf!; wlth a


I'lungc !'OUl'" is hokIi"II tbc w ortpk ,",'hIk ilmu\.
~ )Upportlng and guldlllJl thc: mutcr. l'hs JI,
mttt> the tehillO<!W' ha<J.,on. Il 1> ,;.impl<: '" nuJr.c, cur ,O

T:

CI

up,lnd a sn.p ta u<:,

1.

woodwofiodrlf!; 'l """m~1


ar<' 1I<llng tu W''''' ..,. a
woodworkcr and <.I",-.;Iop y..... .kill., you 11:1,'<: 10 maoIrr
tlle "",kiog of tlle munbe4n<kcnOll toln .
ll>e "'"* ",",,,,,,n I.,., ,he monlS<'. which is . I>ok:round. "'lua~ . OI" l1""lI-"ur- :ukl ,"" .enon, wllk:h 1
cut on file" C"tI of . lIe joinlnJl " .. m"". 10 Al It",
1II<H1~ ()rItt ,..,.,mbk<l wllh g1..., ar """" , he ",0"1..,...1\<1,enon
mi.,i .11 rour I)"pa ul "rn.~_ 'cn,;lon.
romp~. shcu. and r.od:i~ An<I 1. doc:;It. ~tcr II.. "
am" OIhcr typ<: 0/ joim.
ll'oc nuln ad''3JlI'geo of II><' roule< for monl"lnll
inci..&. ,he stDOOIhncso of ilo finl>h.td ~'U~. and .hc xc ...
De)' of ~nl arni oWfIJI
pobIbk ,,'" 001)"
dis:KIv1tIugr .11.. cornel .0 mlnd '" tI><: lin,hro rr:och <>1' .hc
mu .,.,. bit. A rwrow. decp moni>c:-'Ii Ind! wkk X 114
inchc:5 OI" mon: det:p. ro.. cnmplc-itI probkn ... k for
routcr. l'h<" ~ caii do It, bu. It eullrn on'l. (GI,,,"
thc: >Umph 01
1IIuct.."""""".",,,,,,,,, tuJluw m<>t'
u.e """"0 SI!'O<Ijj joi"",) A pllII1JI"
I >piN!
Slr.tlgh. !>il. and an ~ Ilui<k 'NiII h:...dk """" ull"" ITIOI'
tisins}'OUl! ft.'" ...~ I 1<,I do
111" "I<>nlsc.nd'cnon

fr:>m<: join. , )'OU Imow So if )'OU

'''''8''"'

joi"'

,!W'.

""""'m

'"

mu.".,

or

1'0 rouI a ~,Ihc II ... Ihl,.}'OU m .... do b cdlhIt


up a ll10Itbing ils 10 hokllhc """'1*'
l bc orltllnal vcnlon o( .hlt II$! ..~ c~ ....
buU. by """ Bun"", " , """ o( Rod.llc: '. """""..........
booIr cdltOf'J. "",," lItI h... ha. mI~""Orid Iook - 11"5....x
of !oC"'P .. 00<1. Il0l nnl<lulI IlUICI'b.L 1. h:u Iou of "'...
hule), .he ro:min,Jc ... 0(, ,,~ otl",. ,hlng>. $1."1"> tluI
1>:1,,, bn ",poMlloncd. Thcn: aro: ~ .......;"3' iti

rrom pl'()jt> p:>S'

My dUpt;co.IC , ~...,. In tho: pOOIoo,b a tlrtlc: dIff<n: .... prittWtly In ,"" lwtJwuc and 1"" qu:illly 0111>0 malmalllnCd..
(Wc "'... n'lhc!oc III!:'I IO ~>OIr ""'" "" " 'd 011 ..."0111 IlIupt'l).)
Thc lltt ~ ""~ t/Ilnst>. It

_ hol<ls onc ....... r1<fIka al " Ilmc


ml'.cd;
- holtls ,he won:pk.:e

loO

"""'''''''Y'''

Iw>dll,. is mini-

1, <1000' 1 mo"c:al

)'OI' I'OUI ,

- . lk>W5 )'tiu 'o $W1.ch wor1<p;a qulel<ly, ~,~


.hcm con5l1lcm ly;
- pn.wt<kt- .<ktj.t:ltC b.:.rln[t WrfOlCC, ... "" Cu , Is C<><ft.
proml..cd b)' ..,..te. lip o. wobblc;
- cnahle!t)'tIU ' o jlOSi,iQn ,"" cu' W<\S1:stcft11y (tom mot
. 1", to monl",,;

_controh Ihc ICllJllh of Ilie cuI

IICMIT1SIHC JIC UPlODED VIEW

....

Cuuing Llsi

Building the Jig

"rt

~ lmlIIdtr 10 coIlttI alllhe

nCCdoS:lr)' I\lInlw:trc bdurc )'0\1


Iqjo il, 10 ...." aJW8)lI appropriJ.lc. Sollle of . Ile l",nlw~",
111110 pidco<d uP "' Ihc local I\lInlw:tn:",Of<' 1It, lte 1111
_ , WCIIt wlthoul tllc.(IfCgk c\amps. and It Is II~dy )'Ou
.. ltntIOOIdttobtm. !ll1M _
tlmc:. <M\k'r Ilie pIa>Ik'
..... 'l'hm IM .. utr arm-o. l!I"t to ...0lIl Of! 1"" li&-

1. C\Ic Ihe body parts. Tbc: iiIts body. iInncd oI.11c


1f,1Ioct, lIId ~, Ilo lIUodc of Ihlct It:ardwood. """ uocd
I~ .... pIc;I.1Oed l !.-!nch popbr. u.., " '1In )'OU ha,,, OI"
1II1",oor hand!; OII c:ronomk:>ll)' Whik 'Ile nlllcriaJ you
Iboukl 1)( """""'ben: in 'he I ~. 10 I ~ n:aIm, Uw: spt-

'*

tIIkkn$ of II>c parts b rcl;ollvcly unlmpo."Unl . ( 1IU1


--.... to odjWlI dimcmions It
<1<> tIe .... IC flnm llIc
l\iIdo t/IId<J>c:I.s 1lIhoo>... In "'" ."Uiou!o dr~wln~.)
..... Ind Ihicknooo IV~ (rlghl-quutcr) IIInl ...'OOd 10
1'<I . . . . 1lIp anei ClUllllJCUI tM body'. componmb ' O II",
"'"Mil..-;fkd .". tllc Cunn8 u...

j""

Dime ns io ns

Qty.

'"

Mlteri'l '

1"" X 4J'," X 1SW HI.dwood

F~,~

1"" x6" x

1""X3"X t5W Haldwood


I"X3~"X

Horlzonl,,1 worbeil
Vt<t,,~1

worlc,eil

SIId'''9 Slops

15W Hlfllwood

10Y.!" HI.dwood

I"X2WX7"

HI.dwood

""x ' "Xg"

HIt.clwood

Hardware
2 P~Sh' knobs, I~" dll. W'IIt Jl-16 x I y," Sltel SlucI;

101(-29 I.om ReIci Too1 Supply Co. (!QO..25HM2 1)


4 b.-ss IhreadecllnulU.

~"16

2 piulic knobs. 1~" dil. wltlt \("20 x 1 Yt"


.01::20 from Rtld Tool Supply Co .

$~,~I

SI"";

2 brll.. IhrN>d~ In"'t}. \(-20

2. GIue up thc Ils body. J..... II"" 1.... lOf> 10 IM


Ii tbc btt. Ind gI"" thc boOl"'" 10 II>c td; oIlbe
a..MIndIcw:d In thcc " ....... ing
I~ lhcr<: . n: ne)
.,maJ _
1\0:"" but do 11)' 10 kttp 1.... body "1 ...'" a:.
.. 1ppIf Ilie , I;oml'".
AIIu "'" iJuc hu ~ .nd .he d.mf>' III"" bccn
~ tcft!'" olf ""y <ltiW "IUft,_c'<:JUI . Then joinl 0110:
la lI!d 1"1' 10 .... kc 0IICSC" . urllK:o absoIllIely
10
.other Thi!! is cril~.

,.f,,,,

"'1"' '''

1 log;le tl.lmp

(Oe'S~~<o

4 p;o.nltud SCfews, .8 x

~"hud

M>lt~

nc 21 5U)

Jo',"

boIts. \(" XI\("

ou", Ilie front antI

b;Kk ~

0/ Uw: lap

""",lId 1ltl, 100 '" crillC":l.l . Il nnSary, lip 1....


10 """'It. 1. p. r. IJ(,1.

td; """"

MOftlsln; Jig

125

J:
:1
O

-.-.

PLAN VIEWS

TQP'JlEW

Plutlc knQb .. ith


~ -20X l !4" slUd
(Reid ,OK20)

1 - - - - lSY.r" - - - - , L -

~=!I,f"

,."
,

L,
"

low" - -_ I

SIDE VIEW

FRDNTVlEW

IW-dla , knob

DeStaCa "C""'

1"991~

damp

FRONTVIEW
~t

Up for End Mortling

.-."

III

'f
O

::lE

~~0---J

Plastic knobo .. iln


1i"16xl "'"stud

De-Sta-Co flC-215-U

(Rtld ,tOK 29)

\Ifhik i!'s noi csscn.i.aJ, )'()tJ nur w.ml 10 seu", cen,c!'


.._ .... line .c...... ,h.. lUp. I r.n<I lhe C<:1l'<"fIlno< hd~ In .euln! IIp
,h~ jig" Ihe ~nninI; of exil moni5ill!l: projcct.Juso """'.
su'" 71. Ind~ frtHTI dtllU alti uf thc ii~.tI<I
line
ac""", ,h" tup. 1
ulili'y knlfc 10 seu", lullovo' V
gro<l''''. Ihe" Inked In Ihe Iim: ,.!ith . n finc-tippcd n:d

usc.'"

"'1"""'.

ma"'e .

3. IIlSIaU Ilie I,hrcadcd inserts. uyoml<X>I;on5 of


lhrca<k<l inscns In the f.Jcc..,,(I top, '" ,,'cli as the '''''0
hulcs fur 'he slKling.... op 10",..i"l\ pin,;. 11Ie .potS "'" .110","

1~

in li'" tl .."injl.

ft,rl~ [,uJ'OWs.

II "'tiple of ," Wr<lU: In "".,. IIl<: slWinli OIop!I sl\ooJld

12&

RoU ler Magic

_____
IO~lt

cli mp

,h"

edllC1!-ukk rods. II is good !da 10 set ) _


plufl,IIC rouler-flual wi'h ilS alge guide-on 'hc 1is.:tIII;l
sec lf )'0<1 need 'o
yuur lis '" an... mmod:ne )"OUI
ruUl~r. [f II ... roW; "",n'l Iong """ugh. )'Ou will "",m 10 <1>
ti ... ilg tOp 10 m:oke it """"""CI', "nd Ir.1>o: !<Iiding $top$,
:os po:;f.iunnl In 'he pt..n" 'uu<:h ti ... fUule' ,,"het tIwI
sqOJ:l.rely comactinll.h" rods.)'Ou will ""'ni 10 nlO\.., lbem.
TIt" \oc".lingl'in hol.,. ~re ~ Inch in di.mcter. UriI
romaei

',lk>r

th~m

.bot"

I Ineh <kcp.
(>rin pilots for Ihe ,ttn.-".<lnI ~"" nal. In 'h~'''1''''
LI", tWO 1""''''' fur tl>o: oIidlng "'o~ In ,h" (.ee, there ...
tWO hoks r..... thc hOriWOlai ,,'on:n.'g :>nd
for ,"'o
t(.'2.1 "'011<""' . If)'OU don ', knuw Wh.l di:lmc<n hok

,"''O

". 1

,.un LAyoun

'"

SlJOINC STOP
\4"-d;". x )li" dttp
hoit for Ioc.., jll(l pin

\4"20 'hruckd Instn

, j
VERTICAL WORKREST

."

,.
1r

2.

HOII;IZONTI\l WORKREST

.... L - + _'O

1" _

TI

r ; . S\4"-

. Urt---'-,----,rl

t: . ... ;;rl

}-.-.,

1.---"--- 1O~" ---<

R lor Iht ~ mc:lSU"" ."" """ o:IUm!:tt'r ci (J<I(C . .i.h


611 abpcn.. (Ibe moi diamct~r It ,"" d!amc:ta ci thc
. . . 1MIok Ihc 'Iuods.) Note ,tu. '''''"' a"" ' ..odiff...."..

_ 01 iIIonu mzuim,l.

~ Ihc hoIn ."" born1, drh-r ,"" iMIon . l\H' du.fI

opm5h-r rucn .001; usc: a nul ~Mi h"II .nd a


.-:II. Thm .1", nu' OniO ,II" boII, ,1I~n ooJd Ihf 1""""".
"'" thr nUl down .g;ohlSl 1"" Inso.n , aMi >IlOn lumlng
... imn 'he pilot holc:, Ontt)'OU lt1
In!;cn swtC'd.
., thr .. f'fdoCh OII du: md ' 0 turn ."" Ocmb/f.
,...j . .

t""

t""

.. Makc Il..: ...orkresls. Tht.- Cun. . Lbl 0Ip0Ci/lc>


~ ~ .ho:

t""

..'Or'I<n:5o!;:Il I1dI: ~ .hcm tllidn .,..


. . . . . . )'013 ..1011. !lut In any ~ , Iht oIoor In
hori.......... a>iot IOruui. 1 think, I')'UU worIc ""itI> a wi<Jr
10IId r.ICbo:r tIun (J<I(C
~ riPf>".l '" fini>hW wkl'h.
lip I boInI '0 ...idlh uI :aboUI 6 1no:tIt~, and C~lIt
10'1-Inch "'nlllh. Uty oul boIh tI><! hori"""t,I .Mi ,..,...
... rntJi OII 1., Mou, Ih" .k>ts ", i.h pluf\jjC: ro"'",,
~ ,,i.1> an nlfI<' guldc. Ro", ti", hoInr In , t.. ,=101
al. ' " ''''' IWO ...... rrom t"" boanl, and ~t tt.. '"ft'

t""

,tuc'.

Iahat 10 ""'glh.

S. tnsu.U Ihe

toAAk c bmps, Uty oul tlle poooItlon uI

_qp; cWrIp OII codl ral.llorin polot _

and (..,;tw a
. . 10 r:ICh ft"I\ lII"ilh ruur JCR:'W1l"o. )"OU dorI'I realI)"
aci IWD daJop.. )"OU nn a:siJ)' wort- ,,'itI> onc: cl:lmp.

Un yotar d.1II ",... 10 dri ... Ih...,d" ldurts .


Wolh Iht Instn th<faded onto , bolt. and tht bolt
c h lKk~ In .. dfill IIffU , II Is usy ta d ...... tht Instn
squaff 10 tlle fact of ItIt jIg. OON'T turn tl>t cI,llI Pff U
on; lu.n "'" chuck by tund as YOII advanct IM qulil.
TI.. n twO tIt~ nul' onl O Iht boll .. oo l!ghleo ont
agajnst tht other, J"mm ,nll th~m $0 ntltlle. wlillu.n .
Tu.n IM 10$tn into Iht boit nt~I . The jam nulS p.t
venttht Insert rrom worklng Iii WJY up Iht bolt J~
you lu.n th~ drlll ~hu ~ k.

1 0 la )" oul . o1<)n""'o ~ a liCf&P 01 thc ~


>Iod. and (>Uliu.. .t.. mortJl;C o:octly wl>crr II. iri ' 0 bo; . .
M.'" Ihc ~'(o ..:fil"" lCnlol4.hc mon!se.

2 . CI.. mp thc Ils 10 a ,,-orkbntch. Sn rbc ii8. rbr


"';Ih a """pir de

w., oIlh.. wor\hencholod damp ~


cbmfl!"'" quld<-a<:lion bar d~rnpo;.

}o Set I'OC work""", an<! toggIt: clamp. Ad, .... tbt


""",t plea w ill l1e n""h M lb.1>c lop 0I1br
"II. It )'OU a", ""1nJt , IIe h<JrI4>ntal "'"', m.o.ke .."'" 1, i PM'
oJld .., .he 'Of>oIf)"OO an: Uiln!l thc: "CMk:aI ..,.., m.o.kc ""'"
It', pcrpcnUlcuLtr tu ,hc 10f>,
,,'ork~

""'''c

Mlj.... "'" $ndk un the '0SI!k darnp OS ~. Tho


..... mp.'ihoullJ Sn:Ip .",anly >JId bold "'" workpKa xeun:tr.

40 Clamp thc .....rkpkt-t 10 IM Ilg.. Se! thc ,est pKu


on u.. .....ond line lip thc ccn,crtiIY 01 rhe monisc wlrh rht
CCtItCrlo"" >ocon:d laOII6 thc Jitg. Sn>p Ihc "'I!;gIc elam" dooni

The s lo" 10 th .. ho,I.l.Oo\," ... orbest an IN!


,0ul..:l w ilh. plunge roule, ... ilh an Nlgt' !ilulde ...
IhoWR. Work ... Ith 1 w lder bo.ird tllan nudHI . 10 Ihe
rout~r w lll be ldequllelv IUPPGMfd. lheo ,Ip 1\10 Ihe
final width.

r-...

an<ldling il 10 ... hiehe,"". ~ )'OU In: ""1"3. lIc:ar In minii.


'00, lh.o.' )'OU mor nco:d 10 tlltifr ,he v<i'ion of ti", '''IIIk
dilmp. ...""ndin' upon . t... wkl. h of . he ......tpkcc brtnJI
mon;,ro. 1O In opinllk doesn 'l Intco*n: wlth tt... .... 11 ....
1':lntocM.l.5C1'tWS Io:nII . M)'IiIh ap"",,,no.ncc 10 the Iil!: (.ntl 1
Iblcd rhmt !n .he Il>"'.....~n: u .. ). h Ul 1.....,h tlryw:t11 ""n:w~
...., more n:al-....".j,J.

6 . Makc: thc ,.1id1n8 ,.10,... ILS wlth Il'" ...."' lte

ilops:an:""" made rrom I "",,",pIea Illat ', ~ t""" thc

finished ilop. 1#y out 5Wp oJotI nch cdJI<: 01 I .. Of' s. . _ , , _ bo:wtlo an<! damp II. U) 'loc """"'hendt .., 'hc
_
iln:2:i 10 bc .Iounl extcnd oIJ 1).., bo:ndt cdF. Wllh
plu..., tvUlcr C<julppcd ... ~h ni.,. guIdc. cut t .... sloi.
O
Croacul thc boln.IlO 1n1Ith. ~ fip .1Ie ...,....,

1:

::lE

7 . Imcau ltM: " 'orkrc51 . nd thc

.,uched

~tops.

Exh

S
10 'hc ji8 bodJ' ""lth ",...;Idcd pb.>!k
kno\)oc lumed !nIO .1Ie "ppropNl(: Ihmdtd Inscru

WOI'I< .....

>1.,....

n.. .udi"3
:an: >lmibrly txhaL 'Ib ....." nch
stop ~ . , \.IK'd hct-hcld bolt .... Joo:;uinl pu>.
I"",n lng 1, Ih rot>gh 'hc >lot !n10 the .ppropnole hok In the
' - _ , Iil!: .op. ""n u.ed 00"""" ror Ih l> pufJX* bul lhen ~ued
IItem !nIO Ihc holaI. Lc:a>1l3 .hc pitllo- " 'hclhcr boItli Of'
<luwc1$-1oo!Ic: allowa )'OU 10 SUKI Of joint the ji!! ,up 1<>
""r""", II... ,urf.oao.(1'or Ihc: .. te of)'OU' jOinlcr kni'"o'
.... kc "''''' Iile In)CM' an: sunk ..",U hclow thc 5Urtloa
bdo"" tloI"\{ Ihl,,)

Using the Jig


'J'hr

li!! b real". qul.e """y ro >ct up ..111 ",.,. [)an'l bc Pu'

o by IIM: ""mIleT ohtcps. 101.........c but .. mOfflcn, oflwo


10 oa:oonpllsh

121

Rau'" MagI(

S. SclIhc pluoll" dcpIh scop. Chuel< "'" .pprOl.....


bit in your pIurw: ...... t t Zcro<>UI Ihc dq:IdI ocale, Ihco ...
,1>0: dq>tll )l\0J> ror Ihc dq:IdI 01 rnonisc .,ou in1Cnd .0 lOll.
6 0 Adj"'" the edge guide. AI thc cdF guid<: 10 rIx
" ......... Set ,"'" ruut .... Olt tbc: iii!. witb Ihc: Juidc n:ft ,eoocq;
,hc baek . . . 01 thc ropof'hinIII' rhe bi' -wlh rbc roo:.n
HnplIlggN. 01 rounc-Io rbc wurl<pIctt. WIth rhc ....
guidc: Ioo!;c Olt il> rods. ;odjuo.t LI>c posirion 01 thc router ..
.ile: hit;,; <'(n'cred ""ltll.", thc rDOI1ltC' b}'OUllioQ.1\Im Iho
bll by mod. and ~"'" "'" cu'ung flu .,. 10 CIbUI'l" rJur l
n::>tly is CCOIl"n:d.. Slkk II>c guidc: up apinst thc ",o, t.ct
<.... It<'. a ..... "j{h,~ n ,"" lc:><:Idng knobs .
~ "'" ruuu:r from _
to _
._
thc Jl*k IIN>/J'
>PIn>! II>c ils. n.. bit ~ n:maln ccnlrmi wiIhIn Lho
",,,,,lsc 1..... 'li""'. 1f it doc:s OOI . !IOmCII\InjIirI out 0I ,,hac1
Elther "'" cdfp o( rhc jIj( 'OJ> :an: 001 pMolId. Ot rhe &tu 01
"'" lot plece arc noi p>JlI1ld.or thc nlOf1lsc byout b

_o:wnt

7 . Adj .... thc ~11d'n8 ~IOps.. Thc b ' tftl """"""""


0I11>c tvUln' i :at1'C>ltd wh"n Ihe: ~ lIuk1c rods conu.a
rbc ~ >lope.M.,..., Ihc: tvUle. k: ~ Ot fij{hl lo ~'Ioo 1""
bit ar rhc >tty c:nd 01 thc <rIOl'USC. SIkIt II>c $IOP o.p.IlUI m.
rod on tha, ....." . ...... IghLcn 1" "" ob.
SIidc tIM: roul .... 10 II>c bit is pobN 11 ."" othcr cnd 01
the monisc.
thc "'09 :aplnst ,mI :oidc:'J rod, I/>Il

.,....,uidc

1Itin,

~.cn ""'~
8. ROU1 thc ..,..1 mo"*,o WIlh ,I>c """"'pOt
dampnlln the fix' .. "". ond ,,ltll u.. tvU'n' au ~ upol'Olll
tbcmonix.
i'lW1fII:'O" 'hc cndJ 01 tbc """"bc: II ..... Doina tlIb
thc cndo o( ,hc monisc ...01 IlO' wnlcal. n...
tvUl oul u.. wutc het"""", .IM: cndlln a Jcric:I 01 p;w;co.
Wl><:n)'OU t"UI , bc 1Ut1:)'OU Ittd.hc ,.,..' ..... In ,he ....
d,n:ction . , 1><: an" ,m, .. ,.." , 1><: /OKc oIlhc bit roution ..
p"U thc: lIuide apl"" Ihc: wuri< 'Ib 00 III ... )'OU"", JOI 111
n:'.-.cI thc hIt het"""," cuni ... pusa. WoIII 1).., . . .

"""""'" ,m,

SETTlNG UP ROUTER AND $TOP

L Sol Ih. workp,eee on III.


worl<reu, hning up Ihe
(.nlerlin.on II w,lh Ihe
<.nlerlln. On Ih. JIO ,

2.

~vo:'

Ihe roule, 10 posllkm Ih.


bk tuclly belween Ihe lavouI
IInu for III. monise Ihen lock
down Ih. o<Ig. guid.,

1, Movt Ilie r(lule, 10 posillon Ihe


bkJu'lln.lde Ih.l~youllln. al
ono .nd of Ihe monl...nd
"djusllh. sliding SIOP agaln"
lho e<lgt ouldt's rod,

f~_.

4, Movt Ih. roul., 10 poSilion Ih. bil


Jus, inslde Ih. I"yout lin. allhe
Olht.r .nd of Ihe monlse and adjus,
lho Olht.r .Iidl ng stop iga,nsl lhe
.dge \!uid.'s MII .. rod.

_.

VI

:s

III

IIIII:T1SE RDUTING SEQUENCE

1. Plunoebore one
end of Ihe
monlstloth.
full deplh.

2. !'Iung.bo,e Ih.
olh.r tnd 10 tl>e
full deplh.

1. Roul lhe wi srt


from belwun Ih.
IWO hol , nibbllng
aboul \4" detper
willl ueh pass.

4. Continue 1111.
proc.ss u"lillll.
monist Is
eompleted.

glri<k <>ppo<l.e )""'. riWng .k>ng .tIc jig 'Op'S b. ck cdl/:<'.


you DU~~ .hor euu!ntt p ... by moving ,lIe "',u'e' rigII' .,
Icf<-l')M,n n::tnct 'hor bit clnr o( .II~ wor1r .nd ~lide ,lIe
......,n back 10 ,tic rigln_ Then "'plun"" 'hc bi, fo r .noth~r
eunnJI p;as>.

9 . hncll poe; itloning nurb On tit"

t-

tht

ii8. ","umlng

rigll! . )'U\l tu>"c onc mOn:


.xltJi"3 .tIc octwJ _
.
poctt<. y"" nccd 'o dcri<k ,,-tu, ~ .... 00 you wlll .....
0 ...... _
tht ....,.,.".,;00 o( " 'Qr1rpkccs bcing m.onixd.
mort;"" ,nI '''"''' <>UI
$CfUP t:i.OI< ., complet" bd()r"

y"" 00 NOf nttd W romplc1cly ..,. OUl


....,.,1".,1

~.

,.

"'"CI")'

.,

''''' ,,'" nuri< ,1>(- ttI1.erlonc o(..,.,;:h

1. n"'Y 11" nsicr .0 L.t) .......Il<' mii:>


you con ~Wn::ond nuri< ~ ...-nr1rrWtt"""

""'m ~nd .1\tI\lkr "'" nwtJ ..ith 1qUU"<" ...., pmcI.


GI.cn .hl. ~ppru:lch. )'OU nttd .o lillhtly pmdI OII

moni~. S.. bdorc ~='~~.:,:


.,od J)t'nctI '0 ""'~" II

IiI! wp 'hc "nds of.1l<'


monl"' . ...., >q ... n:
nur'" on .he 1111 .Of' .

,
The eUflIlu,1 100)'0011 mark 1, 1"" Uni,. (Ifom Ind 10
endl of
mort,se. Tht,e~ a unle.m.I,k on 11>0 Ji9.
and yOI.Ili~ up the ... )'OUt ""rlt on "', WOtkplece .. ,tii
it. Beciuse of 1\ow)'QU"" se. up 11>0 Jig and 1"" rau",.
Ilie morti" ... 111 be pe'fect'" POSitioned.

1""

Loos.." non jOi"" are ... lIitlhe venlul W<),mSI ~


tor. To mak, a Iooseltnon Joln1. you rou' mo"IJtIIo
both raii Ind stllt, Illen Inlen Iltpa,ale plece as ltot
ttlIOII w~n Ilie Jo,m Ilusembled. Typlcally. tllt
p<obItm 1, haldlng tllt ,aU SO ~ monlse c~n be fOOloC
InlO Ils tnd. As 1hown here. Ilie vt",c~1 ...o,k,nt
iOIw. 1111.1 p'obl~m .

ROUllnll a monl.e ulls for 1 it,,,"s of Itgll. cu".


Plungtbo'e tlle Iwo end! fI.st 10 ts.abl,sll 11>0 par1t.
m"t .. of .lIe flnl.llfd monlu. TiMn plunge Ilie b'l
about \4 Incll Ind makt a PUI. (unlng from ont end
10 .lIe o.lIt . Rttra<1 .~ bll tree of Ilie work. and
.ttutn 10 .lIe l.a"lno pOln . PlunOt a IInlt du"". 10<
tllt nUl P<l11. Rtpt~1 IIIIs 'ouune unllllM mool~ I~
<ulIO III final depIII.

110

Router Magic

Shop-Built Siot Mortiser


Irrth Illis flnure, rou a.n un your
plunge rouler 10 CUI monisu_

nd
10 rOOI lenonl, S1015, .nd groo\les,
(Ve" 10 (UI moldings ilnd riIIislI!
IMlttls. II'S il Milrvelous Milchlne.

nd .1lII ,'''' ntt<J ." "'" hund~ 01 mortisa. Hol>


Monn .."mi obopping for 3 .....miM 10 do Ilie job. It.:
~. "" s;,ys, " had ncI.hc:r tIM: ~ nor lhe
opn l<If a CO<nnICItialIy madc
moniM:," Ati .... thinkint;
00.... """ Ibllng IIIs l'C<julrcmrnl:f anei <loirn. Bob A<"
lRd WI hc ""uld hener .;;,,~. 1110 nCftb br 5imply
....,..,. ond buikling his uwn ..", monoo.
lkIb b\IiII hb !lxu....: around 1'1.. ,,11" n.>U'L.... n.c, mute'
_ _ni hortzo'''illf ori. 1'1>1" tII rido hac~ .oo fonh
.tbW ftuod 10 . bcndt. /I.S 111_
a pbin in dcuil ,lhcn:
.. 1tm'OI ~IS yotI an nul<r 10 control ti><: <kpth,
. . . IOd poMIlon of mori;'" 10 C'Ut ............. fOII
.., . . Mlfkpic 10 II><' worio:1>mch. thm p/uQ8c tM
.... and loIid<" il "1\ong 'hc: moniJolr'l Wftf.
In ..., ,cii J'O". mb b OM . k.worl<inll ~. TI>t
_md It>moum rol! cffunk'!l&ly I:r.od: and fonh on 11><*
. . .Thr l'\rJc atIjUS1l"cn", posslhl" an: Wpc<'p!ttS<' . ItU"ll
iIf rod oII "fI't>I1<bc:nch '" Ilie b>dt 01 ""'ta
_
doton1 lakc "I' v:1I~,* .hop spacc. 'fhc roUle'
CII tir ......,..... '1uiddr . nd usW lOr 0100 Iobs.
II llIt maur
>ina Bob d<:fOp1ed and hulit hb
......... Mort ....... it Il. . "",,,"ni it...., 10 bc
...... """"'1('. and eon ...;nlcnl li ~n bnt5 thr COfI>o
..mal OMI .vII,," ",o"i&l n~ 1~~ , ullwicldy >tock

*"

,.hIc,,""

,"t2N

"",,,,..,.,ty

b:ouo< Ihc

~ock

iO$d( is Il.cd durillil manl.inll.


lItot <II oU, io ;", ., a o:>nc-fob Ib:lun:, li <:MI function III
l'YCfJ" "Of lh3I. a hoo"ilk>tM3l l\>1li .... tlbk ~ . Yoo ~ rut
Ocn0n5 OII io "01.1 ~ rout ~"Cf :and oIoIs. 1"" ~ _
pantlJ, ,..,.. CUI

rollO

maIdirIp.

"

de""","",

a """ lI",n~. n<Jo: 00 bc abk '" """.., Of"


bc adfu>tcd In Ih= dltk.rnl dl...,.,lionJ:
1 In:anll 0lIl

_.._.
O

CO

How It Works
11> ~

li:

rur Ih<: okpoh <II rut :

2. oIdc: 10 ..Iok lOr Ih<: imath <II euo .


~. up .noI dor.-" lOr 1"" hci8ht <II CUI

..-..,.,...,1

Bob lksIsncd hI:! JIoI mo........ wo1'" lhoor


III mlnol .
'" und Oz. I:"ThI: Ut-and-UUI ..-"t:ffiCfl1 is pc-rformcd hy
111<" plunglng :&<:tlo" of III<" "".Ie'. Monl<c: <kpth Os con
IroIlcd by IIlr bil D<lC"'lon. whlch 1. lI"'......,cd hy II><:
fOUIcr"S """Il <kpth .."""
Skk 10 $"", """, ..,..,on fI>O\"Cf from sidc 00 sidc by
.....ano o(!hrtt ~ 1lIr.of'"""ion pilk>w bioo:I<.
oIldc ;do':qp; "'"o pn"ci!.Ioo-ground >Ied sIWU. "'" 1'11""'"

1"'''

'"

..o". .... ...


~OUlt.

ellllul.

moun!lng pilit

s;d~

Sl..OT WORTlS(1t (XI'LOOEO VIEW

oi,,,,,

~ ...., lI>OUn!cd on ."" JkIo


lInnnII pIa'~.
Ind Ilie ""'1'" rnountirlA I>o;wd 10 allac:b<-d 10 thr fnInI 01
lha. ploI., n.c: ohW ...., """""td wilhln m....a .haI 10
huna /)(...,..,11 a wOftc .....t.oce
SkJe.cQ4kk ....'tI It wx1y Iimitcd by ,lor rna..o
Imum moftl .. Io:n(rth UM.,; h abuuI .. ~

lndoQ (cna Im&th abo b atfeacd by tlle bi. <IWnc1cr).


I fine ~ 01 !oI""" lt:I>'d "'lhin .hol _
b p">"
. . otdtd by ocopo .... tlundftI rod lIw. aI"!Ido froon IIM:
_
~ pIaIe 11'1 ........ hoIc:o In .""
l'*IcnI

>i<b.'''''' ......

chuooiI...,.

1:: _mm, lWls """"'" thr .....,


,IM" ~h:aoob.o.k.
O lIy odjuollnw ,"" ..opo In ..... oul on "'" tOd.)'UU ronuul
2 lIcnw far Ihc ro."'" In"'" rrom loIdr ... Jkk "" ootinll botII
CXInPCb

'''nW .........

OIopo; 'plnJr .lIc chuIIb !Iidd. )'OU ~I


menI compl<1dy.
Thc: >"'1 . '" 'fM'Cb1 dbk.ffi<., nub, ofiCII calkd cht
nuu b\' 1lUd'l1IIi5u. 1IlIU$C ItIt ~"'Imrol rod .... 16
iti"""" prr Ind\. ,"" adj...unm. can "" "" RrIe .. '" Inch
(,\ fuIIuom ~
nUl \\o inch.., a <(lW1C"'''''' """""
I-_~ II .....,. 1t.. 1ndI ) P\lclkW twO dIk nUll tOfllrlhrr alImn )'OU

!""

10

jomont . . . . . Ihor _

10

hokI ,.,.....

IIp..w 0 -.... \'nUaI ~ oIthr """'''''' b ClIt2blWwO br ..... pcMlo:In o( thr I00I.............. board In
mallon to Ibr bnfinII ~'"'" ............ board II--...w
10 ."" pbIc .. lIh ll'Ioft pbAX knobo; ..-.th 1n..,.aJ lu.d ."Tht
........ Qlcnd lh""'llh """ n thr txwd !nIo ~ In Ibr

plale 1" ...." rou.c:

"",*""'01 oI,he rvtIIrr,

"""""''''II

Ioooien IIM: knobt.nt.1 ~~ OI" _ ..... he


hootd.
fin<' """I<.-..IlIdjllSt",,,ot "made lhe """'"' ....y 1I1""'~
er,,,,.,,1 .dj1lllC.... n. Ilo. A <htn<ktl rod porojl' rrom Ih~
hono...
bnrInfl pa.e. ... chcdl...", "'''''' 00 Ihe rod

"",hc:

.... oodI ,,,,, 01"" w .... ';~~::;:t


mounllng kftObs Ind Ilhing lhit -lInII:.1
roul~. rrom Ilie ehlonJ. , " - of Ilie ..... nltal Of IIln
s.m;"gs lre !osl wllen wou do 1h11, tI.UIIH WOU dOIn
hol ..... 10 Ulmpe. wlth Ilie ehed: null 10 do 11;, Wilh
tlle~ !Un. .e_d, Ilie monb" no ~ IntrvcIK
In the WO.k1j11C" TIIe ehlnl. b o'" 01 Ilie w.V
b~n~.lh Ihe heneh lOII,

CIur 1'" _

"""om

. . WUUt

$Iot,e<! pLlK >C1'tWe<! ,O ,""


01.".,
..... moonUnlj 1'10.". 'T\orning .bo: chede mII (.fle. 'bo:
bIobo_ ""*"'<:d) dtbc:r ~' Ilk nlQllmlrlJj 11<)0'" up ....
.."., k \O <lc!a'nd hllS o.I;USCing 'h<: helgh' of 'h<: nxo.
.ln<:tnnnIlJ .. ftnt: ,., ~ Inci>.

Why It Works
I h rnd ahou' Ma.. ,,', M. .....,Iou .'olan;..,. In ,h~
, . . of A ... ~,iC<m lJ(x><Iu",,"'" When I ... n cll ""rce"

"ptOjt. fo, .h ls

co U ~c' lon . It " ;~> on~ of ,hc O.. ,


N' .... me 'o mi"lI. "-fie, ",,"" in~ (>Ve. Ilob', origin al , I
"" a!Io<u m.klng my O"'''. CKep. ,II., I fei. I could
'ilprove""
Wh had rod,~11 ilie .bou' ,II~ .\" ,,,doll' Morti...,
If ,..., COSt oI ' bc p. n5,1'he panleu'" pillu ... bk><ob
MICI ,,11at!> lIob ..,Icc.ed h. d <:051 hi m
t , SO back
II tbt '~ ( Of WUrK eo", ,,u:",,.1 sluot "",,",1..,. eOS' &
M y " lmprov"m~n, " wou,d bc. "1"""
_~ llKWtisc:t; m. lle "r J,.nd1nl bitdl ply""ood anII

.boou,

"'6,1Inn '".")

bron1e bu.hlngs In pl.ce of ,he pll low 1>kN:k.s.


1111' ,,-hen comp lelell, ,he poor n,.n ', veuion ","
no lmp",,~men . Whllc " .:0.., ."n lflc,,,,,lr le05. It look
mon: ,'me and con>ider:ably mo", p""," ee<l . kill. 10
bullll , .nd ,h~n It lIidn', ..-oril: ( which or "Ou""' .." bc
",. 1 kilkr)
11,;.1 Ionll....,. .ruunll ,o""y lwo ' hlns>
l TII" o ri8iJ>a1 monl.." 1. " 'cll
2 ,"ou gel ""ha, yuu p' r

1'",.

~e<l

\lob c h~ 'hc m",eri.l nll IunJ .... n: fur ' l,ilie


q".II. I"" and "h'r:>C,~ri .. 1a Thc hI8"-<1u.'llr plywood
U>C<l ( '-"5'S more .h.n oundartl blreh 1''''''''0011 ...11 i. 1.,..,
wkldy ..... II.bl". but i, """ .hc .. ,rr"e "ceded.o coun'
c, 'he lI!ffcrc:n. ton:: ..... ppllcd 10 'ile <lev",c durons u ...
S'a" d. nJ hlN:h pl)'wood lactl ,h .. ~"IT.. cs . 00 when
ruu .uh>ll,,,,c i l for ,"" "'het. 'ile mort,..:r)'Otl c oo up
""ilh ;.n' , rilld . OO ,hc "U'5;1 ..... ta.~ noi CCU
""e i n ai i ~"ua,IOR'

Cutting list

" rt
t\ou,t, moun"11j;I

Qty.
~

pIIe$

CII.I$Sk sklt pll".

Ch.Iun Net ply


CMssls blle k ply
,

8ul1n~

pla,e pI,u

MOun' ino bloc.!ts


Vt,,;cllllIdjus~nl

pilite

TOYllle'<:!lImp [>Jocls
,

,
,
,
,
,
,
,

Dl men slons

Milter lill

W)( 8")( 1814"

8ihk blN:h plywooel

W)( S")( la"

hltlc blN:h plywooel

W)( ,2")( 10"

SaliI( blN:h r>/)t'o!ood

\1" x 014" x la"

hhk: blN:h plywooel

\1"X5"XO"

Salile b,rtII pIywoo(t

10\" x Joi" x 2"

H.1tdwood

\\'x2")(2W

Alum,""m

iii" x 1\1" x 2}\

Salile blN:h plywood

Il, fi&! ..nllers,"" 1.0.


l i nuts. )\,"
Ulu

I blurled "uli, 4\",16;


I 'i..N.1 1!<)tI> Reld TooI Supply Co. (800'253-0421)

"

drrwllii senews,'6)( l)t"


18

~nhelld

senews, U X,"

16 [>Jonheid sm~ws,'8 x "..

Iwudtd I"se"s, '!oI'"'18;


11121' from Rt'Id Tool SupplV Co_

1 plutle knobs w,1h studl. 101,"1 8;


'OK, 27 !rom Reici TooI Supply Co.
2 100000le e!ilm," (0.,.51.1",0 Hl,23S'U)
2 'OlIIIIe e!ilm," (o.,$I;ICo ,n22SUl

1 Ibruded rod, "-. 16)( 614"


1 dus "l" lI'OIJnd ""el .lultl, )'.. )( 1 2";
KIS jt'll2 Irom Thomson IndUJlfIeI, Inc_
lIQG-SH.... 66 for .... _ 01 li dulel)

I:

I L'" "'" 01<0 ~&l1I/s ""',. frr>m /6"i<'''fIC Jiul. ~'""'" <W l'IHoc~ fIIr*o<>d. <W ..... ~
ShOp-8uiil 510t Montser

a._.

10

JoI"

4 [>Jonllelld serews, ~ )(

OI

3 IlnUf-beilr'"", p,'low blocks;


'SP8 12 lrom Thomson Indll",les

IchKk nuli. "",16; .V4 lrom R,,'d TooI Supplv Co.

1tloIuded rod, " -. 16 X l!r

Hardware

",,,(-I'ud boill. )'1,")( 3y,"

I . lD ","s, 14",20

1]]

lJk ....,I"... thc piJlow bIod<:s Bob .sc1lC'd ...., ~..


<:.llly ddiIIfIt'd
Thcy 1>3\" ~w.,;

ro. 11_" _

1>:111 ""..1n",. 1>01 ~ lbty ...." df\dml du>I ..,.1;.


"'hleh 1.. Inll'Ofum In a woodo<~ ",,..;ronnomt Tl>cy
I><'rf<:CI1r nl",d >Ctl 10 thc pn.", iI~ , Iw'<k......
""d ~ .sckc:.e<l l es, th"y ~'" CIIMIy Uh ..... bIock~ and
t...., .tiUft,! COlII lIS $ 170 In I."c 19')S), hUl lhq . ... 'Iroisnnl
lOr ""'*'11r lloc klnd 01 .."..., Iltcy .'" doIn~ , i\nd icI n,,, .,,11
)'OU . .. onc .... 1>0 1<00.... (rom ""I><'"",n",,-,
lhoey III
oNtI~con>I~1oo .. 8 ......'1]' oIm[>lillc<l

.n:

1Irc:t,,,.,

1""

II >ekctlon 01 >pWitt'd 1wdvo'2n: Is mpdrW 'u .... iId 'ho::


n1OC'li5<:t !It) ,"" II .... "cp in ron!oltU<'tlOo'l thouId bt thc purchulnjt. You <:.ln cn<kn'Or 10 OlblIltutc lOr 'M J"I'U I
>pil'y Of) thc 1I.Ith<"re UsI (,,'hieh II
my cohnru
"mii Irktll"" IIro tim<: around). or )'OU caii ,..''')'<ltIf'ldr
_
tNuhle an<J !u>' bUl' ...110' 1',,, put on ' '''' II...
1'c1cJ>l>Onc'<lnk'
p"'-<t1c knohs ",llh "'uds and 1110:
t_ klntls ur chni.: nuu &un> R<:kI '!bol SUllllIy. I()"OU "",, ',
I'lnd r:w-- t1ttn<kd In:;cru; Iocolly,onkr , hem rrom Kdd,IOO.

,,'1\;1,

,h"

,....,

a"""",..,

Condon

Cl I 4~6-4 1 1 1)

Making Ihe Chassis

Building the Fixture

,'"Uow Pasa ro. """"'e>' ,,, bc':onn,ll5; , hen

O>cck Ihc

booI<? <;aJI ,li<: DWlubeturer, ~


(8OO.Ss-oI-8-i66), for Ihc ""II><' ofa n=bydealtt
Thc rc:rnau>doI' of thr ha"' ..... '" "" tII<: 1i5t shouId tir
.. od<ctl b)"", lot':>I ~ ..""'.
Arul!)', hu)' a .,.,.... ur ~"'nch lWIic DiIdI or AppIr ..,
M ...."'OO 10 USC' lOr ti", ..vudm M~un: of ,II<: rnorti!n:lI
!DU>! ";luaU""" tl~ ""'lcrbI .. opcciaI-onkr, buo II . . . .
bc '2i"'bIc. Ir)'OU .re tfuo;t for
)"OU an _ 1
b)' " ",Il (rom lIuullc. ''Iy<o~'''''' (6J"-!S66-1}4O) nr III. L
In Ihc u,kp/'K>n<:

c:alI and ' " if lhq "od; or caii Of\k1ll1<: "",ulmi pili"'"
bloci and oIWIs. OUt loC2I -""""'"" hali tMK puU In hand
..i lhln ....-"rl: ur onkfVlg.hem lOr .... Can', IInd. K>Un:f

1lllh tho:: m>lcrlaIs and l..nI ...-.", in fund, 8<t ~ in tbr


.oo,>.1IuiJd ,II<: d ~ !\ni, th"" ,li<: rou ..... moon.lng boord.

1. Cu t
.."UO)d

10

(;., 1""

..., oii

,~ ,

nlrx ........, fi ...,) ArId 1

""k.(....., Thc roult ... ..iIi:r rnalcrial.lloc:

..........,.. In ",,",binl",
Ur><:aMI><.\Ilon . I

lIoh bullt
Ltmin.tlnll (our

",~ n~ h

cornpon""IIS 5ItdI
"'''''' >hafi, wtoh a

plrtC>l

(urm

'Q

CHASSIS PLAN VIEWS

loIo" 16 x 19'
Ih.e~

.-

rod

SIDE VIEW

SlDE VlEW

'1

-o

~.

l't']f ""

OI

1:
2

,.

FRONTVIEW

'1

r i C h " " s b~ck

Knu.led nul

~~~boh:l.

'""I

,,,,o

S'

,~
'6X ~.
iNnhud Kl'4!w

134

Rout er MJglc

""
O

.,

x l I':!'

~tIt<:. nul
Ch.iuis side
kirl~ pI~tt

""L .........,
"

rU

11.

}"

1oIo16x6'4'
Ih.uded rod

COIIIpOII<IIt!. In ""'kin~ 'hc puor n>.n~ ,'C1'Non. We u.<ai


OIditw}' birch pl)'WUOII, 0011: of Ihe no,.ble f.ili.>g> of II,,
poor man',,"Cf>iofl " 'aS Ihc fla:lbihlY of the
and 'he
_1Ill! boanJ, For our filUl """"Ion, >hown In ltoc ..-~riou>

""'' ' si!!-

pbotos. l lI>Cd App~ l'Iy and n,,::oplU...<J 'he riJlkli'y of Bob',


mon;.cr.
Set. rrom lhe propc:r plywood. CUi Ihc pl;",. ~>r thl:
lM6is p:>rtS 'u 'hc <Ilrne",,""'" sprtiIInJ by Ihc Cuul/tj!. lliI.
Gr\inaI

2. GIuC,'o1an>i " ~tl: th" c h :!.';Olb; 81""" a n d bcarln !,t


plai<. Tho: b(,.ting ploi" ;,. "",d" up of 'W<> pile;; """h
dwIi> oiIk. of
lIriH'e gI~mi ..;"lng 'he chaMi5 .ilk:s. )'011 m",1 ,;,10.
ib< .,Wk pllcJ rur Ihe moun'ln~ hol"", "" sllown In ,II ..
....'I/Ig 0Jtls</s ~'I<I" UlJ'QUI. Thl5 an hc dom- on Ilie
..... .. bleor OII lhe b. oo saw. Th., l5Iots an: .uppos<:d lu
doody a<:commo<lal., ~inclt h<:J<./1L-.d hol ..; do.,., cu.
D '00 b.ooIc.l1l., hol' heod,; .hould hc Of"knt<'<l lIS .hown
io .... AsstomlN)' ()(!/{I1/ o( Ih .. dr.wing, w;,h
51ldifljl
iIIto 1110 noIchc5 . nd "~11t pOntS ptOjc<:1ing ou, of Ihe ply
!It <adi $(k. Whcn ,lIe plies .n:: I>,"'inol"". 11105<' poi .. ",
... diB btw !M ou'er 1'1<"", helpbljl 10 Iock Iltem sa Ihc

Il".,...

jb,.

hoit. " '0 ,1'1 Iwisl. (Such Iwi5ting would hc db.ina


probkn> ,,-hL'fl )'Ou ins,.11 'h.' clwo>b bcn<... h " wurI;,
hen""'.) Tht: ~h.nk uf """It hol I>oold p,,*,-~ I ~. Indt""
hc)-ond Ihc opcn end o( Il, ,;,10.. Whcn Ihc corupk1cd
chasoi. is moUn!L'd undcr" I I'.r'incll~hid hcn,,1t 101', 'hc
boI'-'I "i11 hc n::ttSS<--.J "boUl \It 1" -)1, i""h.
Wlth thc"""" CUI. )'O<l Cl/I SI"" u p ti", lwo ch:LssIs
Spr<""" 1II"'" un ti", . pproprt:rlc f....... uf Ih., plio, Slip Ilie
tnOUmlng bol... in 'hc sJot,and nndwich thc paru togcthcr_
Ikc.tllie o( ,II.. bol"',)'OU wo.I', 1", .bI<: 'o
'II<' 'op edges
o(l/I<' c:hos6is .1de:5.oo ~ ,II<' ,h= pli..s "ny =fuUy. ''00
Cl/I. o( romsc. ,Ne III<' 0100 !ltrcc Igo::5 aher Ihc 1Ll"'" seu.
Gh,.,.u.min.,., thc .....0 "lies furmlng th., bc-~rin8 1'1>" ...

.1<" ..

,rin.

".rIS

3. D rilllhc c h assb s idCli. ".., m06l cri.ical


tlul )'Ou11 bc ""'king """ 'hc ~ sidc:s.l1lcy cns"", thJ.'
,he sh;Uts "'" """,,Iu'el}' pr.UcI and 111>1 Ihe 1'1;111., of ,h~
"""ri"ll pbl~ is pcrpmd;cul.r 10 Ihe ~nclt lop.1b
,he nccrkd "OCUr.lC}. m~rk 'hc inncr bccs. and !:lpc or
""""",hc";de> 'otI"lI.~r. inner face IU inne. f.ce, Th>1
)'Otl ..... n work oolhcm OS O"" uni, .
Wi,1I Ihc side5 ",pcd OI' serc..'cd 'OjjC1hct. ltim then 'o

adl"""

"-.r.

C!lASSIS SlOE LAYOUT


ASSEM8LY OETAIL

"'"~
CIUf up 1 plie . to
form n,~ (ha"I, .; .....

Inse" mounUno bal! In


,10' In Innu ply, Ihtn
sandwkh IL bt.w~~n
tht ou.e. pliu.

,
I

_.

OI
INNER PLY LAYOUT
J<j"dla . hale
for 5haf,

l,.
,..

'-

"

SlOI for moumin9 boiI

Yl"' dia. ~I~


for adju5'm~nt

,,'
,L

le

2r'"2i

".

,.

"

",
'?Il>'1lf

,.

I
Shop8ullt Stot MO";5t.

135

IEARING PLATE LAYOUT


FRONT VI

'"

~"r
r-

,.'
T

"

-rl

~." 20

//

Ihreadod i

'11

tJ
9'

preelslon of th~ e hassls sldu 1. cl llle,1 10 Ihe


a(eu"cy of Ihl. fixlu",. To en.ure Ihallhe hole. for
Ihe .hafu and Ihe laleral lravel adjuslmem rod align
petfeetlv, lape Ilie sidH logelhe. ,nd bore IlIne hole.
in bOlh piece. al Ihe .ame Ilme. And do Ihe borlng on
a drill press.

..

Th~

1---,

Icngtl. and wld.h, 'hen lay oul Ihe ho~ IDown in Cb<us/s
SI<k lAyo"(
IIcIi>o<: boring tlle hol",. d>ttk tu '"'''"''' th;tl )'OU. drill
P""" .. bie I:! ""rpmdlcuLtr 10 thc drill, ;md usc fa>cr
... hen boring Ihe shafI hoIc5 CO kc<:p tllem Ihe s:.mc d~c
from ti><: edllC.1"" $IUfu; shuuld fit <nugl}' In tI>ci. hol.,;.
' ''''n ""p","~tC the oi<kll.

4.

Insl2.ll Ihc Inscrt In Ihc bearing l,lale. lltc


rotl'C1" mounting pLote is ""amed It, the fixlu", with rllrcc
"'-odd<.-d knob.< th:Il Ium InlO Ihrco<kd Inso::ns in Ihe ~ring
pble. Trtm Ihe bcari1lll pLole 10 It< firctl slxe. squ.oting It In
the p~ 1ltcn <ltill and In>tall .hc ;11S<:"S.
UI
Sa:.1Ie d""'ing Heurlng f'klle 18)'0"1 for Ihc 'f"'dnc
loartiom of thc- in5crU.~OUI and 00'" tlle pilol hoIcs. usillll
thc dllin<:1c-t of bit i-f><;dfocd for .he
.-rul )'OU an: using (a
)i6-loch in>cn """,,,Uy ""'lui"". I'>1ndHli:unelC1" piloI "'*).
,"OU""" boR: the holcs complelely Ihrou~ tlle pble.
InSlali Ihc inscns """'-"- pcci:l.l "''''nch """ bc pur
ehuc<l tO dri,"" 111S<:"", hut che-.p soIullon bi u..,
hcx-hcad hoit of th" approprl.ol"
chucled In a drill
p~. Sec the plloto on p.ge 127 for d"""ils.
1Ido", ,;cninS thc bc.-ari"S pbte
tlrill Ill<." hok fOr
, , _ - ' the ""nl~-.J.tr...d .djustntcn1 rod. uy oul lhe holc auha"'n
In n.-aring 1'I"le Layo"I. Ihcn driiiit ,,1Ih. \-'o-inch hit.

.-.
i!

i",

:1

si,..,
..,iclc.

5. As5crnhk the s haro.. pillow biock5. a nd


e bassis s idcs. Unpack Ihe slufts ID<I11tc pili"", blocb. M
)"OU do s<:doc"-. in mind th tlle pillo", blocI<> ,,'" sc".ltl\""
tO du;.< and din. ~
<:."<cdl<'nt dtiSt seaIs. whleh wlJl
keep out din ,,"Ce IIKy.", mounled Ofl Ih~ .holU. lluI)'OU
h..~ !O Jrc<:p Ihcm ci""" 1xifI.J.. thcr :orc mounted on thc
~. $o c\can up JUllr won: .rca bef"", yuu 0f'C11 Ihe
~. An!! ilS 500II 25 }"OU un .... r:tp ~ plllow bloclr.5l1p II
Ofllo a "'ah. ll"s .., slmpl<' as ch'l.

ha,'"

1 36

Roule. Magic

. , r~

1,

::

8QTIQM VlEW

~,

_" ,J
'"

Clue up Iwo !Il" pliU Co


Sund Ihc chusis slda Olt ~hci. baek Wp.
lns1.>l1 'he """er shafI fiM. SIKk the shafi InIO
hol<' In """ of 'Ilc slda. fll plllow bIocIr ...
"'ah, lhen ,Iide Ihc >haR imo Ilie lo,,"c' hole in Ilie odIIr
sidc. M"'.... thc ,wo sides os ncccssary 10 po;iitlon thc: !bII
nusll " ilh tllelr .... Ier f.ces.
I'o:>kc k-I nch.Jong -6 pan ltclrd sc""" 1010 Ilie ...
het ...""" II><: "'<Iod ID<I th" ~<:c1 sluft. Dr;..... thc ~
het........,., .he ,,""" and ..ed; it wUl bind tii., . _
logeIha. In Ihe ......, fashioo. dri .., screw 10 lod do.otha clussis sidI: O" thi.. fir$< shafl.
Thc oct."ond shafI Is Instotlled In ClCIctly tM ...... ""
cxcq>l Ih., tIIi. shaft-Ihc upp"r 0fIC-II>., lwo piI<rIo
bIocks 00 It.
0""" a ocrcw h2S bttn dli'..,.., at <:acll end ni
>hafls. youU ftml 1""1 lhe chas.o;is enlls stay In pooition al
OUla enlls of Ihe shafls.

""'=

10"*

6. Mount the pillo'" blocb 00 thc


plate. Set Ihc bcaring plate rac<: """." on the "-ortd:>ood
(Ilie face h.., the insc.-rul i" it).
Set thc cha>sis ..... mbt) "'..". ti...- ptlle.AUgn the ph
bIocb Ofl thc pI .. c.as "'",,n In Ihc SecNon 11.....<1: ",.,
piikow bIocb sht>ukI hc S~ aport ID<I p<><Sit1oncd >1
at thc cdge< o( thc pU.e. Thc Iowcr pilJow bIodr. _
a-nlncd. Thnc .sha" ld hc an ""ual amounl o( opatt
!hot upper ~ 1r1d bclo.... thc Iocn\-.:r bIoI:k. M05t Im
" f .11. tI><: pbtc...,....1d hc squarc 10 thc IX<=> o( thc o/WQ.

l.kkl.g Ilie s ha f1 1" Ih. chauis sid. 10 KCom


...... w d,iwn ;"10 lhe ... am belWftn .he
TM ~ takes UP enough Spoict 10
)IlOl !/It l"'-fI In Ihe hoIe, but II an"!. iri any way ..... ,
_Iwtdonecl "HI of IM INft.

lIii/Itd ..... h a
1*1'."

."""'n.

lkeIuK tht bclring pWc .. J>fOOd 01 tht cIwoW oI<b.


rror. ~ .... ""'"" paru ohould lor balancftI aboul
III lIdI 011" It.. bm<:h lap.
Drt", a .:ouple 01 sc,."...,., !n.o codI piIIow bi<>dt 10
kIId lIIrit poruun. . 11Icn ;.Iitlc
ch.a_ back and forth
JIU """ tht lnMr r.ca
ctw6i5 si(la; an: pa.-.Jlel
..... ctl!IcS of 'Ile bc2rin1! pute. If ...". =n l, II thc:

t""
01,,,,,

"ollnllllg Ih. plllow blocks II a " ..,glu'orwa,d


Krew-dfllllll9 pffKUS. Wi,lIlhe bea'lng plile OII anat
OUrfK', .... tt.. tha 1$ au,mbly In plac;. , line up the
pillow biks. drill pilot lIoIu. Ind drive IM SCftws.
chas.sb iii "-"tly rodrcd OIIIM plai" . ...khd ....... 1"" ~
Ind molljpt 'h~ 11>c:n m:Irt<t: thc: xn:ws-run ,hml lmo
dJlkn:nt hoIc:$ an lhlt ~ Iry_antI d>cdt ."" a1itJ:n"""'1 apIn.
Whcn 1,"" alotcrunm' b lt:>Cctl and pruYm conttl,
''''tell
.t.. ""'"'" hooItIin thc- bIod<:f. I)rivt :tnd , . . . _ ,

_n

'I&hten thc: """ .... Iht """""'"

SECT10H VIEW5

st:CTIOH 11

V:CTION AA

J:
:l

Thomson 'SI'112
Nnearbeafll'l9
plllow blockl

_._.

" " l 12

,.
VI

CO

.",, ' . plate

MOU NTING BLOCK DETAll

Bea,l"g """., /

Shop-Bulil SloI Mom ... ,

117

ROUTEJI MOUHTINC IOARD LAYOUT


FRONT VIEW

RO"1 Yt-dtep

C."ono.fll d.e adj .. ,lmeoHod _011"9 .Io<h


10 Ittt mortioer as ti wn '''-'Pe. Wilh 1'" rod roughly
t_ered w. tht ehassls""" ltoIeo. olide tht bonom
....., MIM bloci, under tht rod. as 'I\owo . ., II _ ,
fii, thIve the bonom wiltl bloc. pI,o... ~a It fiu.
HI Ittt lop ....., la pa,.c, .l1li se..-. the bIeK. ,o 1'"
burtng pI,o,e

,.ten fu<
' OIIlt. bu.

7 ""tali Ihc b", ... I.tn ...:1 IOdllblmcnt rod.


V;;tbooo ~ 'Ix dwob ........ hIy.>IlIk ,1trtJvt-...saI rod
wiU ~.., It ~ b'a2k ... ,-.:! odj\G!mml rod lhtuuiIIh
.Ix l><IIa la IIx ch:t_:oklQ ......, _1tna'1! oi rod ohauld
o,tfId l>c1'OOO 'Ix plaI .. OII aeI! ..6Ik. oi """'"'" 11110 rod II
fMlmrd 10 thC' bC'2tIrIII pLoI .. wilh ..........Ina bIod.>
Cut ,Ix ~ bIo<to ' 1) ~ WJIC' , and tIriI ,Ix
piloo ~ rar tItc ....,..". ... ..,""'... !lut don' tIriI lho:
bob r.. tItc ~ rod ..... ,.., IIx ~ ..... )'ti .
..... nd, ....,.. tItc a d j I _ rod JO le II ........,. .....
~ iri tItr bob In ItIc ~ ....., ~ Wn b dlM ItIc
..... ~ _ bta _ .",h In I t - .........ithouut
mlrtnIoo ..bm tItr _~ " ia ltfC' ~ m.a ,tic
plat .. 'o 'Ix c:cnt" fIIltIc rod
~ hc in ,tic Ikft<bb<w
hood oi ..... 1rtdI) by _ ,tic CCfllnpolell'" tItc ~"*
bIoeb. Ind drtII ~ hok" lhtoufll\ ndI. Thm wkh
hal"b:l,,. .... ntdt bIod: In ....." llaIvina Iim hoIC'
SlIp IIx huu...., p;1ft> flltItc I*ldr.. undrr ,Ix ....... 1<>0,...
Ihmt . 1 IIx OUl" rdfp 01 ............... .. >I\ow.... In IIx SKrkHf
110'11'1. Sa ,Ix OIOUlII"w bIodr. tOPt In plac ... ..... iim.., thc
""........ ~ ,""'" ~ II><' rod 'o thr bnt1ntI pLtt ..

'ho'

.-.

CIt
C

-i

r.

__J 8 . Malle .nd InstaU Ihc bac... lAc" Ihor mot oIthr
..'OIXlnI "'fU, 1hC' bo II aluNamillMftI fn:Im 101'0 pleca
I
0I1Hnd! pI)..."OOd..F<ttthc
fk.1e. hc:oc ... _
..... this

IOTTOMVlEW

ADJUSTMmT PlATE DETAlL

r - - , .. _ - ,

~6- ...t ... hol. for


mounl,ng screw

poIot In ,.... pro;en to eu. ~ 101'0 pin


Mc'_ thc chz>o,h, CInt pir . . ,,,,~,
t("O tItc ~
oItIct. .. I!IIC' thC' >'OOd pIy....m.y.. than. ln'" n..... ..iIII
IlK'irOUlct bee..Cut thC' p;1ft> ... thcconttl ",-dtm p.r
,h...m be .. 'o btt. A h:df'<lolea WIWI IWI> driYm I~
1"'-' plio ",'IU hoId t"'-'m in :oLogruncnI .. hiIr ,Ix aIuo: I'I-'U.and
JIC'""lt )'OLL 10 COfIlplnC' thC' asomtbIy ..... ' ''''7t
lK." 1"" b.lCk In pl:lCC' and ICTCW II fut. U"...,. """
"'K"~-1lO 1d~ -~11Qw) 1'OU Iti rt'IIIO\T tIM: bxt 3t 3 blO:r
(b1 .....b''''I.. li !>n.o,uC' n,.., ... ,."",,),.
131

Ro ..

't. MagIC

,.
f-'<--,,!J

L}to-JjoI.-L

U16 -

1t-' 1hkk um.....m

...... bot, ..'hict! ..'oukl r~ OJ, 11110 ,IM: hok ano! ~uin
_cposy.
If,..,..,cpoxy i> ,he 'hkk. JM"'y kJnd.dIilI a....,U ......
bok in> ,IM: t.ouom of ,tIC' ~ud hok. and SrncI, hoIh 'IM:
iI!i6< oI'w ."'d hokt. ~nd ,he R,.j cnd with thc pasl", OJKl
""" puIh " in Wip<' tip
ne .....
LrI ,1Ie q'lOxy cun: a, insi 21 hours befun: diS1urblnll

,h"

. . aso<mbIy. Ep<>xy do,onn ', ""lui", ar' kind of d.",pi0ll.


... ralIy docs late IIWI)' houN eurc
AfItt ,1Ie: q>oxy cu..".,
,hc f>"t$ 01 >piaJ nub ""
. . ~ 1'Of.b. borb:o<tl2l u ..'dt as ,~ioI . Thm 'ile
'-"" II1II "" ,IIC' rod Il .... ,hen Ihc ct..d: otll. I.n taW. )'OU
... m. odju:stmm, ";,h Ihc kourlcd OUl , Ibm la'" 'hr
ebed nuI:opInot il
hukJ.hc ptn:ix .... 'inc.

,um

.0

'o

Mitking the Router Mounting BOiilrd


lboll'lOUll,'nK ",..nl >hown '" >i,al 10 0001""""11" ,hc
bQI:SI FJu <It [1I:~'.Ilt plurI,IIC "'u'e'. It .. Wd "", wi,h ,hc
.. nil ,~ Ind," (rom .1Ie '0I' altle.~ .dltlSt"'''''' """'"
"..u jusI "'..". ~ Incho of \'cnk':IJ ,ro"..,1. ,( """'"'~'tl
- . . 1~hid< """""'bIe,'hc bit
l'1fljjC> I'Ullghlr
. . .~ iod.., I)do}w ,..., ... bIe ...rbcc 10 ~UII lnctItJ
...., m. rabir ",..f.w.:r , Ser 'hr dr.o..-m,; Imkdlli"''l'
,"ou ...,. ......:d OI' .."", 10 aher SOfnC' oI,hc oll"""""",,"
OIX' .. , ..... ,,, I difkrm. tuuler OI' I "'der ...'OI'Io:1abk:.
,' ........1 """"" Lhb Ib"...., w ~'hln8 tu. ,han I ~.
.tie:! lhidc.) Fo, a l~ndHhidt ,,'OI'Io:tOp, kor
add
\-) iIrlI Ut ,IM: mou.... l'lII bo:onI Icngth, ano! aUd Ihc ~
lItIwttn ,IM: oIo<lIi .nd 'he bit opcni'lll' n .., .., l:ry O\JI ,ho;
"" br .........,ring up (rom Ih"
of IIM: boonl. ..

u"

cum""',

boc,,,,,,

Jhoo<ll in '1Ie: otrnrulg 1i_N!r oII'W"'/~ &>uni LU)'O"I, and


l:ry "", Ihc bil opm;n, bt' ~ 00-.-.. (rom tIM: t"l".
Imglh "'il r:.u wtM;,,,, ~ ohuuI<l

'""" o,,,,

1. Cui thc p lywood. Ukc !tIC' dI.ossi> sidef, and


"'-," ring pla,,,, thc: ""',...
bo:onI" . . - fmm t .....

""""'''lrIjI

plc<:es of h-in<:h Applc


CUt 'hc pktt!i IOtlghty

PIr

pIyomod. bmiou,al '..........

'o 'hc d,mco!olon. >peciftoed by Ihc

UItII"l\ ti>!.

2 . Cu. thc n.'CeIiIi ()f' tl~ rou toer, SInoce Ihc m:co;5'J
\kpth "'luai.'! ,IM: "'i<.'I<J>oi!i of onc: M~'OOd ~=, It Is ~
'o CUI Ihc <>pminB bdott Iamlnlrlinfllhc mountin8 h<wt1

Uy ""llhc cm,erpolnl ofl"" bit OJX-'nitIg. Grnler.1M:


C'>'C't tIM: ........ arid ..:rillC' arounrJ ,"" ba>c Cut 'IM:
"""nins. for a s/upt ILke th>t 01 ,IM: Elu and Drw..I,
rotlle.-s, rotii .hc ... nJlthl """"ion, ...m, a c:b.mpcd-on
knce ,o lIukk Ilie: rolll",.11>cn "'" up W rotiI ... "ilh a
, ,,,mmd , and rou' 'h<o .", fl'Qf!1 onc: eOO of 'h<o "",ilhI
gn>!, ..... 10 . 1M> OIh ....

rout",

3 . Laml",.." tI~ p lles. Wl.h ,he op<:ning fOc- thc


complete<!. ~PI'1y 11''''' 'u ,1Ie: bceo oi , 1Ie ,,..'-' ",ncl,;
and cbmp ,bem 'OIIC'hcr
Whcn tbr:: ,,1.11: ...... """"', Irin, ,IM: mounling board
blinll il 10 it> final dimc.'1Uions an(! ' o ~1Wr ~

rotii ...

'o

nu.

4. Retu, . bc adjustmcm ~1ot5.


can bt 00....
wItIt fii......, ........" .-quippt'(l wItIt :an .,.. JJU!id<' :and I
h6-lnch ><raiIh1 bit. t.ry OUl' ,ho; tIou an(! rotii 'hem

VElTlCAl RA NC E
loI!~lMUIo!

VERTiCAL

~NC

MAXIMUM VER1'ICAl Sdr'NC

,=- -t;fj.

""Is of bit

J:

Ll

,..

CI

WorklOp

a._.
OI

"

ICI

ShopButll Slo, Monisel

139

,. Makc and InstaU tftc, ''a1icaladjustmc:n l


p ble. On 1I<>b', ~naJ. Ihill I'I~IC is li-inclHhick alumin..... T1lc ~ oIl1w. m31ctIaI >iCcftt> I<l h..!o .., ben!
tunctlon 01 ""~'Y For tIM; job M JK,b" ... I~ plale
could """ ... ca!oiIy Ix -.Se 01 I~UIIt' acel. %ici> or
\'Hnc:h pI}...-ood. or ~ pbc1'I<>Iic. iI)'<>U ......, ihn. I dId
~

,,",.., _

jIhcnoIK::.

:10

I ....,.. lIw.

ori

,1Ie .....

monilcr :oho\oo'n in Ilie phoI ....


If )'<>U ..,.., pIywood OI" phcnoIiooc. IOUI Ilie sloi ori Ihc
n)Uler W>k:. It )'<>U ..,., mccaI. drIU ~ _ .
lhen cut Inl" lloc hoit ..ilh. hxkgw.1onning thc sIoI. CuI
,~ plate 10 oile. DriIl I~ hoks for mouming ~'S. F'.!c:
any

fO\IId1

OI' sh.1tp~.os

nca:ssuy. M'- Ihc pIo.e 10

01."" ,"o'.!ling p"OIe:lO II", .hln<kd md fits


In!o 1"" .......
'loc bonom

6. ,,,,,taU .hc ro Ule r. I!crn<:m:.hc ~5 hucpb.e


Set .. Inwlhc "'""" In

u.. """""InS boaId.:aneI ..... it .os

p;oucm 10 driU hoks lOr IIIc

~."", ~

Coo,m.Cr$ink ,"" hok$.""'n rnoun "" f\lUlCf OII Ihc boIltd.


Slncc Ihc router 01'''''11'''' In , horizorK:tl poSiUon. lloc
",Ium "fKInI!;S """ bc a nuis;Lncc.
1oI1ov.'Cd 1Iob'. k:>d

"'O'

in ~'hc!ll.
If !hc
}'OU ..... ori Ihc rnortacr ha> a ~
Ioadcd ",unii'" 1od<.}'OU ha ..,. dcci.oon
~c.To I\ob..hc
"fl'!i1lll'1oadcd plunge lod< ori tus Ou ....... nul!olncc: . " hc
di$;lblcd 11. 1Iu! he "'aS ~ his mort;"'r lor nKK1b1n(1. only
If )'OU ...... n. )""'" ..." monlscr 10 doubk u horilOmoJ
"",Ier lable. )'OU ""~I nd 10 """ .Ioc plunge Ind. '0 So:t .""
bil Q;;:nsion . TIm rou (>ft>b.>.b/y ,..",, ', ..... n, 10 di>:ablc
cven a spnng.1oadcd plWlp' Iock.
1t)'OIl <lcckk 10 ""TlO'''' .1Ie "'UnII" Sf>rit>lP an<! .""
pl"nll<' Iod . .;hcd< ,ttc plttS dilIgrmI ro.. )'OUl' "",.er 10
fiII"'" oul how 10 IlO aboUl i., Rcmming ,~ p;ut. <Ionon',
nlClln 'ha.)'OIl con ilO ~r u,",,)'OW' rouler >cpu.. c from
Ihi5 r"'UlR'.1'he p. n s 1$"")'
oirnpk .0 "'I'!xc ...
Ihg' arc ., remo''C .

"""a

r--I

-.
f

1:
O
::lE

.0 ....

= ...

Outflttlng the Work table

1110' shx rnoniS<or i. usck:M untll it i. rnoun'N .0 ."" un<k: ..


~
"'urtly worl<l.bIe. Sine .. rou ",i ll bc ",,>hl~ and
l'ulli<18 <In Ihe ro ... a and IIK fUI."'" il i. anachc<l IO.IIK
wor1n;oblc shoo.ld bc rigid and hen}'_
You """ """ a worI<bo:ndI or a ~1laI rou1a t:lhIe .,
"'" worIo:t:lbIc for w oIoc mOrlM. fIIn A:m"rnhC"r Ihlol )""
il:...., 10 driU and ooumabon: ITI<)Undn" h/>Ici.......,11 "" h/>ID
L I for I~ ~ You wiII :;urdy ....n..... CIclI' wt<I ~"o
ilie t:lhoICIop !Il fxWut .. "'"'"ps.11 ..... >dd "1' 10 >I'<:nlk>ns
)"" 1113)' noi '....m 10 ma"" 10 a goOd .."O<\chcnd1 o.. " ..." ,..
I>bIc. If ,..., h...c >fUtt b k , and If )'OU wUI "'" ~ ofI~n
cnough,)'OU Olt 01"',")"1 buikI a ""1""'I~ worI<.aI* ro.. ,1Ie >101
morthcr.
)'OU choooc 10 deal ... ilil thl!. m>uer............
hoa' 10 aulAI Ihc "'~.Ih ... c:nrnplctU'ig ilie A"."",

01.

II"""'.....

1. Mou n! Ihe mo n l!lCr '0 .hc .....,.. I.... h l.;. "


couplc of poin .. hcforc .hc ;IoCIuai ..'Q['\( ~n>
1ir):I. ilie
'0 ""hIdl )'OU mo"", .hc nlOrtbt'r
ohouId ""OI loM. I \'li _
thIck, and ~ >hould hC" It....ith

""""lOp

."" Ind booo<n SUtb<:cs p;or:oIld. It it Isn ', thidt ~*


mountirog I)uh,j ""il pn::>lruIk 0l)000>;: !hc ....ucc.lftht sudica
....... . fla, and I""'.nd. boIlirtg d ... ",.,.,.,..,. l~hUy '" ~
..TO<"k Ihc ~ tIJro."ing )OIIr IICW """'''' OUl oftilltr.
lbc serond poin. tw. '" do .... i.h Ihc golI' bctwt<1Ir
<:Iu.>si>'~ Inding . . . . and .IM: n""""i<4I b<wd. Tht: . .
..iU bc .boul I!.. inch. and )'OU probo.bIy don~ "'.... lIrot
rnud! 6pa bnwttn Ihc mounting '-tU .nd Ihc ~
'Thcrri>rc. U"l' .0 ,;n Ihc dtasoi> bad: rrom ilie "'"<b:f
cd8" 'boul h> inch.
1 bu>d 1.... ~ ....,. 10 by "Ul .IK hob b . .
"""",.iiIt! boko ..... 'o maltc a ''''''pl...... rtom "'" _
Cur a 5)( 124nch pica: 01 ~ndI f'II'WOOd kt k "" "",,,
Ihc """In ng boIu.:aneI allgn li Oush ""i!h IIx: fronI . .
oIlhc ~,...."" (HokI .........aIp: opin .. thc dIatoIi.
an<! sllIk Ihc f ' I I - ''''''plal'' lip 2pIJUI h.) T.lp OII fir
,.,..,plale a. cxfl boIt, dmtlllll'hc Irmplole. t'lp k
driD ~ hoIc ccn.cn:!I In ad'o dcnL
l2y Ihc .,.., .... '" .... Ihc worI<'Op.:aneI :oIi,p M,Tho,.
0I1hc lemplole "'jHdC""1hc (ron. ~ 0I1hcm.ir., ..
)'OU ""'n!
tel
hac" ahi . ..,. dril~ ......Incb hob
Ihc ~ ....,..,....,. ...,..., )'OU " ' " roundf just liI*
room for odju>tnw: ..... SO line up Ihc .an..... e ..... ..,. ..
1l1th tIIil or _1. tJWt.: Ihtou!!h lloc ."mpl...., 00 ..

om;"

.0 .h,,,

II

-...

R~.hc .mspb.... o driD a 1-lndHtlamclct, ~


dftp rounltrtoon:.. een.cn:d OrI nch marii. s.,1Idi bIIt. ..
drill '...IndHII:>rncta Ih ........ hoIc> for.""
')rup ......."".1.1). rw ..~ In ., t:>d> <:OUIIIa'boot
........100 .hc ~ ...un- thc worI<'op. and p.ao ..
""""'I;na boIu "1' Ih""'Ah Ihc .......... TUrn nUl onto adi
bol and 1'Ih''r'''' nch llUUU Ihc InOUnlin1:Io:IoW."
adjlt!ol .IK ~ pooIoon undtr .hc worI:lOp You ...... fIr
fXc <Il Ihc rnuunt"'ll boIltd.o bc p;or:oIld 10''''' _ . ..
cdg<- When Ihc: mortb<: IJ Jo) >liSnC'd.up""" Ibc ........ fIr

""""""-1taII.

t1\()U1\.inl boIIJ

2. FIne-tu ne lhc rn<>un Unx- Oncc )'<>U _ _ ..


rUl'u",. 1'1<1 ncaI.o chcdr; It for ali&nme", . ~ iftl-'
,..:1)__

1. <:>n bc mi>:aLif1t>c4

"""0"

I Th.; ul, ollhc:


hi. ean hc 00. 01 p;orallc1 ...
."" bcnch 10f'
2 111e .....<1<18 .hatb ean bc ou. of ",,"""1 witIt fir
hcnch 101'.
Any rnlsalJgnn ... n. m .... bc: rorrcct~d by 1111;"11
het"'""n Ihc cha..... L. and Ihe,,~ 011"" bo:nd! lOp.
11... oIl!11\"""''' """ bc "bcd<td by dlucltinjj
.sv....,1 pin ttn.c:ri"ll ",n,OI" <....,A a ""'I~r bit In.o thc
( ..lth Ihc IUIllcr "n"'.'IlJII"d) and ~ Ibc """"" d
d..w .... pin ~I>,"'C ."" t>cnd1 101' ""hlt a do:jHh . ';;'_~
",mkr ur oJl>J caUPC<ll,''''' hd.{d1'. ,",'hen .hc
i>:tI.
"';1}' 10 ."" 1d'I.
hc: 0".W:tJY Ihc tn ... ." "hen 1. 1..1
"'';I}. ... thc ritth'.Ih<: hc4tIll n"l>1 bc Ihe .a",,, whel"'"
plurt,IIC1J Of fuDy ",.roctCtl. If ......., . tJWt.: .hc rortIC1'S d
eh>M w ......... 1"" n.... Wren ...'.. b hlgh. """""" Ilte
hokli"ll Ilie chaWl . nd 1""," p;opc:r >hin" 10 ohIm

".u;!

"""'a

TOGGlE ClAMPPAD LAYOUT

."
(Lo_""'-1

Pilols for 1099le


mounllng 'CfeWI _
~"

p!ywood

1100 ooonlnr mounlln" II p'aperl)' . ' Ign" If


-..rttnents laken al Ilie lim iU oltlle mon 'se,'$ LlI '
"_I;ond wlth Ilie ,lMIle, boIh ',,11y plU"~ and
.., mrKltd .re ,U euetly Ilie nme , TlIke 1'" mn
th. bit to
Uobletw u~lng .. pa" of
dtI:IIh-l1Ifa~url"!l dlal u.lipers . as shown .

tf"

1'"

1IIrtJ\lt"" "om

. . . ....11 OI. ,"" "urkcd ~ "Ibm Li8ht"" " lip .....


dltd;th< ~.apln. RqInt ... ""'" , .,. .. tU .....
............ :II

:aII1bur "","1> b 'hc lOaml'.

}. Gri<! tbe """""lOp. tJsinJj ..... fIlt,u",

1""

1""

m:ju1re5

l<CIIr>Id)' poeI.lonlng
_plece on
baK:h an<!
~ ~ IIM=." '"" '" ~ 1if\CS pennanrntly
t<ritrd!n 1"" hend110f! lis uscl'ul.,"ou .,.., OlIjml ..... latmll
IMI iICtOtdIng 10 ,h(:$ U"""-:Il ..'dI :Il pooitIon tbe .........
,...,.10 Ihtm. I >U~ ,~, .1 flr>I ,..... ..... pIy U5C penciI
ltrtt1. ()nco )'00 kno .... ,..h," kioo 01 a gnd .."""" boli b
TWlTOP LAYOUT
HoIt

:=:::;:_tj)

e
C

Mountin" .. tOllgl. eIamp '0 tII. workUobl.


,,"qUU1'S only' ""Ille bolt turned InlO a nui !n Ilie
,..orI<top. You un IW'ng Ihe P<ldm"unttd damp
.."und Itle bolt. orienllng II lor Ilie best conliOct w!lh
Ilie wO<1<. 8ig eLlmp. III'" a Iongft ,,"ull and ipp!V
mo,," pl'6'''''" Ihin .mall "ntl. BUl boII! un tie uled
productively.

'OI mountif\9 logg.!e wmp;

nU I

on undentde o f loble.

i
o
~ofUobleloP

,
C;rld "MI ." Incremenll

O
--.1

"

CI

Crld Ilnu 1/;" Inc'tmfnt~

1
.-"_.

fOIIr P"IJ"l'i'ia, """liCit ,h .. lillC'J In ,,'i,1t a .\It. 'l' _I..nd fiII


'lo<, ..:r~'(""" ... I.h a 'LlrI< """,,,1 mlt-r,
1,., Iml"'l'Ur1t '" lIe ablc '" """I,I"n d:u"p> on <hc:
,,"Qrt<plr :t.\ ..1aer ,.. posoIbk '0 ''''' mon~. n.c lllOM
~..,.,'... nk,,, ..... y 'u "':.mp IS ,,-i. h lt'!Q!.k: cbmpS. Hu' of
~o"""" )'<"' "",,,', ..... n' 'o clutler ,,,,,, "'O/'I:It,,, ",i.h 'OfO!I<:
Clilmp"

,,,.. ,,...1,,,,...11'1:",,, l..y """0 "" ,1"" ,,'0/'1:,"1', ( Ilun:

hol ... 1t""'lIh ' he .. hklOp and " p 'he T... o' In", 'loc
un<kl')i<k.) '\' ""n, I rottplc 0I1i1~ ."II8k elilm",,~1 ....,
lk<S,a.Q>', ''CZ,W_on ;Ja"nl JWlS al:Jdc o( ' +-Ind! pir"'''''''. Turn "'~I 1010 .Ioc T... ", . and o,dt il In ,hc !ilo! ci
ltc "lIlIIie ebmp'o
T1gh'cn 'loc "'~'. Ind you'vo:: g<>t
'olQllc da."!, f.... ...-1",,,,, fOU '>ccd 1, ...... 'hc Juba, hand You
on """ 'M T,,,ul> dI=t1r <It" vb. ,OIQIk dunp 10 iU'"
pooltloni". st"P'
proWcIlon tunS.
,\> ,,'lI h ti", JII'kI, II'li pn.tb;:tbty !)d'ef .0 <
'''dor> ........,
lQr
T-nul) ...., ..... tuI, r.thcr tlwt poet ,"" ..mIop
",hit 'hcm haph;tunlly"'" /oyt .. ~ 1 """ ." ~ In <hc:

p''''.

rar

"'loc'"

1IM*IQ{I

Lu)vut (/r:twi ....

Using the Fixture

r-..

""" _
'loc D>O<I>('r"It 01 .rulh b uport ,.. You"" Imblnl
In """""""" fliIn) bu, """'" onIy ........ pk- 01 ",'<'fIitljlS
pullln8'M monl!io:r,~ 11."....;11 II ......... ,
Only kw min",,,, ...., nttdrd '" ~ <hc: mort..... up b
eu" ,<.> damp I ."'" pic In pooItlon, anii 'Mn 10 ~tully
moke
cut And 'M 'ruth ..i ll hc In <hc: '""'''''''-

,ha,

Mortising
Tho ou.. joii b .. hich Ihc fb'u"' ...... ~ 1'aclll".
,his opcn,ioo ..m""poM' fOU '" oii ."" ...-orI<mp 01 ,,,,, n.,:.
CIt
'o adi.... :dI tltrtt ua 01 .......~nt
( tIucu>ocd., ,""
o( .hb ehopttt). , ..... ha .., 'o
,,"0.11 thc ,.hk-lop grId Ind "'" 'ogk cbmp>- , ..... """c
,_ do I/x mon~ (bncc

c:

'Vi
t:
O
::lE

......

,'-= ,..... ha",

II<'&IM'' '

'ti

1. Lay ou"he mot1l-.e. Thb b " 'hen: h hq;1" "Qn


picctminll stact. pnl<'il u4f ,Jx, """,itc }'OU
" 'hen:)"QU
it. \VIU it lQIlow thr MIIk oITh1nb-,
"">ing. "idtlt <'<jUli
ltlnl'hc Sloct ~ .ltlckncMl Will
Mbe <:en,nnl ~ ,Jx, Slock .hicknoo? Ilo ..' IooM ...1111,
bel U..... dpl Yow- byou' >IIould ons..."r 'loc nI')! ,",,",
'I"""'OrlS. ",., .........,r ,a ,"" ""'nit 'I1ICSI1oo ... 111 ""
""nlcd In """11lJI up lloc roU'ef

,,-m.,

oi,,,,, . . ,,-m.

'o ........

2. Set tIp ti.., rou' e r. 'lliS b a ,101 mOMI..,...n,,,ln8


monlsct ,,, bat:k ~nd ronlt ~ ,. gh.,n 1c,-d.'ll"",lhc
"i",h oI,hc nwnlsc: dleta'6
"/.1",c, of . he bl.
Thc r" .,,,,,,,,,., wbtlom I~ ,ha,
,,[>Cu, bir. "'"
tic" tor mon lsing. and ,h.". 'ruc, lIu. )U" nccd nOI rcd

'he

.p'''''

H' ....,

.ha,, .Ioc- 01,1)" st)'le ar h', )'0" can ,,!le. I\'e ...""'" Slr. ittll'

hlt$ of (''ef}' s'ylc-"r.t.iglu fluc. Shc., fluc, lngle ;ln<.l


<!oubl .. fiu."

Eq""lIy Imponam u 'he " nx'er 1 he IC"M111 or ,Ire


hit To .he <Jcsln:d monl!le <.Ie!,'h)"QU m"". ",,<.1 h Int:h tor
,tic ,hlcknC)S or 'he n'u"n,lng bo:.tnl. m.)'!)c, .. Lnch 01

splec bct,,"ecn ,he moumilljli boonland 'M coIIct


al Ieut '1.1 i,,~h uhhank 'u Ix p;ppcd by thc cuIIo:t
bi, ncnI:i <O be~, ml,,'mum 1\. Indxs Ionwr'
nwnbc dcpth.
Givcn ,hale MuiddtnC$,~ your .,"',~ _ _

:_~:!.:~,~~~~:~~~;

Na... >CI u... plWIJ!t'


Ind ti!ll<'cn it int<> ,""
tkpth . To do ti .... )'t>lI
witlMKn ,Ix .sprin8S. it ,...;u

it-artd.........., tI1C

"""Ion

mouOlirtg boord.PI~:i'~"~-~~~=;(:~~~~:

ci bi' is exposcd. tItt:n >CI ,


puU tht: """tt """t.
antI rndy ti", mxhInc ro. u.. ""'" ""'up MCp

~ ,IIe "'''''' of.h" bit "1I"1n>l ,1Ie monl"" I:r)"'"


..,. Ii k ...aru appropri ..". kx>I!c:" II", knob(.) and lurn
.. cbod n... '0 tabe Of "'wc. 'hc bit When }'OU . re <XIPl.
"uit ,"" """h'lto '1)Ih''''' aU .11= i<nob. :and j:lm
.. otrond dleck
:tg:Iln.. ,1Ie

"""*

n",

n..,..

4. Set the IlUn"3.I.lr~vd IIml"'. Tlll$ ,,>ti IX' donc


...... bkk>u' morti"" Of ,IM: grId on ,he
~'C.T

l_os"'. nor),,...

""""''''1'.

....,iI' ,tit St0I'S !lx ,1", noonif< ""'!II1t 1$ (2$j' 'o do


... thr tuW on Ilie bcnch '''I', Plck OIOl ,IIe jUI<Ill"'"
lqIIl'>tIIL ,tit ol",n,111o of ,hc monbe Wltll 'hc bit

,Iu,

~.bJk down "" ' Ile grid ..... aii", ,IM: bit., "'1'1 . .
..... II.. Unc "'prco:n'lnlllh( 1I>(N1!K', kfi ~ nd, !kt ,""
. , OII ,II< adju"mcn, rod', IerI ." p ....." nl IIM: mu,cr fron,
....,..;,q:...,. f.nlle. 10 " "" .11":" " 0 0 . SIkk .1", 1'OUI tT 'o 'IM:
..... ~ ,t.., blo'.
" 'i,1I ,IM: llIIe "'J>flX"'1nJc
ri/Ih' en<! . So..1 ,IIe rilthl >!Of>.

.. _lot',

rtjI.h,.,.

S' .....11100 Ilo., w..,rk. n ", Ax, ..", tu. bttn

lin

'o

ru 0(. Sf'Cd1k Letljllh ,.".. ,UkJi ...,.. a", to pbcr


.. ....npi<" "" ,tit monl><: ..'III loc " 'hac ).... ""UI' ~ .
&10 pol6,Lon . 'OU'" rttmp '" lod< u.., "'Of'I:,*"" do .....
....... root!ng Of><TO'Lon.
f'IJoItionll\Sl , ........ot'kplctt i, moller of oI'snillll .....
II""" ..itll 'hc .pprupri:t,., pid bt'tC&. For
pr\IIhIctloo fWI. It ... '..,. 'ilM II')'OU cbntp a "Of> bIoct .0
klntr It.. """"J>icccs ... ,,,,,,,,.lcaJly. TIM: "'''1' CIIn bc:
<iIItpnI wAA . Cdamp ur ,,;'h OfI8k cbmp
Thr '''I!!!''' cbmp doigtu'N 'o bold "'" _pINt
III'J\<"

>1>001.1 hc pooItion<d ... tiu, it> spindk applit:>'


"'" ,...on: .. dooc to W _
as

""'"""*

~'" tu

6. Rotit a ..,.t morti!IC. W"1lh .,."a)'thng set, k>d:


do".. n , .... 101 1'1""" and ruuI .... mori;'" 1lM:n """mIM
and .,.001 .... ., Il", mon!C ~ i. 0.. ..,. adj .... mrn..
nccd ' 0 toc madclls it ttntercd in thc cdf:r=1 b il "'" CQrrttt
Img:Ihl n.. .,........" <kpIh!
Ir ~. adj .... "'" oct,lnp.
7, Ilou. tbc ,,ork.. Whcn oii Is fi8ht. II"" ." .."Ork on
'Ile JOOd otock.
A ....:>nI OI" , _ abouI 'ccbniquc is In ordcr har.1 (Ir1oSp
,1Ie """cr', I<nob$,.,..., 111..bul loct ...,. ,ltumbl
...1..... 'M n>Ulcr mounU"8 boanl 'oull prub;t/>It. tind . ... 1
dld.1h>I }'OU lIwt: _heT control oIlhc plut1jtC oaOll f
fOII .ppIy """'""'"' ..itll )'I.IW' bo<Ir r:tW' tlwt ..'itlt yuur
hanob. n..
.hc
nl ...........
u.;, ~ c:on'mIIitl@.tlleoat.,andlleptho(plUfltICWhh
JPinl Upnll bitt. il 11"'" ~. 'o ~ """ .....lI ta,t...uy
In onc con,;_
modon . r.' ......h:ul ptungL"tI fi..,.. .n"
.hen cutt" l3 IMcr:olly } .... bc ... '" )'OU don'l Ibrtt bll .
csp<:daIly lJOIid caro;..k onc

ha"".

,h....."" .... ap''''''

"""""'IIII",..

1'"

_10)"'"

End mortllu are ni)' 10 'ou, "'lth ,he sloi mo.,


T... n tM "'orkpli!'Ce la III Ind conf.on" Ilie bll.
r.nht. Ih"n 1" t idt. ThouOh .. sloole .oogle cllImp ",III
hoId Iht "'orkplece In pl.ce "'hlle the morl,!e Is
rou'ed ... >tap block loc.'CI II for Ihe t ul &U'Ofnilkl llv.
li~er.

FixedPosilion Rouling
1oIliItt.1Ie flOPI for ,II. _rtlse leolltll Is done
tU\' uslng Ilie b.:onchtop g.it!. look down on IM
pl. A'td .lign Ihe bit ",nit Orit! lines 11\;11 ""prl senl
.. ft'I:Il o/' tM morIlse . W-IIh tM bi. a, """ m"nlsc
.-1 .... rtIon, spin Iht chi!'Ck nul on !hit sidt uniti i,
It.m ao;Iln" Ilie cllaul, 'ldt. 1.1_ Uit bIIto Ilie
... rml6on, ;aneI set Ilie Slop on tll. l .idt.

Undorr IlIb hnditlJj: 1coIi"!.U ,II""" lIori""",:tlrouICM.bk


op<'r:t'iom )'OIl an do ,..ilh .lIc ...... monlscr. 1h<.,... ~
""I'Id'I 01 tltem: tcnonioll . Io"ing . "" wunvll\jj, tal>bctl ....
rou"1\jj mt>kIlngs. r:t.I";"ll pan~b; .
In ndt of.beM: opcr1tiOlU. IIM: WOIk ilo fi."(l irita nr "''Cr
Iht: bit. Sa !O ><.1 Up Ilie Mot rt1Ol'I!d' lOr eht:m. )'OIJ lin ,1Ie bl
."...d-tr.,'d .. tip< agaln.... ,IM: du._ skk:o., Iod:Ing II", rou,~rlll
ShOp8ull, Slo. MonlSt.

'43

""'" pooiIlon.l"ho:n you": iI'X a horizom~ rouIn- l:ObIe.


Th ro.. a IV"""., witll a .."..;gh. boit. J'UU ~ dlUSl Ihc bit
atcnoion anii .hc .,.,1eaI poo:i.lon. TUm un 'hc """e., ond
rttd .Ioc "'""'"' ;oaOM tM bit. It you a~ <Io!ntt. an m<i-f,lr,ln
CUI, ai In 'rnonins. lIS<: a pusto.bIod< sk<l 10 kc<l and bad
up .hc ........,wcc.
~ )'OU ctnbrxe II..... op<1".tlon>. )'t>U . h""l<I
... ~ thc: 1mJU'-1 <JIthcDI Of! 'loc bmdt undcr whkh Ilie
lIloOI1i>c1 i> mountcd.ln aii thc: mortising """""oo$, lhc bi'
/s aboo.., thc: labktop. " ~ ......... 'he lobk.op. llul for
ncarty ali thc: fu:cd.po$itlon <>pa:I'iOnJ. Ibc bit S p;tftl;olly
burInf in thc: tabInop,
So tM qLX:Slion Io:Do I ..~, a boit CUWllI in thc: _Of)?

II you do tcoOnina only, thcn 1"" Injury > Ihc .~l>k1op


b
1II<JLk3o.." 'IM_wido:. 1" 0 I ~""- !oIoI. If)'UU
t3Iot pands OI" rouI. moIdinog>.. 1"" "'''''''op ",iU _lup a
,;igni6can1 """ice lhal', "" Ind! OI' ""'"' ..."ido: and ""'"
~. 1 , hin!< tItioI f a oo.."JUiok.
n..",., ~ at'c ~ ~Oor <kdok ,,'hcI11cr
'hcy at'c od>isable

fU""

10 , OUI a 8'00". ",111\ Ih . s lOI mor'lls, <, lock Ihf


tOUltt In PQ$ltlon, then fud the wo,kplece pu\ I., I'!M
PQs,uon Dthind IM roule' _ku the fud a<tloo OiI
ft~nllhln wlth I '''JIul .. 'OUlet t.blt .

Loose-Tenon Joints
Th~ mon's~-~I'ld-ttl>Oft

JO,nl ts I good JOInl


II PI'"",d~1 ~Iat'~~'" Ia~ a,~a. 01 141
lIralll<!d 1I1uI0JI surlau_ It 's thtot lal'fle. 1la1"'9,alr>td
beClU~

surfaeu Ihat ,"",k~ It supe'l(N 10. do ..,IjOIni


T'" lI.-.al futu~ 01 I dow<ol joIm. wNc:h ~ ~;al1v
JUst I sJ)ill,ud 1l>O"'J.<!and-tel>Oft jOom... Ihil tlot
rounde<! hoit It'" monls..1 un be qUICk.., Ind eUl'"
bored Ind
do .. ~1 tlhe .mon) (lin be ,"",,..produce<!
W"h ,n efflelf:nl .Iot mOflIs..r. Thot ..av..nt'Jlf:' of
th, mOftllt Ind Itnon Jo,nl ean be eomblnt'll ",th 1'"
adv&ntlgu of t'" do ..,1 joInl_ Tho eombl"i!'1on ,"
JOlnery unlquely suited tO the small s~ prOdU(lng
on~-of-a-tlnd Ot hm,,<"d-poodu{!lon IU'nltuIl' Of hlllh
~nd (lb,n~try.
TradlTlonally. mortlil'S Wi"f tht hard IllIft Ind
tenon ...... ell! the tUV Pi"_ Tod.y. It .. more efr,u'nl
(Ind JUlt iUOO\l) to (UII""'O momsel and uSf. SfP"alt ,tnOn The mOrllSU IIl! quIC"'" Ind letu,.te'"
CuI wlt~ Ihe 510' ll>O'tlstt. ind Iht tenon. It, easl""
mass'p,oduetd OUl oI ",,.p Of IflfXpen"\Ie wood ,n
.. h<oTever S,Ztl the woodwO,ktr "teds.
Mak100 up bi."h of tenon stock 15 ",~htforw.rd

t'"

.-1:-.
iii

c:

:lE

Illp a Itnglll of rough ~toc:k 10 tht ,ougll wldlh of


the lenon
2_ IItlaw 10 JUli Gve' the desi,", thk~neSl_
3. Su,fue 10 the desl,t'II thkkMU.
4. jo<nt 0I\t !!"dgt
S. Il,p 10 "tUr." wldtll
6. Iloundov~, Ihe !!"dlltl on IM 'OlIte, ... b~.
Ont Idvlnlage oI k>ou-Itnon jOI"ts 15 Ih'l pariS
110 Ion!lf:' nH<I tO Dt "zed.o include an int"ll",1

- -

Template-Monisi
c;wId~

templul! 10
an IMse h"rdto-pOshlon montses.
your rOUler ..... llh

il

""me-

"''''pbIc

oina
10 guidc IIlO<IISUljI; CUI io
,imn tI'o= ....... co,,...,nkn ,..:' . .. 131~. aOO &1"'"
W2Y 10 WOtII You ,,~tfi, )'OU. punp: .".lIc. " 'ilh
. . ",""",,-:and >lrllll.l1l bi' , 1htn . - 1, wi,h a lempbIc
_ dw: 0JI0<tisc

n.- hT

ii

noi

,IK .....,..... ptt se. but

tii<: " ,"',.....,. ,.

laDpbtc. Uk~ .ny "'hcr ''''''pl<"c, an "" lRI<k oi


liIIi:I:IoW, mn!;UJtt.<k ..... y fIbtrt>o;o .... ( ,\II)F), ~ . or
an "" joIpcci1Ic 1ilI, n,:,,1o;
.....d for .he
JIIIICIIbt .ppllc:.. lon .1 tund. 'hen ,~ . ar I an Ix
'wtptr, OIle' JOII .... ~, .""r . gaIn>I ti.., oby "'" n<'rtI 10
lllitlh>l...,.,. _
.goln
1...........kc Icmpl..c for monbi"Jj <k>O<' r..... """
fKr '11IlIIC$; but rr.nkly. ! III> li monislng wor1r 1oi do
... _ 01 'he Olt.." monioUl!l lil(S p<t:scn.cd in
'10&10 _ . Ihe ........ od... r wood"'<ln:ln"
<O
otIdI dw: .",nl""" ,cmpb'" b beUCT 5ujtW ....... y In
.... It.. trmpbtr b ,"'" onJy ... Imlon. Lct "'" 6" SO"te

.0"'"

'-"'/1

'"I>

"'U>'1oru

9'rlk lpplic:lllon .
'tK~

I'I>Ottbc In . p;u>d.sudI:as tii<: m"I'1I.... In


ono Of ca..e 1lIi<k:

" 1IIroICh

monisc in

''C'I')'

tllid;

""''''pIc, ..mlch

""'*"'}'OU 10 wol1< r...... boIh loid<:> or the ..


"'II.

M CDlDplC '" ...,.1>ud:


...,n>hIy Iha ha>
*'-Ch monbc for .... rnd>c'r.
..nbo In 1"" bo...., oh ~1: 1 W.1o.
,h..
ao', b< dmlpnI in lhc ) Ionising Jill <In
124 OI"

""'"'1"<'Ct'
pa""

lloc Shop-Hulll SloI Mon"",," OII P"8" 1'1 1.,.,.,., "'J>t'Od""etI a rourllry ch<:sc o( d"" "<:f$ In ",-hkh lloc r.....,
r.tIlJ "..,~ mortitftI !n1O tM >'kb To cut lhc m..rtl..........
t ~ a lnnpbte.
- . dtflkuII~ ... po<itlon moni>c, 1Udl as onc in n>und.
on~ CUI !nlO Ilie arris 0(. kr- onc ClU Inlo an . Irody-.m.pnI pan, OI" one 10 bc rut l i .n . rIj/;Ic. In lhcoc _.
sjluarions, lhc ..,... o( a lnnpblc allow. )'OU 10 nul<t". Ift
rnMIk br thc ",'OtI:rMI ;ond stiU pn:wklc fbl, 1IOUnd ; ~ ... "ace b" lhc rotIler. U.<Ing tcmpb.e ftttJ CI
)'OU of.hc n=;!10 J"'l"Itk suidc Sl.IIfaoc b" an c<IF
lIuklr OI" thc 1IaIq>b'" . . ..

J:

::1.

W1u1l'm lIUinI!: 10 <10 hc~ b ttpbln, stq> by Mq>, hoow


10 nake ;ond w.c bask monising lnnplalC ,,,.. b thc ......
<>f .empialC ~ In .tlc /lrst a:omplc &,v<:n ~oo.- ~ th~
morti ... In a bmch !ICOll 'rhrn 111 >how )'OU lhc t""'plal" ~_....
~ In Ihc OIhcr ~oe jobs (;Ie<! '00'-".

Maklng a Ceneric
Monising Template
noe cxm.ioc horn: b 10 m.kc I roU''')'<lIJ\e o.-Nxwtl bmdI.
nx, bmdI -. Iqp D<h tu .., ."'., .CDO<If a kWlS ... lhc ..... b
thlck. n.c... tmons cxtmd !nIo mortloo::I an lhroLtr;h Ihc K"
hoaftl. nx, 1~..rnmwidc )( l~...indl--lonJI mortioo m: ruuletI
...ith aJuido bo.hIng~ ptw>g<: ""',.,.
tcmplatc

_:>

'"

(;IENIEltIC MDIITISlN(O TE MPi..ATE LAVOUT

T~mplale wlndow 15
rou. ed wi\h " " bit;
COrnel ,.diu. 1. h ""

I It" X 2M" mon'H

..... ,ed ullng 'em~e


wi.t. \Ii" bit.nd MO"
0 . 0 . guide busl'lIng

Cuttlng Llsl
Pa r,

Qty"

~" X

Ttmpla't

ali

,-.
'f

I r)( 16"

Mate ria l
Bireh plywoo<!

11><: '''",pb't 1,,,,,., b a pkc<: <>1 \ ..ind> or h"inCh hin:t.


oct IM Itn 'pblt OII II ... worI<pi" ( ..'hidI
""" .' o.' a pie
sc:np) and applr a coupk <>1 cbmps.
...:cur/nit II... Itmp""<: '" IM ,,"01'1< :ano.! IM .........., In lM
W'()Itbench "rIItn rotiI
Ilo:""" muln", 'M '~mpb'r . )'OU "''''' 10 .... kc fUncb..
....:n,al \lo:dsioru ab<HJ tIc l>ushln" ;u>d ,tic bII )'OU ..i U
..,., . You "'''' 10 mUc I~ ~ up (1001, I:>faUliC

M''"''>Od . l"ol.

c:

Ol me nslon l

Or

CHOOSIN(; A (OUIDIE IUSH IN(O FOII TIEMPLATIE .. MDIITISING


COLLAR LENClli

Wi.h n.ilndud !lU"'" bu.hing ... t ....


coli., Ifl>gIII 1nUl'".e. H the col'"
d l.ilmttt' inc~.ilSu .

The longH the col"',. the thkh, the

.::J

'emp!.illt malerloill mu .. be, and 1....

!oi." 0 . 0 ..

!eIS dHP .lIe bit ulel\(ling Ihroogh


1. Un ~",h .

CHIP CLEAAANCE

SlIme \Ii"-<lII .. bit In


K"-dia" bu.hlng

\Ii""dla. bli In
h" -dil" bushll\g

Tlgh. durlnee
betwHn 1....

,aiia,

Ind 1.... bi. , _. rlcll


Ilie p.IIs~ of dllp.
f,om Ihe cu, .

i::::'l

Ample clurllnee be'Wffn


'he coliI< Ind lhe bI.
promotei p.oiuge of chlpi
OUl of ,lIe cui..

_ _ _ _ _ _ _ _ __ ,

~bmo:tn bil. U)'OU """'li ~.id<: n....,l$c!. "'"


I~. 01
' M mor

roti..,..

"Hn<tI~n bit. In lhl.

'*' 10

Itl tit 1I0I0 in<r..:, wid<:. lnd ~ '. unlil;dy )'OU ho...,
,.,.... bir 01 'hol <H. m....n . 1lK brJIc,;l"~
col-

In...,.

louiorI D I In<h in dimlc1tt


IM ...ilh l"",pI:o l~. )'OU an ...asUy ...., hinch .,..
"'-to biI 10 ~ lhlo .......,ise.ThiS l txo...., lh~ I~
pitit ........ . , . guiIX. coolfQlll "'" nn. 1.... cad of n" kina
!U1l1k .... Igh.linc CUI. )'OU " " " """,nd l M In"".
~01"'" " ,mpblc. thm fQUI baei< .nd tUnh OI" md
10...:110 rtftO(WC lM Im"""" " .... c
A ~t <;'OfttI .....""" in ch<,M:t,ilng bit l lhe:
...., 1100 bil diom ... cr to.o. on lh~ 11><JItbc', rornns. A
~l"" bil
OUl , h(: " ';I.'IIc quiddy bul "'.....os
MIounlbl ,,"" oi """"c 10 bc " .""""" ..~h chisel U)'OU
11< . Ii/IIlIkIi1IlW:n tlu_r. a '~Indt bil-d.., ,...<:1> 01
...... i> m...iI ...... tI"f, nn"'" ""'"' ra>llf "'mo......d .
1110: 60uI (Ur\!ilcknllon.lnd ~ ,1 ",1 ' '''''. b IM biI .
oormI ~ . TlIUy 101' ,1", nttds:. minimum oi h indo In
_ooIfl ~ IIM: <Oulcr """" .hk:k""",, + IIM: tIoid<noIl 01 "'"
......... + ,he tk:sirnl .......,Ic: "'I"h. lO ........hro....
_
in ~~ (fi'~) .. ,><:1< ....... hineh I~m pblc
.... III< bit n'u$l1M:: " minimum 01 2 Iod'>c lung
In thls 1"",",,". 1 .... I...:IN ' rindHll:lmt."1Cf bit.

"'*'

2. Choose .hc .cmplllic gul<k bush lng. In


. . . . tlIor JUidc bu ........ lhcr..- . rc fWO tattu ' hol m"'1
lor , ......,N Ihc colbr dWnctc 00 llIc cobr I(,'Mlh

""m.~ oboiOo.l:!oly. Ihc IrWde di2tntICf of .hr roIbr


mUSl bc aa.,.... ~naugh 10 acc:ommodalC Ibc bit llul )"OU
.h"uld .au coojkk.,. dllp cIcat:ln<'t U,i"ll ~,""Icr
Muidc - " ' l I whh ~, hl1 p"".1dc:l plen.,. of
do""",,, ro...hc chip" lNt "'.... U ..... I ni ' h<: CUI. It you CUI
nwu.., il. :0.110'" al kaot .... Inch btlwa."n ,"" bi, ~nd "'"
1....... of.lle _
. which Ol(.""" " lhol lhe: 1n.Wk' dlamt."1n 01
1"" oo.oJ\,"tI obouId be ho lnell bl'Jl<."'" ohan 'he bl' dlamc1n
An """"'pir. For a ~+Inch-diarnncr bit. USI: a \~IndI-O. I).
b,ulti"", ..."Ieh typk:olly .... I ' ......Indl In>Ne: diamntf.
In _ . ~ I ~ ...i.lI. ohon coAar ... )'~'
an """ I thln 1""'f'btt. Tbt roIbr.'" )'O.>U pn.lbabIy tn" ....
_
bo jus< I ~""" le Ih:ln Ih<: templ:olC IhIck"""",. AnII
Iht tlll..."""", 01 tht
bc o:ubtncoN from Ihc
"",~in'"m moch oi tht bil al fuU
th ... llmlllng .....
dtpth oI lht ~ ""'1 ."arI ht rour.cd. lf)'O.>Ur rnoni!oc _
bo rnon: ""'" 1 lndI dp;ond ,.,... ''''''pLlI<." 1:> ", Indt thlck
)Ull arc fiPin810 MCtl an -fuIr Iong bI ""va')' fr.to:tion olan
ind'! )'O.>U >100.., oIf ' h<: , ...... pblc ~ th<: moniM." dccJ"'t.
1lw:: ltilcll . 01 """""'. It .hal la~ lIlIidc t>o.t.n.
ing< .eOO lu ho'.... ~ colb .... A vI,,;1 10 "'" benc" grindC1"
can CUllh<." coIIar <Iown.o ............ ~ k:nglh.
1'0. Ilie _1:>In8 Icmplalc """".... ..,.. l'..Ind>O D.
~ukk
an(! makc SUn! ,toc ""'-la. 1, 110 """"' lhan ~.

",,,,,,,,,c .... ,,,

pI..,....

buohi,..

'"""

} . Sc:ka and cu. Il.... tcm platc..rock. 1lw:: I ...... plalc


Sl ..... k . ... nOIW carlicr. an loc banJboan!. MOf. pIywoocI. OI"

r--I

OIOO5IN(; A.IT FOII TEMPLATEIoIIOIITISl NC

.(l.D. busttJng
.. "

Ed\le of monise
(

Edge

Edl}tOflemPble

~=""~='"'_
:-

~ .... ,'~"'"

"r monl.t

Edl}t of ttmpll!lt
Sm.U-dlamtte, bit

wlIf-diameler bir

c!tJrs IlIt monlst

mO,",
p;lues 10 dtlO'
Iht monlse. JOO
~ul,",.

qulc~lv. JOO luves


... ide rlOdlus cornol!'.

IU"tS tlght,lOdius
(<>mers.

WilSlt slUIIO bf! 'Ou led '''''Y

Pon ion 01 bit In r",ner collM

TtmplJle Ihk:kness

Wo,t pltce Ihkknen


Stup

.,

11:
O
::1

_._.
.
VI

ta

TU4PLATEMORTISlH(; SCHEMATIC

To Ihe IonQth (or wldtll) of tlle mo<l'~ .ckllwke


Ihe offfellO determine how Iong (or,.;\de) 1""
olM!nl"g In Ihe lempiile mUSI bit.

Tempi.le

ROUling It.. Iim plat..... lrl-do ... Ii ~ slrillghtforwortl


OIM!'<lIOn. Th~ y,,Ir><II1hlck tempa,le _,etIIlll
Off,el
pb>lk:, 111111 IIM: k:nJtIh of thc gulde b ... l~ng'. cui!.>. In
rnlod. d'Icdt 'Ile !iC"~p bin Jur a us:.bk: pin:e. F:iUing 11te..."
lUt Ille _
n~ oI!hoc """crU!> fu. }'OU' lempl>!e.
Thb b npodalIy ~ iftlle ,en,pI..1'" wil! bc jotM;pccific_
,bat It. rrudo Joc- Ihb p;utICula' job lIMl """'incd lOr 'he
,.,...p bIn ... hen
job 1< romplclW .
. ._ . .
For Ille ~ templ..1lc Wldcf considcnlion I>rn:, 1
..sed 'o-indIbird'l plpood. II's. m.JlaW I ~ an hand,
and It 1< I""~ on bfuu' lincJ show up mly. M DF
(mNl~r /lbcrt:luanJ) In a ',..Ind> <X ~ IlIick
nc>o It ... o .....1lcnI m:olm:d.:II Is .ny goo<kpWi<y p/)"W<I<Jd
'" cilht, oIllIoo$c thIdoc:ooa. U.....u..:.:.na ....... bIc. bul I
ftn<llt nat 10 ImpoMlblc 10 ..,.. b)'O<a Iinol dn .... n an iI.1IO
1 JCOCf1liIy .mid II for oppti<'3Iklo> Iikc Ihio..
lloughIy II< thc 1<HIpbIe 1IUICri:JI.....tq il btl!I' .........
Itw cIIInps an bc :oppIird .."ho<tt thq ...,..., inIcrkn: ..;u,

,Iu,

c:

OI

1-__1

' hc l'IlUICT"J """........... """"'" thc 1aIlpbI" .."indoJow. l1lc


CUninl u.o op<rif"" Itw ,hit lCnlpblc Ix: Il X 161ndoo.
uy OUl Ihc win(\o"no' o n lhc IcmpblC ~""' ....
l1lc guidc: "'1..00..' il Ilie <>penins inlO " .Irit.... IIM: SUidC
bu>hlng fii . 1l11h Ihc I>u>hins ,... ppcd in
irotIow. Ihc
""" le"5 """..,menl i'I UmllW In "",en,."". II """ """"" from
Of\c elld 01 Ilte ,,~n~' 10 Ihe othc:r. rrom ..... oIdc 10 il",
OIh.", Rea..,., the bI' 1< in>1<k: 'Ile bu>hlng. ill .....,.. of
nlO"en"'111 , 100, h lin,hcd.
ll'IC .:1.>1< now is 10 design and Iar oul IM >'loc ...,.,.,..
' u r I<l produce II><: <ksi~ rnoni,.,. To illn. ","c IIM:
wldlh ."d Icng' " of It .... dc>ircd monl,., (In . 111< I",,~ .
1hoir>< lIwkk, l " .. incllk><ljc OIle), l'ou'", al.."..)y ct.o.;o,n a
', .. ineh-<.llarnc,e ....... lgII. bl. 'nd h lnCII-O.D gul<le
~Ing Cornp"'e ,he off"'I, ",hleh b <k'e,n,InW by ",1)'J':ICting Ilie bit diamC1e' r""m Ihr """"1"3 di<lrnc.C1" Ind
w'iding by 2. In 'hl, <::0,;0;,.1><: ofr!lC1 b ~, In~h .
Ite..., ', how.u 1".'1>10'" , lIe dlnlcn<lon. of 'ht <lcslrcd
rnorti>c ntO .1Ie dlmen~ktm rO. III<: """""""r Icmpl.lC
>lot ,,<101 ,wlcc <h<:: off,.,. 10 'Ilc Qwnbc k lll!'",;oS ~hown
in ,Ite dr.",lng n-"'llIal"'lfartl$l"lI Scbemallc.11.u5. lhe

4.

'Iu, ..

c,",mpe!! 10 scr<lp. ,.... windoWs ~ngth II controkcl


bV IM stop, ct<lmped 10 Ihe 'tm~te .... , ....1. Tht
rou!fr"s elIgt gulM poslt lonl Ilie wlnclow.
,~mpl'''' .tot m~ Ix: 1"0 inchcs "'idc and j ' , lndIn lttIl

o;;;,;;

Follo", Ihe d ......1nll (jto",rle Mortis'",


Scribc II><: ccnl~t1I"" of thc 0l0i, thtrt
ct()&/Uir a he nddpoim Rea""" I ~ II
agaln a od :qIln 10 po;tfi,Jon ."" <'<)mplctN
workpleCC5. Ihe II".". ,,",.ukl bc <Ir."", with I
line n.. rkC1",ll>c'n Lor Ou' Ihe " Ind..,,, rrom I
}'OU
lrotlbl~ .....,111,11
. I"",f' I
b<'lllt'\I. ll>c'n
ti Iln~.. on'M

'''9"..1,

Iu,..,

""" ,Iu..t n:.>tJ' .h/UUW' 111c "pc,)


S. Motii tI'e ... Indo ... In Ihe 1<,,,,pJ:ale
to etil .Il<: ~uklc

' '''ry .,......,. an<! accunle


"';111

"'lth

.n cdSI<"

~"

oii 1

tooac~ofthc

...,rcwncC'd rrom.t..

To bqln, d<ltI
IICr.lp
""n'."h . l""" ctamp .1Ie ,,,nlpl..11e ' o 1, . "'1T~ngc 1
!lO
you ",m ""kn."nct wiUt IIM: fOUIn,
iltJidc projttt. bcy<-t Ilie """'P" nIlI<' ,"ou " ... nllO
cntt Ihc ' C1I>p!a'( ~ ndtlslt-dy ",i,h It..
( l'ou o:ouId II.., ""....... ,IM: lCa'pI..1lt ta thc """'P:
'httt hok:s In i, ........, Inlerfc"" ..illl .1Ie ...., <1
''''''pla..".)
""-"Ien .....IAh' bit In

1"" .....

".p'

dcP"'~'~~;~::~.::::;::;;,:~: :::-::.::::

plW'l(l:lt"
InMllII 11

t10Il

.,..., wp: of

" indow, "'.. Ia\'lnil "'"

1Icfun: "",11ng,)C1 up, poi. of ..op ..~ . , . ,,,;,.~. ~


rrom Q\"Cf'IohQotlng dlhcr cnd 01 IIM: .tot.
'tl'llh Ilie bIocb JCI, """ ,"" r.... sloi. Se< "'"

!il""
po..... ..

:~~2:~~:

.1Ie ' empblC ....llcb it 00, pt""",


tQ il"" il(:l;Ct IIM: ~ guidc. 1"""
klcn llll! Ilie W\ndow
Ilie
",Ind<>.. b con'pkIW.
00

Re""",

,,(>cu. hit Ij

11'I<)S(

ur'en I'n'(lnu,ocn<k<! for

n,unl~nll.

'Il...,.,

it> tlcs.iw> 1> C'OIlctll.:tl~ 10 heip ~'llII'r d.11"I tIp ou, oI.hc cut
If )"0\1"'" 110' 5UCh bit Ind II I~ In"g. hy .11 rne.ns ....41;; 1, !Iu.
",...... 11 Icn!llh is "fien I rn"r<: sill"lflC'Oln. >ttSi\k ... tlon In
..-....nH. 1l1c lnnjCOl ' .....ch hl,. 1'..., III't-I><Kh fn,rn
An ..... ~.,.., noi "f'I...I. U". L~ an: 'hc bit> I ...... nlO5t
ofInI lOr rnonlslng

.l ...tty. "'" 'hc plunll" dcl"h.

Combining Templates
SoIVI"O Itmpl/llU lrom

proJecl c/ln make II


f"lu~ .
.... , ~'ng I",mpl,..,. Cln ~llO If:ad 10 otOf~
"'oes. If everything yO<I ttWtf .tqu'~s lWO Of III,u
Of fou, ttmplolt . '1 ... oro\ bot 100 Iong before Ilie
KC .. m .. I~11OfI push.,s OUl of liS "lllf: co"'" .nd
crowds Y'D'I ,nlO Itle <>PIH"C 0tH' .
~llokt ltfO( live-boird beIKh
lnWIvt-d IhrH 1ell\pbIH-O'le for shllotn!l ~ legs,
another for ~n(j Ihe ~ MdI.. anei /1 lII"d for
1tIUl'''IiIIM lIIOfIJl.tS. Bul gllfts wIIIt' .... th~e I~
pl.11H (it' be OM. Che<k DUC ttle pIIoIo. The leg s/w.pe
OCCUpoH ... tnd .md a sode of Itle I~I~ bI ...... n..
_Ih;tpc oct...... Ihe oehH oeMf sidt anei end.
The w,ndow for 1/1t moru.u li ln IhI moOdlt
/1

euy 10 'tprod"'", Illil pro].,ct ,n Itle

CIH .... lrs

_.

~Uo ...

)'0" 10 pOsllion 1.... I",mplat'"

..;chouIIi)lin; 0\11 I~ monil<' complelelv OII Itle wor1t.


)$11\' 0II11he unlerl' Mi Otngth and wkhh) of th.,
.wtIM.. 'IMn /lllOn the Cf05s/1.1irs OII Ihe Itmplole wIIh
lIItM Iints, ~s s"own. 1l>t mon,l<' ... ,11 bot perfectlv

Usi ng the Mortising Template


II .... IIDOI\bins Imlpblc sucttSo1ully, il .. imporum 10
_ ~ hidI bil :md Jui<k buslUng Iu ..,.., wilh It.V"" WOfI'1
"'dlfflcuI<y MIh 'hl:! ""hen)'OU ...... t~ lempblc lJnmco.
"-'Y ofIer h..ing """'" II>c lemp!:".,. But _ oboul a
,..,Ia!m Or Ih-.: l~ laletl
I lhm1 ~ is C$SetIIi2! 10 ""........,e IM tnl'pIales lha ...,

,. """'*

,...,ol)o:~.

JIlSI ... l1le Io.giblyon II>c lempblc"'luI.


roo,bin't'on Os su~ ,,, bc usa! ...lIh It.
_.u }Ql' p"'ran= 'o muc .nothcr I,,~ bcnch.
1'* !!fi O\f\ t!le tcn'pt"c. then l'etcll tlle C<:>rTtt1 h<t>hl"tl
III bit from ... he", Lhcy .r<: kcpl In yuur )hop.
~Ib/J.

1. Set up II", rouL", . SlOn by

fln~.

J:

_.._.
O

' .. lnch suloJc

::1

lto!Iunr: il1lo LlK bit Of"'nltljl ln thc mute. b>.>cpl~LC .


NaI, LlgIttell' ~.. Inch ..... ighL hit In ,he coIle, A ~pir.1

la

"" <_""'Ied mon ls .. il clf:in ind neU'il"'lv


ond posiliotltd .

"*

Thtft It mplales In on", mak.,s for caSy "ora!!".


OII tht 12 X I SInt:h p~u 01 \','int:h plywood
(nm,nq on II><! botnch)
Iht JMUtms for alllht
Itmpl;lIeilu!ded CUIS .....d., In eonSltIKl,ng Ih" livt
boHtrd bcnt:h.

",t

TMl p!.o leMom , in\l

1 04 9

2.

1..:1)'

oul Ih e o>on lse 0 0 ti.., work plece. Thl'

<!onn' , mean )'O .. muS! dnw l't'CI~ngks on ,h"

won.:

plr. ddlor.rilljl <'Xh moni~ '0 I>c rou,,,d lI .. h",. I!


you .hauld Kribtc Ihc centerli"e and m idpoi' l! of
c.e h mon;!iC un 'h" workpic<-.., . ... )"'u OI n line up ,he
,empl:llc . If
made ,I>c .em pl " wllh 1'=1.10" . on<l
)...u r 1. )...... III>C'S an: .ecu""e . Ihe monlsc. ",iti hc prop.
crly 1' JC:Jr'cd
man~

yau',..,

lO<k '" 1IiIk. nihl>ling ~ "'-.y ,1", ...... c het",,,,," m. tnd bom.
1"hc nkc {hlnll ~bo<I' usIn~ a 1<'1I, p l:lI~ for thb
{h~1 fced dln:clk>n <... nfll.""" is elimi "","". u..altlC
hll)lIhllC is , ~.ppc<l In ,h ~ ,e"'pb .., $lot. 'Ile CUI
( vct1 1f)'O<l fced wltlt ,1", bit
~~ .~.
' !9h-.l II (Do .h ",-hen llui<lilljl " monbitq CUI
lIukk: . an<! .hc cu, ~ , ...-.:r oIJ Ihe c ..mcrlinc_)

_""(r.

""",Ion

A Base-C:;uiding
Mortising Template

3. f'o!IUlo n Ihe Ic m p b 'e. u y.hc wori<pIr<...., on ..,

.1[> ''''''

o:><peno,bhk: pktt u, "'


""m back 1. up. dlmuu.UlJi:
dllP'O'l' "" Il'" wl<l<:n.itk vi Ihe .... or1<p;n:c and prutn:tJng
rt", I>cnch rop. Sc1.hc .em"t!!e on.hc work. and.IJgn.1Ie
ml<lpolm "",rit "" .I>e 'mljIb.c ";Ih Ihc ~
.... "" nil 'hc _
. AppIy a rou[>lc vlcWrtps._h.,.,hc
, ..... pIa.c. """"p;n:c. and badtup >enp 10 Ihe """"bmdI

An ahe .... ';..., ,,, .1Ie lempQ'c u5N Wlh ~.".". .,..~~.
thl5 .cmpl;Ite. ,,'Iuch lncuol,ou,a r.:na:s , h;rt PI'
"""cr b.uc: \ . .... lIon' "",.., .u . - a gui<k bu>ItIn& ...... l
'i)U

"""'! rven "",.., ,,, IIK a plUtlll<" rouIn1

4.

,,,,,,pbtr "",,', ""ve: 10 " ...... " ..10 .

'he. mortle.. Sc1,1or ......cr on 'lor


"nh Ihe """'inlln ,hc 0l0i. S..itdI an Ihe fUIIlcr. pIurtw .hc
bII nd fUUl Ihe .....ru... n... ...... inc I ~. lbIIow b to
",," .oo.r lhe r;:urnen; 0I1he lhQrt5(; II) fui do:p!b 2IId Ihcn
""'". ~ 01 ~", .. ~ dttpcr pa-. badt ond bitI>.
MOlii

Choking O" Chips


Spor ... l u!)Cul

.-.-..
i::E

I,~ ..

ab<>uc tllis tempLu( ii tiut ""


'cmpl:o'c .."in<ItJw tIw'l
laJ"fII'I" lhan 1"" moftir Thc w lndow is Olactly tIM: _
Icn8th and ,,klth as lhe moni!;c So '" posi.On tIM: ...
me",1y It,n", ,,, >CI I, an lhc b)'OIJ' liNs pt"II(ioI
on the workple<"c

Whol I p;trtirubrly

b"~

no,w,lhlUlnd,ng. chilii e... nand doi-dO; Ilie 'fmpille SlOI wllen VOU lrf
mOM'''ng_ TM ,uul! elin be " unden'Zfd mOrl,se
... <lh Unfllen ... ,,11s
Wh". IIIppen~ 11111 chlPI well up In Ilie cut ;lAd
pusll up ,nlO 1"" .empl e ilo'. A. IlIf guide bu.hlng
moves IlIroulIlI ,Ile slo,. II paeks chlp~ a~lnSI Ilie
ends. In .ffeel. Ilie "IO'lItl\ shOM.r. The "'SIlit ls ~
Slfpped monlse- One ,II ~ IlIf COrrfel Ifll<jlh nfa,
,he lurbec. bu' '00 SIIOM ,hree'Qu"Mers of ,hc way
down tow"rd
bouom_
Th. problem II moSI p,on""ncO<l. in mv ""m.
Iion. wnll wlde. 'hroulllI moMISts. whlell ",qul",
slde-.o-slde Cul\llIII u well U flld-Io-tlld C.... ling.

'h.

""'(.)'OU

Wha. 10 d01

The beSi ",lul'OIl I~ a rou'ff-m""nlfd chip


nll.Cilon '~IUp. Somc mlnul."u,en. not.obly
OeWal, ind 801(1t. offe, sucit accenonCI. 1VpiIIIt.
plutlc Ihroud ..... Ith "viCUllm-hOSt COIl .... ClIOII II
mounltd InJld. Iht b.!'!_ The sltmud "urr""n.h the
bit. Thf vl<u"m pulls .lte chip. oul or the cut.ncI
th,ough Ihe bit open'ng In
bue. Mn sucks
"w"v 10 lne IhOll ViC.
Thf "lttrNllvt " 10 SlOp work Ind Vkuum the
clI,ps ou, or 'lte cu,. OII lOn1t CIt'OMS. uSUll1y
wlttn v.o<k'nll plAt. I'yt /IMI 10 lin" K",wd"vtr la
d"n tht ledgt belwn IM {tmpl"lt 1101 Ind tht
monlse 10 CnSUrf .1111 ,ltt lIuodc bush'"" could,..
In.o tllt co.fItrl of.he \emplitt Slol _

,It.

.'.
,

.,

Wh. n chip. dog th. CUI , the re~ult,nll mor. ,se Is


St ldom ."urn. USllaIlV. Ihls muns you hlvt 10
S1 0P Ind vacuum Ihe ehlps OUl of Ihe CUI Bul w lt~
a v. cuum pkkup """ehed to 'ht : ;;~.;;;:~;; ;;;',. . ,
suc k Illose Chlps ou. or Ilie Cut as
duce~

1 50

Ro ule, "'"Ilie

. hfm.

IASl-GUIDI NG MORTISI NG TEMPLATf

~~

Making the Template

Cuuing List
Port

Qty.

Ttmplalt

,_o

..

""'

f.n<t

Dim~n s lons

M;"~ril. l

Ioi'XIS'XI5"

St,ell pIyv;ood

)j,'X IWx 15'

fbrd ..ood

)j,'X IWX 15"

Hi,d .. ood

)j,' X IWX 15"

Hird .. ood

Hardware

Imlpbl~ il; pmr,' mtK'tt


U!C" 2JI oIbct gaup:. ,,'IIid> il; _

""" 'I-mb.5 pn>fIOOoI", ...........Ij' ......,.)

MDIIfI!. Ihc

1100. You

in IXl'itloninB "'n;ghl""" fOr ruuri"" <Iadot>o :mii IIJ'OO'"Q.


NoI onIy wlD thi.'ll...rnniqur""'" brthls jla.1I 'laboa ~
~ 10 gu;dc a rouICT ,,'hen """nfI ...onbi"ll " 'in<kno.'> In
Innpbt"" inl~ndnI ro k ......,.) "ith guid< ~
,._.,
1 . M:akc .... offijd

:md bll }'OU "i11

gaU(IC. Cut 1....

lIliin3

Ik mulCT

'*' wllII "'" onortisi. . """pl:d~ that l"'" ....,

mn... Sn up "'" rQtIIn". _ CUI 6- 10 Il-inctIkIIl3 "'lip fA "'.joell 10 l'Hnch pIywuod, MDI' OI" l",nJboani.
rippin!! it :d:>oul f 10 5 Incb<:s wkk. Thb Is _
bbnIc.
(]::unp f<:n<:,: ~ ttw: cdJo: 01. ""OO1LIxnch. tlul! ttw:
11"l1li" bbnk 10 ttw: Ilo"",,; txk II <I<'.... n ...illl ('\lOJpk ot
bl3ds. or stkk il down wilh ofPCI "'pt'. Gukk 11>c: rouIn""
oI< l<lg Ih e fcncc.am lng IhMl(!h 11>c: >to.:k. Pry up Ihc ~UJC
'ou nu .. II. ""
IU poo:I,JOI1 )'OUl" ICltlp"" " r"""Q.
oI)oul 10

Drywall ,cre.." _6 X) '


'WIII~ 1, Dp"......'''Q'. C~"Q (1, ..h,~ ....I"""r Q,UI>I -

M".. ,.... ""'PIIo,..

"-' y

2. Cui tbc ,...ns. V.-..., n<"CtI pict:c of [l1).....OO<I;Ib.:)U!

15 ilIdte> "I~ lOr Il",

I~m [ll'u". an<!

.1><." '1 4 fecl of . X

..g_._.

I l;.inch haRlwood ilcrl for IIlr frncn.

3. Lay oul thc wlndow on tb c IcmpL~t~. Ury a


drop--Inf IIi".... mn-c,1 up, In Ihc ccttln" o f II", pI)'WOOd and
I"""'..round il ..ith a Wrp pcndl,
11>c: c,,"lcr1lnc 01
11'1<: llinW pin. 100, CIII~ tIIil! ~nc ...cll 1>c:)'OrId 'hco OUl
~nc 01 Ibt hirIF.

"'.tI:

4. Sd thc tcmpbl"', r~~. u ... IM off>ct ~*


for this. as .no...n in d>t dt:a""Inl! ~Mf"S" .. S#<I ....1t'L Ury
,hc ~ ... ., ...... C'dtJI" Iu>t CO\"Cn onc ,,, IIlr pt'fI<:1I II"""
outlinionK thc morthc oa"'P Ik
10 tM ImlpW<'
_
. ,hen buu a >lnp 01 tIM: fcnco: llloei< 10 iu 0()f'0tiI~
~ Sc..,.... thc rma 10 thc ,nnpbtc bbnk (10 boc. 01
COONc:. If,.,.. .tm.., thc S<:..:wI 'hrough Ihc I~mpblc OIcrl

P"

Abu. . uldlnll m orllsl nll lllm plaiil 1, .imp'" 10


... ~ IrId ",. TII. w.........trn rl ..... rracllrd ro rll. tom
pili. mllorl.11 guld. Ihe 'OUler ;'-I il CUI! Ibt "Indo..
~ Iho lomplll', Ind al.o as II CuI. rh. morti", lutlf.

inlO 1"" tDJc.: ~


Now U!C" Ihc ~"II" in "'" _

"'2)'

10 po$illon IIoIICQ

Ttm~ltMonli,"g

1 SI

"'_oi

monisc ;$100 laI"/\<' 0 " 00 omaU djUSt thc fcnce: poN'iom

FENCINGIN SEQUENCE

FIRST fEN(!

SECOND FENCE

.nd fCpc:l111Ie 1<:>1 p.-ocnJ,,'"

Using the BaseGuiding Templilte

""" -~:3,

Offm

gauge-l-v
~-cr--i

Mo"".

layout

Templlt. ~

W;,h Ihc ,,,mpl.,,, matk: and U<.:ccssfully 1C>tcd. nJI.OitI


n\Onl"", I.s f>.rlly sin'pk "'""er. This ten'pl:lte l:i """ ..
Ihc sante ""'Y Ihc n:xular1cmpblc Il. ","cept IhOl )'OU doat
neal a guidc buo.hing on)"Our ",uler.
QmUnc tlte "",I'ti:;c OI"! tit" wort<pit'CC. t/tcn:aIign .....
1C1l'pl:llc ",~. II. 1Iea~ Ihc Icmplale'. will<low Iw .....
s.mc din>crtSions as thc n>Ot"'Iisc. alignmcnt ,,'ltIt thc 10)...
Unei i,,: """y. C:lamp tlte tempb'~ U. 'ltc worl: , ontJ t'UIIl.
Ifyvu
m., .. " fN''''gp rou/<'r. Ihl; b:ut ~
.... y lu rotii 11","00. You "houkl bc: . bIt: 10 lip t"" NUIlr
I<:k couul:h tu han, thc bit cI= of ,1Ie "'...... )'CI Slill t....
tit" muter ,r.ppe<J behn..,n tbc fcn . l1lc fCOC<."llIhco 1'1'>
,i <k cnotl~' oomrolth. 1 t""' ... u lum un tlle ntUlcr, .....
bi. Into ,he wOl"'k. and rou, Ihc monis<:.Al'ter thiII ....
1"'-"" .",ilm uf( tIM: ""'tcr . nd lift i, el"". o( ti><: """'11ll'R:"aSC Il,., bit
ond ..".,... t It,., ~ 1<> mii i
liuk dccpcr. ","'( Of (our qel'" likc . hi$ lII>ould maI*
)"Ou to mut 1ll{Jf1isc OI Ic:lst an lnch Ii=p.

,fOI",

THIRD FEN( E

FQURTH FfNCE

,h"

c:;

a'''''''ton.

CU! down offset gauge


oi c""" mii o( II><: jig, I( 1KCC$!o:OT}; trim thc ofIiK:' gaugc ' o
fi. beI"'<:CR.he . _ end fcnL'eS, ond ...., It tt> po.;;tlon ,1><:
. ,_ _, (ounh arni las! (elia,

5.

T<:>jl Ihe

JIg. Tu do this. on.

picce of \'.. inch pl)'

",00<1 o r h. robo.m to IUSI tlrop in,idc Ihc (elKCll. U""


II'" cllOSCI1 router .nd bit 10 cUI a .hallow monisc in Ihis
te'" """'p , ( 1:) 0"' 1 c ut into ti'" tcmpbtc
)<'1.) ~t.,...u",

,...,.,1<

.-.c:

GIi

tl><: monb:c. 1f it 1, thc cu"",,", din'eru""". roul Ihrough the


tco'pLiue. (urmll!{( tI><: window. On thc OIhcr h,,,,d. If Ihc

A Template-Mortising Sam pler


Tcmpbtcmonising Is . vcry ''<:rNltilc "l"",cm .Thc JF!ICil'
monisil1jl. Icmpl:>l'" )"OU ' ,~ IUSI rad >boul - .nd
lricd , J hopc_ :uc JuSt an ;nlrod"""ion.llH:n: an: otft(r 10
ali<tns in whieh ,,,n'plate.monJ:.ing i,,: .J>,;olutcly 1"" la
' l"l~m . At II,., bcginning of tiris chaplc" [ lIS1cd ... ,-m
lhosc oppliCl"iOns. In ach . llte nIOnlsc "'x>uld be diftictIk
il.1Ot In'pn<Siblc, lo ",,,t withoul a template.
",., Il"",, uf 000..,... has bem <kalt wtl h by thc JI!'O"II
JlKH"tlsinf!, !empLI1<:s. lIul what " boul ,hosc: Olhcr "=
applk-.ot'o" s?
SAWIUCK LEG ASSEMBLY

Slretche.
T"' ough mon.1t

TiP.mplalemonlslng wllh a 'heclbue rotner 1,


possible it)'OU uSe a biSoegu ldt!lg template , With th.
l'O\ll.' tlpped sti th. bit i. elta. of th. wo.k, bra". Ih.
roUt.r's ba agatnst th emplal.~ fences. Switeh on
the roole . thon Iower tho bit into th. wo.k, Th. lenee.
contine tbe rooter. p.eve nling it from eultlng ounid.
th. mon' ''''.
152

Rou!o. Magic

The Deep Through Mortise

SAWIUCK LEe; MOIlTISl Ne; TEM ' I,ATE

oa..anIr.'

'"mugh ..."nl"" ... " Il<: mu,~ ~!iinll ,Il<: al'"


. . - llr:octiIlnI ah,,,,,,. II.. , <:'.""1' OI"'" In whlk. ,Il<:
* - l i 01. mon"", ,110 Ixyond ,Ix meh <li c\" .. lh<'
.... of """'" bilS. The righ' "_.... pl c ....~ uf' <.':In """e"",

Mllcll IlIoek .... ss of


lempl.ote.o Itnglh
of lempl.ott

guidt col~,.

,..""" ..... onch.

,."

"" cample ... ~k<Iown ,..wbu.ck .a"'" I ma<k


..... of,....... ;ofIO.ll>c ul><lapln..l'W' ' ..." " ''' 'C) "",wbuck
... ' . .... , joInctI .". "'",'chcr. ~h pal. ullqt> "''al
...... """"'f'.A ,,:non on ,,,,, ",,,,,cht. pu&N '1lto\IfIh
__
In d .. 1cII;f Ind _ Iock.,d In pI>tt wi.h . "''''''"'"

';-5

""""" or kq. "" ." ""'... In 'h<' t1r. willl!l Si."tJ,1dr. Utti
_~ Sin lIw: ~ ....".., 2" , Incho t/lIdt . h<' .t1rou~1
. . . ... I:q"ond ,Il<: ~ 01 my loI1fII'>I bit..

ar filllna

.IIe ' empb' e ""I,h

klmlk.~1

T,immtd
pOsltloning

. ...

""

"'K'

".".

Morllsing wlndo"," '

f'lI'lU""lng

........ hvth ho:eo. I "'-u .t>Ic 10 do .bo:: monlsc 111c


Wb prOOIo:GI J>cn:, ,,~, II, In Ihlfi"'3 'bo:: .("..

,.. r.o. .... "..,., <lIIIIe "'''''' ' 0 ,he othcr. )'O<l .urn "''''
.. -t< Of ,....1""' ....".."" .cmpb.e . h<' .cmpl3l" Ilkely
"OI br IIIIIalfloN. W1"D. ,...,.. t.a>" '0 do .. mO"VC .bo::

.em-

,... ~ ~ ~ "'31' pIa)~ otd,...,.. "'..,.., moo.ing

'0 .""

. . dlt lOp <li ."" Ikdc


bonom. Af/t:r" ,...,.. """.,
- " lIIIl rcdampN'h<' .cmpb.e urn.bo:: ",1loIc ...""'"
_.0)00011

oomim.. ~

IIII'dc: Ihc" ~ IC1IIpaa, .. .,........" in liIc dnwing


......, iii .tI_ng r~te. I !>iI! otIl and eu. lbo::
....... In .hc <:m ..... 0I1hc tanpb.e stOd-. pM:tt 01 \It.
badt p/)'WOOd. "ilie rnortbc _ _ o:caIcd 10
""'" nil. h-inch bil/)Io.;ndI gW<k bu>hin8 com~.

.".,. .hc ' .... paa'e "'"'" rndy. I I3Id "'" .he cnottu.. on
,., Iq ~. Nal I CUI ..."0 ~ ",*,iooI~
li:d:I 00 6, in.o 'bo:: ctOIch <li clic kp, ll&h' opirut bolii
.... );ow I "'31 ln<Iy. I cm'tml Ihe .cmpLue .....,. ,he

Ctnle, Itm pl.'t (lVe, ~YOIII "nes fOf mortl1t,.nd


tI.mp it 10 , he legs. Then bult t,~ngul.r pOsition!ng
block agllnst Ihe Itgs and fasttn It 10 Ihe tImpii It.
b)ou nd dompcd 1. ,(1 'h<' "'" asoemhly I 110' 6 I""'i-"
.Ionlng bloci< IInnly ~1"'1n." . he k"p . hen d""e ~ . ._~
<I\tulIBh ,"" .cmpb.( in'o ,IIIs bIo!:k. I tllft1Cd the ,,,,,,pI.o'c
0VC1"" .nd '"Kh~ lbo:: liQtKl bIock, ""'Y cardully alignlng
II ... lIh . 1Ie II .... polIllonlng hIock l~n I .rlm""-",, ."" ti""
otr lhe hI<>cb In p",,'kk dnr.mee fOr 'h<' .ou ......
\\"ItI! .1.. plUl1fl" !"OUt(1" Iltto:<.t with Ihe . ppl"'tJ9ri>le bit
.00 II"kk , I.uned rollllng . IM: n","' se. Afkr <'lItll"l
''''''''.'nwcly half...,.,. Ihmugh .ht ....-.rn>bly. r uocbmpcd
ohe tanplate. 1Iohi1\t"d ~ li' thc OIhct 51dc of .hc __ mblr
IIlI"flO'd liIc lqj.......,bIy and ,e m pb.c 0\"1:', an" "-"<Olamp'-'d
the tc:mpto .~ AII1IIy. I romplctnl thc nll>Ml ...
ThIs ;tpproKh """,,', ..-orI! fOr e''''"}" al",""ely dcq> OI
""'""" J'OU m"", l"Od.. l bc: pf'Ojc(.'I: mllSl pt'<:SCl1" <"Ouplc
01 te"'u," """" dw..,..;u C'tUbIc)OlJ to swi.ch .t.. len~ :1
pb.e from onc fxc ' 0 lhe 0100 .00 maim " prop<"1"
aIignmcnt.ArId if II docs.lhis appn>ach ""'Y
)'Ou. ""r.

f:l_.

_.

!il""

A Mortise in the Panel's Face


Any ,imc J'OU '-". n:oomsc .. Ibe fiott 01. pand,)OU Ilo,,,
aiI.mion in ..iI;dI moni!:ing <cnpiau: an bt hmdItt."IlIe
diIlkuIIy, :Il [ _
.. Ibe 0IlbCl <lI1hIo chapkr. iti tIw )OIJ . ._~

""""". pand ia lbel)-pinliiIt; duit!:<K<i to hoId MIlcI


"""ti<itc. Out """'. ""'plate. Ibe pand CUI he
<l<ItI#<I II> .........uxncb onIl Ibe ' cmpWc cbmpnllO II. n.c
tnnpI;Ut controIo .t.. pooItlon :ond lc1!jIIh qI u.. ..-t'-'
My CPmplc ho= Is dtOI <JI "'--cn I ~ b
thc boaI< C-"try Pi,., (lIlklaIc ~ Im).ll", pic Itad
ils fxc raib monlonJ Into u.. ntC ltidQ ( :ond dn\t,..". .........
an~

"" p

....'-8.
,h 'Ollll h mOtll,_ t.llo 10" mo,
. . . ttmp!.lle wlth pOoi.ionin\l blotk. on bo.h face .
T\t IWO bIoc.b .110"," VOU 10 rele,ellCe Ihe nmt edgt~
lllhe ~t fu, PO$ItIon when movlng ..,. .em
. . fnIm """ f.ce oflM usembly 10 Ihe 0I1Ie . Here I
IIM IOUItd u detp AS I un In, o ne....... Hnch'lhltk
III ~ ,.... lempblt design .lIow. mt 10 move il
............ IhoI Issembly. kHp,ng its Ofi.en.a.oon essen
.,. ..-ocNngtd. Then I Uln Ilim Iht whoIt wo,h o"",,,
_ _ ""'" , '''' _ond .idi>!O complele Ihe monlse.

and roiIs b

morti:Ied In.o

ote"""'"

u..

t.ckl qI 'h<' mlo) 'I1ocft ....,.., no

>ti"""

rrom ,op ta boulIm ... in the lypicaI r.,., fnmc. 1,

....,uId Ilo"., Il" j)OO61bIc 10 ...., an ttW: ....- onIl fttodw>d.


rou. Lt.. mon,""" In .he """"", bul I _ pili ofJ from "'..

CHEST OF DRAWEItS JOINEltY DETAIL

.ppro:;ICh by ,hc po6Sibility WI J'd iNd>1:ncm/y _100.


~ muo'ti1o: 100 k>fI3. 10><c0d I """" ,.",."... .....

ci''''' ..........

wouloJ Cf1.>U/1: ,"",cur.lI" oIzI. . """ pbammI


The
I uocd hod .;,,00... in k lor ,"" IM 011\
~.
II
1hNplI,tr. Ikcausc Ihc

,cmpb'"

,1Ii<:t<nc>;o """""

prim<'

diortInn r;ui<k bushin!! :ond '


lI>e
"""'Y 10 ...... I _

''''''pIa'''

>ln;gh'

up lI>e lI>OftWnI

panUd ,o ono: C'dIP< ...,. cd:tat cd!I:c. 1bac I >l1IdoN .


lIrntt 10 lI>e ,cmpblc 10 k>cII~ i, In ",a.ion 10 "'. ~,
thc "",,",pImr.
To ...., thc I,...,pl:no:. I Ioid nul cad! mon ....
....,ncpl<. fi~ , I 5<:ril>ed ~ fro<n md 10'"
~ Ind! r""" thc pand'. [""" c<W.l1>cn I IIWtcd 1lIt.-

Olt"

~~~;~~;'r~::~; I

poInl
()( cad!
ono<tlx.lloid
thc:
ck:oc
b..uC'd.pnsI
'hc .fro<M
,cmplatc ~ ......"..hc Io)'ow. ttnt",.;ng il. by tf<'.1

0..1_' runM'

thc: Im>pIole ....:urdy, ~ ohc rotIlCr on Ihc Icmpbct .tit


,toc guidc); <:OIbr in 'hc 'pp""",""e ~ w~'".
tOO,n . pI..yd 'hc hoit, and . . . - thc ""'.

'"

Template-Mortising Frame Members

.OI

EO
:E

'MI. you un USt I lemplolt 10 _1 mortl'16 ,n lhe


" ' 1 of IUIe. (anei ,,"I.) lor fK~ hme. /Ind door
fiii ...... TvPICII/lV. 1 Clell ~ KlltWKI 10 Ilie templ<ltt par
;alltllo lI\e mon ..,ng IIoC Tht l~plaCt an llIen t>. ,ti
on the wor~plt'(t Wlth U~ de.1 IIQItt ~;"n.t Ilie work
poKt fa<t. Clamp. a"'-lppI~.
lhe lempi,ll! 10
tht ,,"ori<. Tllen VOI! fO<Il tht morlIH.
l/1.111g il Illon Itmpl,nt wlch il clNl WOI'ks wellin Ihl~
1"....1I0n. bulthrel,). 101 01 bu.yw-ork In (lamp'ng Ilie
work Ind then poI<UO'''''9 1h4r templilt on l' Ind
Clamptl'lll Iha . To /I'IO\Ie Ilie lempljol~ 10. new lpol, VOI!
.. , ....11.,. a1so
10 ~'toon Ille wor1t In rhe VlH. Su, "
VOU un vS4! Ihd,tf IfmpLolf lIock. lOI.,. ~,nch Of mort.
VOU an ~uc:t Ihf bu'l"'"or~ Ind ..~ Ilmt.
Wl\lIl VOU do 1, mah the Itmpl;or. I;o'gt enough 10
elamp 10 I wo",!>tneh. w,lh IM mon .. ,ng slOi 300 lhe
eltal clmiltvt.ed off Iht btnel!. TII!n VOU mt"IV haV1!
10 pUlh Ilie work 19l1lnlllht ciUI.nd Iht bonom Of
lhe -mpllle..oo lhen <llmp II 10 the <ltat. To 'OUl il
...eoo<lOl Ih'rd mllfl'''' In Iht ume plect , you llmplV
hilVf; 10 _
IlIt wo,k. not lke work QnrJ Ihe l,mplilCt.
Al; I 11111 !>t~. chl. (. tht Ion of rotIl!,mon .. ,njl wo.k
lhol an be dOl\e efficlentl.,. uSlng On' of 'ht ocher mo',
Ils,"O Jlgl,
BUl. "illlanl of lhll wOlk. il "",ilnl ,n which IMi:
ItmplalfmonlSlng ;approaeh p<ov~ Its ..onh. c;amt up
in bUlkhng Iht ,tp.odUC:llon chtsl of d'lw"s b'ltfly
dtsWbtd vndt' 'A MO'III! In cht Pilnelj; Filct- on Plge
1 5 3 TIlt d wt. fUnn ... Wef' mOr1ls~ InlO IM flce
.alls and tht CUt', back boI..d~. ThtH mOl'llltl ..,,,,~ inel! squart.

_v''''9

c..ve

1 54

IlOUltf

M~lc

NOw If IIwl med 10 .....1them u .. ng the 1I0I0"'' ' 11


JIO on ~e 114.1 eltlle. wOIJld have h.ad 10 ser~e ro.
~,nch-dla_ref ,o .. nd mort'ltl or I would llave ~ ~
fO<IC chem u .. ng IWO Iltffe~nl edge'oul,", !wngl. Tr>lt
.bolll bu.ywo,k!
lJul "nee I UI~ IMI""! w.ndow in ll\eJO,nery_
1'11-1. mi,", for Ihe)Ob Ind I Y..jnch bll. lhe mortiSt.
c... n~ OIJClqUllt w,lh .adu,sed (ome" . ArId by
SCftW'ng' cleal w.lh 1 pOs'lIonlng IIOp unde. Ilie r.....
plai!. I wu ablt 10 Illp lhOI! ralllin plllct. f'O\IliM
moMlle. Ind ef!\(jenlly (hlnge OVl:'f 10 the ne~1 r.ul,

n" t"mplat" Un hold ,h. wOrlrp/ec:" for mor


IISing If It ls st ... rdy tllOlt\lh, Altaeh 1 cleat 'o Ilie
botlom of Ilie I.mpl.ole 10 peKlllon IM wor1r:pleu b
morti.lng. Clamp Ilie work to Ilie Clul. as sl\own.
IMn rotit tht mo<tlK.

jOINERY UMPLATE
Use ~

,emplilt guldt Ind

~.

stra lght bit.

".

----,,---""1

rlr"--F"='~---F"~'----~'F"~'----i'='~"---c~~'H'~--l1

,.:=1"""""'
......\:"... .......... . ............. ........... ... ..... ..........:. . . n

,on .......

6 ...... ...0 .. ....... 6

..........

0.

".

'----1'--

- - - - - - - '.J

SC:rt w iI"'" )( I y,. CIf'IIIO tlte undtBidt! oflM !t",plale.

~ Iii<- ...1Up

ro.. ,"" noa 111<>/1""' .....

oImpk'

fIociro!Ithc d a",p". 6Ildiflllll.., tcmpb\!: lu IIM: ncu

mor-

.. Iocolk>n. II", .. ...:Wnph'l( It. lire",,*, "'" doi _


!O "'" >lois. 1Il<' "",nlses "'..,.., .11 r.",.lld u> 1""

"'*'

"'s front cdgc.

A Difficuh-to-Poslion Mortise
Iloutinr; 1 moniK In a round po5t. 11110 Ilie: arris 01 a &qUln:c
biUn. ""o atI)' pon 011 >h:&pnl pktt. CUI hc voIng. U..,
ICmpbtr hoth Il> ouppon lhc .......... "'I""1'r
moniK
aI1d 10 control Ilie: widlh lfld k'tlgIh o( tbe mon~
WhaI }'OII m .... do In ,"""" lIIkuation>' b tu bulld v
bloci< or Olt..... cnok to
ttlr wor1rplca: and ttlrn
oon.trua <:<Jmplc""",wy ouppon br thc tcmplatc

to.""

"'*'

... ...niSH III lhe f ..... of il piine! ..1,11" Itm..... Iim. tlle temp ... 't is c~mped 10 ,"" sidt! of 1""
dIlSI of d,"wers. W!lh " d""1 d.lm~ 10 . "" bonom
''Il10 1.....,1.11.. , ifs
10 slide Ilie t.,mplatt . 1oftG

ei,.,.

m. 'ene..

lIt~e from mo" i~ 10 monl~.


~ !hot aii .. il! boo tlte U rne di.tanc ..

.. f.

' , om tlte

........,\ tdge. L1ning up thot .101. for tlwe Ih, ~ dtf


monJus ",,"k... i, n.~r 10 raul thom In tit ..
Inl pIoc.. mei usier illso 10 rOtII Itle mon ise

Mortls lng a turnlngls a t . mplat. Job. Here,


turneei leg Is cllmped betwttn twO m lps 01 plywood
In , vise. The mortis Ing templ". 10 allgned ove. ,he
monioe lout lon, then lltUMd to the plywood o" lps
with drywall screw s.

Templ:.lIeMo<tlSlftg

I55

Custom Router
Table Top
II must be " Olt. strong. a nd stU6l,
must both withstand OI .. d da",...
vlbr.lIIio n, a nd must hau a ~
tough , s lidr. surface. He re's hOll.
nuoke the idul 'ouler uble"",

-....
\II

... T:

{!
~

~"

lablctop IS ,tIc d1n<:c f\oot

(>l thc """ .......n"n'a1

perfum"" an do a <lao OrI

madc:, 'hcy

an::

n.., and thcy "'" tn.o<>IUb/f pncnI

"'hr 00

",,"".

nrlh woukI ,.,., I>uy ".... "'-.. po.


maI<c J"lU' '""" pc:JlIOfW. ~ UbInop lot
moncy! It II; not dlfflcult. Il J"lU ClIII ~ ""'"
l..,.ma. J"lU ClIII .... kc a bmlnal~ """CI"!>bIr
(Comc "" _ , an:: }'OU a W'(ltI(Iovort<n- ar a ("OIk(oor

""Of1<l~

runlctl 10<>1:11)

cilhcr au>:",,,. an" e'vy .,}"Ie In "",,,-''''" , foor own I"'f'


sorW <hncc wiU bc mOOl fulflUing on a pbtIorm of )'OUl"
"""" """'ItJon .Oh,)"OU """ rur., tajlC' .and In,.,.11 you cv.:<
...... )'Qu'U bc h:>PVf cnough

Whm J"lU makc)'OUt '""" t>bktop. J"lU 00n~""


!iClllc ilr lhe ~~tl"H>t~<>(-MOF w,c,. V.... _
it
U". 10 ft. hcnn- In .shop t!w..,
ro.. spaa . '00 ClIII makc II: bIjqIcr, "'"ni bIa mooop
xcomnlOtb.c ""'"' ./wI !lingk: """'n-. V"", OII . .
Ihld<cr or Ihin"CI". '00.
Wtw.n J"lU nw<~ your ""'" I:>bI,,"op. ,.,.. <WI . .
choIa ci ,dl!.lI1gs- pbsI k: l'mokIln~)'O. bul .....
bmlruuc . ... 0i0I1oJ.WU<>IJ ~If" In _~
c<J><l6C<.I ~)'k. ,"ou nil .rlm ,. wt.h <Wc ar ..~'" ac; f

wOrbhop. A [liftn!

".bIe

any :;oM of fIoor. Bul an , $l1'Oflg.


Jlbltonn.
wllh , ", ""OIh lm<l frictionlcss ,;urbec.)'OU can ..,.~tIy
$o wh ..'s your plns,",,? 00 )'OU "",rfonn .."OOdbollet? Or .rc )'Ou I"SI , Jownhomc: (kJsi!<:'t' I'ot

Rut

try " swf:ltt """,ooHallorNl 10 your XI. I( )"011

,,'211' il Iust rigii you h,,,..,!O bulld it )'0"..."'1. 1l>cn )'Ou'll


h:!,.., " Wllq ..... IlObIc1op. 0<1C tiut
bc p"rduscd, noi aL

"""'log.

(.';ln"

(rom any
1'11" indu.")' . n nd.rd for" roule. t.bl~ IOp >ttm. 10
hc " I Yo-Inch~hlck X U;nchwldc X 32III"h.11)I11\ "'p.
Sizcd 10 get oi,; rrom a ~ X H .hcct. Mcdlun"'Jcn.lly fU,c,
1:>0.>.... (MI>F) co", ",I.h p"'stlc l.mll1>le OII bolh ol<k .
011)' ,"OI"C. /lOt

Tougt> poIr~. h~l~n~ l'moldlnll wlllnll .he lOt>. " .... lIahk
" ',Ih OI" ","hoUI moun"nll p'>te "pcnlnll an"
ac ,.;,MU' a mi ., 10. 111",", ro",.,r I.ble 11'"' .rc ...dl

,..It"

'"

llul

110<"""''''' .....

"""'. bubinp.
"'hen )"OU m:okc f'l'U' """11 ul>klop. ,.,.. OII iim
coIot ot p,"""rn oItan,Uulc OII 1. J"lU ..-an. IIbck! \'ilO
IL. 1\'''1001''''' ,"O" JIOIlI. Gr>nllCP 1'b.oIf.1l\Jod1
~o"

..... "'1 "ou buy

h.)'OU.f1fIIr It.

The Custom Tabletop

1',)"",.,.,.1".

"'" cii' ...... lOr a (!iOOd.~"U>lOm 1'OtII........1* 'op. 1,


_ Ilo fbI. OI""'JI. :aneI .;tabI.,. 1, mUSI both ..itJuo:ond lI>d
-.,ea ~ion..l, III .........,"" a h.>.nI.lOU8h, 5tid; ~.
lk ....,.. in ..1Uch .."OOd .."Ori: ..... fuIfilI lhQc cii' ......
~ '"""-l "'..,.. "'" )nD. Ibd ).... bttn lOIlowo'in!I _
0lIlUaI pcrlodIc:;Ih ' O .... I S ynrs ~"". 1"OU .."UUld .....,..,

....... for

~ bcnrtIlO(I uni .... mudl ~kc

>hcct produr"I COIllf"*d I'f1'l"'I1Iy o( _.....". an<! gI ..... h ha>


"" Pol wu;:t..-.:.,;o II bcb
Mfm8lh. II ' m>de In
'"2rY!J" o( p;ratb Ibr > '"2rY!J" of putpO<!($. b<c Il ...
common 1OIIIIIln1~ 6gor ~ kiId1cn """'..
1'tJ... ......t; In my book. b "'" ldnI "",,*,,"10. Ila ..... It>
~ >'CtItttS ""'" lIf"In dirt-aion ;Ind Jlm>glh. ;Ind
bea...., dono:: ~ ........... in"'~ p/ywuo<l .... IV<"~1
Mfm8lh lhal 'hc othtt ~ .,,00. """.,. Thc "'" .>boncornintI oIp1ywood b tha' II !5n ', ....."ll)"S pnfectI). fbt .You <:an
compmW<: 6gor lhis, hoo>'t\T 1I you lIfu<: up 5UbsIr.<c fru'"
IWO picca 01 thc pIywoot.l. You wlU probahIy "" thi>.>lncc In
I~ you'! "".,,1 a lahletop .. !oM I Inch .hkk.

lhc

.......Yop Ilouttt"bbk: an ~ 203 TJ"(>icaIIy. lI"d ~ ~


.... ooidcd pIj ..."OOd box .... a >WMI ..ith .non Iegt. li
~ b.nT a '..mch p/y1o"OOd l2"""OP. Oflen. "'" mu, ....
...... ~ from "'" tablctop_yuu'd rout fNQ5 in
.. pIywaocl. ....,""" \. OI" 'II Inch 01 nw.ml (rom " 'hlch
!"Id ltanI ~ mu ...... Or )"(N'd eu, a hoIc in .hc p/)...."OOd.
tQIIICf rrom a pk(:~ 0I1unIb<><ttd ..... ith whlch
!"I _-.mI.hc et"g-., tal*.op (Thc ,~mpercd Iunlbo;tnl
"'*1 nWc!lx.surtKc $lkkcr ' ..... n pl.:tin plp'"OO(I.)
AI _
point. a fru,;:;.ol ..'<I()d"I\'I;>I1c"r modifM;d a
-.p.trduonl mc..p a, tii<: IocaIlumhcryanl.tk Clplurnl
.. lII<:kno ll1d duT.obiIi'y o( pWIic I.:tminalc tor his ""'Ia
"'IOP "ilhouI ......1nfc 'o do ""y Imltl:.llC .....orl<.
loIoore ~d)". .....,.,....,wt.;,.,r:s 1"".., bttn appl)ing pb>tIc
_
tu bolII >i<b o( a pIy .."OOd. panlclrboard. or MOP
cIluing o hok in i, ond 5U!ipCndin,; Ihc. lOUleJ
_, -..mInJI pb'~ o( ">Cf)tic. po/).CItbQfwc:. "" ~....,.. pht-

lin...,. "'"

"nit

""""'.lhcn

"' ....~

In ~ "" ~ ... blelop. 'hc sbop<n;Iodc CUSlOln


onc ntttb 'Q " " " ..ilh "'" RWntm.. I, m_
!It _
01 faltIy ro.nmon~ m;lImab. 01"lOI II"" an hc
poodInod '" omaU "",."" ...-..- AmI<ri<:;o ond , ...... an hc
0\IIttd In "'" I)pIcoIllonw; ,,"<>Oda~ ohop.
SUn ..illI "'" tlni.hcd ourfao..., .1l"c...., """..,.. ~~. from
. . wood lnd wnnd ..i,h ~ IIIm flnl'" ""...., "",,"COl :;n\l3)'
... ~ ,,hidl. thou!Ih l\2nI """ 5tid;. is ntlht"r
_ _ dtnbk. \\1lh "'" """,""'rdaI ncqxiooo......,....,
_
""3)' fiom
as wcll. I'\a.U lami~ KCm!i 10
..". liI<:Ic <:rlI<:r\II. II" h.>.ro :and duroble "lI1d ~ .. Is
lfJIoI* twf),.-t.rn.. It", roIIy t25Y ro 'III'OCI<.
TIIm JOII ,hlnl< abou! " 'hal mu..l lIn<krlk plastic
-"C 1bc ~ an ~ con,;tnICln! 01 ,tu-.:c diff~,
~ IlhInlt

",1.

'"'*

Keeping the Top Flat


ti"", llWly tllt>C1I 1Ilt"" )"U ""J'M'rlcncc<llhb al IM lumbtt,.-ud! ~Uu puii "'" 1"1> oIlCCI rAH" the S1Xk 01 pIy"t.OUtl ....
p;>nidd>cunl. n,,, apoo;cd
t.... pkkcd lip n>Qi;t.....,
from 'hc 0 l"'n .... ",hll<" ,,,," 0I1t .... f.ocr. ,,""Ing bttn ,In ...
:tIly !iC:t1c.J ' jpln,;t 'hc .hce' brnc_,h haJ ,;tO)"'" ~ dry.
1, Ihis shccl tb\1 Th<><W! .." 'hln.l< oIshcct lIOQdIl :LI bcing
fim. ,,c aU know from expcricntt 'h<y atn1~. Onc faa !FI>
damp. ,1Ie nt/Jc1" "'l}"I< drr Thc shcct aops.
HUl you """". I'lAT IIbIr<op. lI"", 'o lIt' il! Stan wllh
a tb, !ohcct, oI CO\U1C, 1)On'1 xapl that bo-.,d .ohcd. Thcn
)'OU lIt' 1"," "",.criaI Imo )'IJO" !hop and jIve ,. dayo ....
""""" <O .celi"".. " ' o "'" !hop', ",mpcn' UI"!: and humldky
~ ......tding II Whcn you lamln:u" """ tayrn.. aIwa)"S
oricn' an)' Qo1\.... ng in. ".,., bointI; al""" b)w ..il coun'era<:lUw 0("", .......... .... ~ you ..ilh ....., Pb/Inop.,.,..,. _ _
Thrn 2pp1y plutI<: laminal" \0 IIOTI' ,;.io:s 01 'hil! .,.,..,.
and ..... an)' opmcd edsa o( 1"," .,.".,. Ir JOII apply l:Ifni.
tI2l<: 10 OI"IC llIido: o( pIywotwJ .... ponldc:boonl .... "'IOn M[)f.
YOU ,.,.., !CI1lng il lip 6gor a......-p "I""M I2miIulnl ..... wW IU)'
dry. but Ihc unbmlnalcd ...... an pic. up moioI......,. 1bc
pmclll; OUl o( ~ Tbe tbnIpn 5kIc ..iU npand. 'bc ~

f...,,,

1'.

mcl'"

"""...
JIl)II

1IbmJo.rd) b tp><>d .,.,.., ""'I~

.. Dmot. 1l iJ rrIIIlk lip

o( '"<'r)' fine

panido. II ..

e"

...-~
ID
OI

'"Cf)"

.......... ..,.,. n.'.!IuI.;" ...,. op"'*"<:':. Illsn', a rtMIiIy

"""'*. biR:h pIt"W<)Od. 1I you 11:1,..,

aaft!' \Il h. 1I you IIk~


Hul bm ....IC bolb;l(lco 'o "",Intaln I~ fbt
MI! ob:c "'" ~ llodOf: >Pfllt~ nIjjr-ban<li4 To

..... '* II

_
" ' . tptOd \hin COOl o( ...hll~ .... ydl<Jw SI"" ......" tii<:
...... In II dryThrn)"" <:an !li"" O<lllle nIt!e-bond!ng..
1la,*,"""",n:I II!; ptObobly oby a > .,.,.., for YOU'
1IiIlIop WhIk I0Il'" ...,.....". .."OOd .."Ottc,,", " ,.:.,,,,,",,,,,, pan ~
ddooMI brthlt ....,.OIhcnccoolrn<l.1I:I1 II dblnRW"'" rrom
........ iomo oi> IOl.II<:'. My I"JCSS Is '11:11 a ~hcmo,h """eJ
-.1. d1r:lp panIdd>o<Ittl n.. k<" 1"""" partncr:shlp. For an
atianakJor tal* e'l'~PIX"tI " 'Ith a n,ttHil.OlRIIIIn; parti<kboord II pn>I>:>hIy ob)\ "',.. h... 'il) t.bnIl;tbk ";Ih bII
l*I; 1) 10 pIj...ood . .... )00 n.. y mvw. p;>n1c1cboanJ ...

Th .. uobl .. lop "0... Un blINd<! of

H"W,~I

dltfertn'

ml,elil.ls. \'ou un U~ MOf (Io,!. ~nlc~d (eVI/oU"


r"Pl. pIvwood (n"r~r bar/am). OI" IUIIK lirdt plywood
(&oI/om).

( "$1om Ro"'tI Tlble

T~

' S7

ANATOMY OF AROUTIEIl<_T:M:":T:O:':::::"",-------~'Squi'e the SubSt'ite


ind glut llardwood
edge'b;ondJ"II to It.

PliSlIe

~mlnite

Plutlc limlnitt 1. banat!!


to in tdgtb.ndtd cor ..
kvtH"m tlle lim.nilt.

Plywood ~rs ire


bondf:d w.th yellow gluI.

W X IW hl.rdwood

f'OO'' '

pmel will ClIp. In (omou . )'UUI'


"iU "'" in" subIk
Ite",,', wlta, 'O do 'o ~ n , thu,

Cultlng Ust
.. n
COft pll..

t:d9t

bilnds

Edgt bilnds
TOI) su,I;oee

8onom SUrfi"

Qty.

,
,

Dimensions

.sallC~ r.

Material

"'" x 21"'" X 36" Sirell plywood J


II" x 114" X J7W
H.rdwood
II" XI""

x 2Sa"

Itlrdwood

lf," X26"X38" PI.sUc: limlnitt


lf," X 26" X 38"

hck,r

.-...

1.1mJ""1' boch llK:o 10 ctnlc: a babnccd JW>C'I'hat ...


SI"t' 11;11.

. S<2J Ihc n.IfI!::J "" _1. If JOII Ippty Iwdwood ~


1wI<lin&>nl1t
~-UUPIe '"
nnWl
Pain! OI" oc"""',"," .....1 Ilie. ~ o( Iht moundns"f'btt

""'h,,

<ni" '"

Sl<ip tho: miler pup: oIot in II", ~"". 1,. UI'IIO


oary, and il brtacho Iht .......

My Ideal Ta.blelop
My ideal W>lctop Iw; " \ . 10 \ ~tHhk..k "Ip"ood """
"';'h pb>tic IamlfUlt on bocI> ><.b. Thc <li"""""""", 01" il.

..

oo:hcr rtwIlbe ~att: pn:tty much Itn:kvan'. I,


bt
!InDII mouN! (J.3y. 16 X 20 ~) 10 lIe. for "tnd,,"P
mu'er .. bie, or luAc ~ (Ay. jO X 48 Inchc!;) 10 ......
lbo :o.; a ... bIe .,,' ""tkcd (00" :as " mul.i"""CI" ,,'Ort:sutioolJ,.
for :any mnfOjtlllll.IIon, "'" IIUItIUbi uscd and "'" nlClhod d
constructlon n:maln Iht SUl"'.

""'"3'1> anii 1, hu rilIkli'y. A 1 'h-inclHhlct

~
~

:s

1 lik., Ihc "Iywood

o::

CUR:

bIooousc" it tw .. """"'"

,,""''0(1(\

,ablc1op dot!on' l n<I ~ f ..n"",,'<In.- 10 .. Ufcn 1"'1 ""On'1 ""Mr "",Ier lal*s tend 10 bc auxlliary WO<kbcn<:hd.!oO theoo:

c:oruider..,ions h.", .."nlllonc~


Thc ,ahk1op

ed!taI ""n "" Anb;htd

~crol ~ l\:III

.""I)"Inst ,!It bml......

an """,fUll)' "'lu. '" ,1", Nil<"> hef"",


lhen
laml ... ,,, 'o 'he ntp: ..... "'..:II ....

a",,1)'

Tht tibletop Itdgu Un !le finished severa! WIYS.


You Cln ci'etul .... sqUi"e tht rOI) befOfe il)l)lyl"ll tlle
~mhw.tt. thtn ~mhw.tt lho flIgu iS wtll '"' tllt IMe.
(,,,,,. Vou un "ppl,!, the !;oml""tt. then OIuI on ~ to

1lnchlhlck . . . .bind'ng cut Iram miple, oak, or


ottltr duriblt llard~ (ume". o. you cln f:dgt
bilnd tht plywood ind 'lin tht ~mIRlU' out to IlIt
edge 01 thh nsem~ COft (IIc>rrom).

t""

b<:u.. Thilil
known a5 '1Ie. " 1It1f~" In ""n", w:I.}1>, '''III .. ,1><: ~
<ahklop ' o ""11d. A' Ilie. oppooJ,c a,,,,,,,,,,, )"OU <"ati ....
exf'O'Cd edgc.h:II\iling. Sq ... rr IIM: ~ ..,.. """.,. ~
1" 1"" 10f' .nd ""nom.TIt"n gI.... on Y.. 10 "'nctHhidt ~
bandin" cu, rrom .....
oak, OI" othcr dut:i\bIe: ~
10 rom""',, , hl .... hk1op. )"OU m.... flul,h.,nm ,!It ~
banding ;ulIl
a nnW. 10 k. The ,"IRI optlo.. It _
tdllC"hlnd Iht con: ~ af'l'llint thc bmj_c. ,o proclua:

"It.

.",,1)'

... mk:on<:cak<J ~n<J;ng. 'Il"hm """


i. OU. ~ IIM: ~"II.
lbI><rim abo bruln.l.~ . abon /"OUl a I:lcvo:I ......-d abo c<lfID.
Il0l.01 roursoe. IppIy. IInbh 10 Ih<- rxJlOli'"d .........J
1bo l:a!I optiotI b my b>Vril~ Hc",'s how 10 80 >boul
WIIqa: """ l2bInop.lbt o..\lna lAt """"" wtd. "",,'d
. . . booId <hr <abIctop r..ar Ih" t~"di"llltou.~r TJI*
""" 212. ~ <hr dimcn>lom 10 >Ui. your CUMom
lIbIc10p ..11h

lJIPIr ltIc Wn''''''c. run

......... ..,. 011

mo=.\.

iNDn, .hc III"" and 11'" .hc ''''0 pic:CC$ mlly ~'tXk
l"II"thcr. Si""", ycl1uw 81"" >cI> ul' P"'''Y fa ... don . dilly.
eblly Align thc cdlt(S.
la4 )"OU apply .h<: ct.mps :UunH one cdjjc dU"1lII gI..,.,.
UP h<: 0Ih<: .. ",!II ,cnd.o opcn up E\..,n.w.Uy. '1u: cbn1p!1
... 111 cklllC .hc lI"p5.and .Iu: bowinI; wiU ~p..,"" .hc
,."....., .he cntl..: 5UtUcc .l"hc gluc bond "'UI tic .ha, mucb
l>c11<:r """".11
lct , he si"" Cun:
"';Ih th<- cbmpo in pbl""r

p""""'"

"'"CI"Tli#l'

Building the Tabletop


fII<t 'fi' tIM: ,,~cp dI=t""'" ro.. buiI<l!n3 ubkrop klr
.,dtha:: """... W>Ics In .his book OI" r..ar ""t' th:a. )"" C1"C2I'"
1oIow"!tIe 51(f' '0 ber, ... tohlcaop ' h:m )'OU an buy

'*"""

1. CUlllle b)en . CUI ",. ...


01 pI)...."'1d, p.anlda:boIrd. Of .\lI>F 'o ,.;re. I JtI:1'ICT.lDr """ bln:h p/).,.-ood
_ _ in &cea are >IIK>fIlhcr lIwI lIUndanI fir pIy'OOd.
iIrr ....... &ce 01 pic coukl mii up "" u." """'" ....,.
II. lxIth bea 01 C3dI pic 5IIookl h<- .. ""lOOIh and
tthr-bft., p<>!->ibk .
.uoo. .h<- pIc:I ro.. <:n>Wntml .nd r.,., 'fnaliry. l lk:
...-.1 bcr o( exh pic-~1'\I1~"" of Ib '1""llty_ bC"
'0 .h<: InsioJc ... h"n )'OU I!luc .hC1ll
~"'" Is ho"')"0\1 em.c a n.. . blLanctd tup. Irbolh

orkn.""

)I"<C"'" n.u .hm oncflt thc best I\IC<.$ OI"

2. Gluc up the 5ub!i1rale. Sp..,ad )..,Ilo ... I!luc ""


, bot)'OO...., .. lcctcd ... 1Ie ....11ng fxd Get on I 'hln
bot IIIoroa.agh co:>.inll. >v.,idin& dry
Whcn both ... , .
im .... "'adf. !.ar ...,., C2J"tfully "op 'hc <Mhcr. SIiek ,he
... poo an">U!Ml on 'hc bot'om plrtt fu... 1I11le 10

'pOb.

Is rour plywood .Ullhllr bowedl Don1 WOtry.


OrIen' ,he ~nel .... lth .ht erowned faet. In . A~ you
~pplV Ihe elamp. Ilong one edOe du.lno Olueup. 'M
olhus wlll ttnd 100Ptn up. Eventuall .... the cilmp. wlll
elose Ihe giP'. alld Ihe bowlng ... 111 spreael ,1Ie p.n
,ule ~c,o .. IIIt tntl .. sutflte . The glue bond ... ,11 bot
,h.. much blnel owrall. and Ihe bowing of Otte shut
... 111 tounte, atl Ihal of IM o,ht . Inving rou with a
labletop eo ...

fi.,

3. PrcP""" ).,.u NF"bandUI8 ilOC:k. I. . . .kl hc


a hard . .. n4tht-gr.dnct.l hanhrood Mkc mapk. :Wa. 00. or
I);n;h.. l' shouId bc ..idc: CfIOllSh .0 .. and bit proud o( 'hc
pIywood CfIfto <MI boo:h !Ii<kf.. ond >bou. }. in<:h .hiook. Milae
It about 1'" Inchni for.1Ie 1 ~h c""'.

'"

4. Apply thc cdgc.ban dlng. Item",,,, .he e!om"" III


rrom <hor cO"'.Trim 1. '0 moke 1, "'lu:a.., .nd 10 clC21I ond

.nac: .h<: cdgal.

Cu he ~din1! .0 n. mi.t:tIllj! j. a, u." rom"",.


CI"" It In plicc Ik ... re 10;> aUgn oda pIttc ofu." ~
!iO 1. SI.:mds proud of .hc CfIfto " " boo:h lop ond bot .,..,.
~ ' ..... ~d IIlu. OII Ih. Ilbl elop
,... 0'It' 1he surfate. Ihen sp .... ad

Ilrer I dtibble
II ound ... I,h a
.. uble .Ippln~ horn ,he serip bln. Tht INktsh,h
~I~. I goo<l jotI of thlnly e~ling lhe tnli .... Sut
Ioet. -'rid when ' hl job's dO"". 'he ""tip IJOH bKk In
.lCllp blll . A roIlet OI brush .p'ud. gl..e .. eli. bUl
-tunv 11 OUl when 'he job 1. done i nlly """ou.

S. Flush 1rim tht edlJ""bandl,.. Afan u." si"" ha.


drk<l ond )""'''' """"",-.,d Ihc dam",. """ """" tnm thc
~ n u>b ""irh thc ,op ond bot."", surbccs of thc
1IUbot"'C.M ,,'iIh "'"n)" UIoI: In WOQd",on:l"lI 1Ie", .." ""'.
croi ..... ,., da .bis.
If )"OU M~ ~gIt'''''righl tou.er :111(1 ~ nle:lns 10
0u"'1y damp <hor I1b1<1op Of! cdJlC' . )"OU Cln """ flu......

'o

Custom Rouler Table TOI)

1 59

,-':;~~~::-~"'~;~~:':~:';:':":'~'E:;~:

aamp 'hc t

TcmpLll...OII ~6
lem bit In Ihc ....,Ie<. anii .... thc
sh. nkmoun,ed bearinS
p",w sqlW'rly In,,, ,"" w.Sl c. l"hc~ '
, IlIc ca""". 10 ~""""'. !O nibblc al II
p;t.SOC5 al thc rout~r.
wilh thc ,cmpLt'c. "'" bi' ... 111 Slor

Jlap

Wllen .. slng a flllslltrlmml"ill bit 10 Irlm ~n


edge"blndlng. yO\O I\ffd a steady hand. It\ IIf,SlIf vou
Un ctamp Ilie lablelop on edge HI thil g'avlty l\elps
vou hold Ilie IOUle. on Ilie na'IOW edg Tak. v .....
.hallow CUIO. f ... dlng In Ihe co"",1 direction . Any Je.k
o' wobble of Ilie .oute. wllileleg",ph InlO Ilie rOUltd
su.flce In Ihe form of 1 90uge Ihal yOu'lI lIf, .....d
p,.., ..ed 10 ,.mOvt Or concul.

100.

Itc:pcJt 11016 pRlCCS5 al c:teh ~"O, ~~,., . . . .


tcmpLl'c.
, ..... ..w "",.., waSlc 10 ",,,,,,,c. al a>u..,.. (uru..
Il:".., 3 paucm bit ..ith 1 hlr>dJ.1ons cuttinll
this ,,~ cit. using "'" just_'ed cdF5
~
,.,.."

bIt ~

100',,,,, .,

belrifIS.
,hc lamln:atr :aRd

to,fuU '
,"" i"..,....,tsibk

)"OU "";11 Irtm "'" ~

eli""

'toi'"
"'~.~,.~=~'~""~""'~
. ~"~a~,.~....
~~"",~~_~

You <.":an

.nyway.lts
wi'" casbI<k

procc ... UM'


,""'" 10
It"s "",,cr.l.

6,..,

'

l:mIiru,e

Un'Iin;I,c

OUt

miI" an:

5afely~!

.-.
...
(1

...

.~
!!l

Contxt n'en, .. WMI h<>ntb II>c: Ltml ..... c 1<l


......tc. 1", . ""I'hb'''''''ed robt><1'
,oo."~,,
I~ m:III"i pIer anr.l Icot"c 1" ,irI' Whcn )'OU
dric<! canmt Ofl IIM: I:Imi".,e tO Ihc
$Ub!tf:l'c. tlKy
m<1'il: be :Kt."UrAlcly olljtnt'11
li tiin ""
toudt IIM: ... h!tif:llc

"""',,."

Wilh <1 n ... hCrlmm lng "lIIeplate , edoeb.ind


ttlmmlnols Ins dlcey bUl laku mOfe tlme. The
lablelOP nOI only can. bUl musI . UI nIl on Ihe
wo.kbench. as shown , Wilh mort,SI,,!! o' bonOM"
clunlnO b,l In thl IOUltr Ind Ih. bluptale nal on
Ihe subSl.lle, wo.k bltk Ind fOflh IlonOlhe
blndlno, nlbbllng II flush .
Irtmmlr\jj bit Iu do It"" job quld<ly, '"" 1Iho..... In "'" ~o .,
tap 1",1 ........ ca" dan'l' ,I>c: t:lbklop nil.anii hokI "'" rotJtn-

horiroolt.lty ti) 00 Ihls. bUl I thlnk II>c: 6keHhood el


.."IJbbk: I"",'U MOUljlC I lie Wsc Inc~ dnma'ic:rJIy.
TI"" OI"'" obvIotIs opti .... .. 10 UM Ihe flusb-uimming
"""'plale anii. rnonlsl"i or boIlomd""nlng bil. WlIII ,III.
",""up,)"OU C2n. '"" obown In ,"" photo at bOtlom Icft, OO tII<:
job ..ith ,"" tabI<1op """ln8 fLI, an ,I>c: won:bench. TlIc
~ elll>c: I'QUICf )'OU I\:l..., II Lcss el. facto 100. Pl.n, tor
tl>c: F1 ......Trimmlnl 1b>cp11\c: an: 1Iho""I> Qn p>1<= 1 III.

6. (opt iona l) Round lhe tablelop Com"'l"!! .


Rounllinllll>c: comc.s eI)'OUI" fOUla" t:J.bIc: tap .....
)'IJu
_
p2lnIuIl!rui\:4 Vou doI'\ 'l rtftd 10 !li) thls. litrI 1f)'UU
~ 10. IhlIlll ,I>c: U- 10 00 It.

$"'''

160

louttr """gle

he""'"

''''' 'WO

Sprnd thc~, Ofl


IWC m:ako I lI"""l trowcf.Ukc

pift.,.;:::,:;:::

~.

but

Backer
YOl.l (In "'VI! IOITII ~ " you ce""nl
.... Ckf ... 10 Iht bt>!tOM,w;It of 1.... I
is umi .... te w,thout tht colO< I
dtslgned
1
1,
counlt.s
knr/q.. pe:. bl"OlOn Ind
rt<,IULt. lam,nillt. blrcke. nonf,htltSS .... $ 1"" ~
molslu.e.eSlslilnt q\lilllllu, ........... thf U _
Ind 1. bande!! .... IIh 1.... ",me cont""t temenI.
An .dvlnlig.e baeke. l\i.s oye'
I
.. n1 l i sllppe:ry. C",mps Ciln IItl
(In II. Thuli.1 dilmpeddo",n leMe Is 1iOIl>eWI!.lt
mo.e IIkelv 10 slly PUt II Ihe lable,OJI's '"',,""
buk" 'Jlh" Ihiln lamlnillt.

"'il'"

s,nM conlacl ceme ," OII uch of Ilie pleees 10 be


"..,t." s.c:np of ~"'lInlile miku II good trowel-like
tpI'Udt< ro. ~nlbasPd ce ....."I. bUl vou un use.
lIIIdt bru,h or ooIle. for wile.b.ued cement.
~ COlII the sU"iees /Ind walt fo, Ihe Umenl
IId1y. Do thls In /1 weH.... ntJl.oted /I'U.

Io"d lh. I/lml"a l. tiv po.illi"V tlle SIWc:e,s OM tiv one


IInd preul"V the ~ml ...te fI,mlv onlO Ilie sulmrate.
It"s common to 1111" In the mlddlt, II ha ..... he~, and
wo,k oo;t towllrd Ilie .nd. Alw/lY' \NOri< lrom the
bondcd irU 00;1 SO voo; dan, "IP I pockel of /Ii,
betwe .. n tht I.. mlnllt! Ind the substrale. When ~I the
sp,ce.. lire remowd. selille bon<! tiv prenin!! the
lamlnal! n,mlv 10 Ilie subSl",,, with tlle ~ of YOU'
h,nd o' II Jroller.

Making a Tabletop with E"posed Edge'Banding


The pnxPdu~ lor ........ "V Ih stv't of tab~op Ire nO d,ff,r,nt tlliin tnost dtl .. Ued 'n Ih .. ellllplO .... Sltp-by'
l\tll. TMv .'mp,", IIrt po,formed 1" /1 d,"erenl SfQuenu.

1. LI",'''''lt Ilie IWO ~Y'f" 10 form the C~. 'nd prtPII"" lhe edgebamhng (Slep. 1 111'011011 3 on Pillf' 159).
2. AAtr .qu.,,"!1 tlle cort. IIP9Iv Ihe plISU<- WI'''''lIlt la"
J rrom 1110 limln.att flu.1I w,tll tlle tdllf" 01 IIIt co,,_
II, Na ... apply tlle td'it-bJmhnll_
1. rom It flusll ...,111 tlle 10p Ind bottom ,""IICU 011"" t&bItlOjI. then apply /1 !ult.1I 10 '1

'"
O

C
~
ID

.,

...-~
ID

1/1

.",m

laminate
flusll wlllt edlle
of S.. tlntlll'.

Nlllu,,1

b";';'k bru-.l' <lr Olbct applK2t""_ ~ COO'


fx~ :Ind " .. i' lOr ,""

,I",~,..

cnnm' 'o dry. ~ II")'OU ~

ooh"en'-boscd o:m"",. do .tus in ....d ....t"f\.!Wcd .......


AfIcr lhc: ~'t:rnem tu.. <Irkd. db<tiI:>uIt "'" ~
....'n lbc ...tNr.'e.The..---m. an Ix 00....,.. ... ....".,..."1'"
~ rrom l/le 5Cnp bin. 1'oM1on lbc bmin:I,., 001 lbc ......,."...

"'' ' 1Iy

""" a:mcr It .....". Ibc fUboor.ac. l'uI lbc opxtt> ...... bf onc.
_ bond lhc IamIn.ne I "",..u,. otan in It.. mid<k.,.... onc
sp.:cr and ~ lbc Ia.mi"",,, duwn onw "'" llIIINr:alc.
Thcn I wurIt (M 1(>W.anJ Il", ...,.. AfIcr lbc lamimIc 15 >tud:
10 Iho: lIlIhoIr.llo:. II-' .....". 1""
"itb J-roIIa. J>lCSSinI!:
''''"1' hard ' o ........" lIw. lhc Wnln:o'c b dllll'Ollgl1ly Il<ln<kd ta
lhc: suIIo<Dlc _Or """ l3p a IICr.lp of wood "ilh Iwnmcr ..
"'" """~ It ....-tt. _ mclho<.li<:>.lIy ~ ,!le lIlIffIIctc
fUI' Iho: """"''''' ....... r, """
<Il" p~ t(I oppty
Lim,fU'" OI" '-ilcr tu lbe "Iber >l<le.

.,,,rtocc

..,pca.

8 . Trlm . nd bevel .h"


1' lrimm'lIjI l!le

edgc of 'hc lamifU'e :uMl .".,


U..., a !le"d-.rimmlng bil In)'OUr ro.ller
1
~'" 10 .boul \to inch. " 'hich b abou' ,,,,1 ,Jt.c
of 'he Iamin .." . W"nh .he
OII II><: 1.> ... 1"",<
and tllc II;,". pllol rkIl"8 Ihc ~ndlnjl , """
,hc l.blc,op.Tum Ihc 101" cn..,r .ud lrim 'hc .,~ . ."
I.>mln,,,,, .
I~hklop

1"00'' '

9. Apply n"b; h 10 ...Ioe,.".poocd ~


>llIb~ thc I:IlXtop, Lhc ...... wood of dIC

,*",Ir

bandinjlm .....
,

nWI~1

lbc

~'4I,

whlk

10 lbc

mr.. ... .

ablllIy 10 t.lkc OII :tnd

Making a Tabletop with a Self-Edge


This ~,yle of ~I"" donn', ... qu"e vou 10 p,ep."e Ind .pply sohd"Wood edg<l!~nd'n\l. bUl 'M pnxus al
applyin\l ,rid '''mm'''II'he ~s"c Llml,,",e ii more In"o!ved. Yelthe Ih.liq",u fo. OOln\llhl. i'e I1Olhlfe<ttll
Iha" Iho.e delliled "'Ih,. clupt," Slep-bynep.
1. Lamllll,e.he IwO "yen lo!ofm Ihe core (S,ep. I ind 2 OrI poI\le 159).
Alter 5QUi,ln\lllli' core. IPPIy 11!e piI"", lam.nale 10
oppo ....
}. T"m .111. lamlnlle flUlh ~II voullll.

,..o

2.

....
.!!

J.

4 Apply IMlOtlC Ilm"',,!e 10 Ihe Iwo ,~ .... ""ng fd\lU


5. r"m thli lI-mlN,e nu.h III voullll. The end. of I/lese ""ps ",,(1 ..... e'llp Ilie end ~ of 1IIi' nm .wo m;"
ilppl,td Ind ",mmed.
li APIMV Ihe pla.tlc I"mlna,e 10 Ihe tOP 1l1li bonom .ud.let. Ollhe uble,op.
7. W,lh bevel'frlrnmlng bll. frlm IM edgeo of IM Llml,,"le. Sel Ihe Culle, 00 II bevel5 .1Ie edye. of III.
bollom su,-faces WHIIOUI Cutt'n\l inlO Ilie taces of Ihe "m,nile on III. Ilbl.loP edqe .

II

"'''WQ

"''''''

15"-2 5" be""t-"Immln\l bit


Flusll ,rlmmln\l bil

~"

LamiRile

~
Bo""I-Uim Ilie
counl.<lOP
limlna .

Ttlm self-.ed\le
flush wllh sunlCe
of SUbllr.lle .

.... minl.e

",
,
II>e botlom.

o, ba<ku.

~lou.IV

,pplled Ind , rimmed Ilush

.... mi""'e o, bide<

'---'

Universal Router
Mounting Plate
Wotk from scriiltch to make yourself a

_nlinll plate thilt'S fitted preclsely


101011' routoer a nd roulU lable.
.;,..~,..--------------------,

'"
O

'taeh Ilie roUl.". dirrctly 10 pin'" o( "lp... ~>Ii. 1lI;o,


uwd ro be thc l1"pical ~ppruach ,<> CI't"O'''\jI;'
!2I)k, ond , """ ,"", ...'Orb. NOI aJ wdl a. OIh~r.
. . o:onttmpurary approacl>es. /luI It wor1c.

"",,~.... o( C'OUlX' 1Ic-

fI.\U""

00n>m<>n

"'-ar 10 ffiOUI1'

..... in a W>k li; ";,h moun.UlJI; pWc, whlch .. lIuk


~ ~pI>'" A ",hbc:ccd <>pm11l8 b
CII ~ thr 'ablet"". lhc: opcnln~ " I>ilc ~ ,o
_ do< !OUl.". Il> <hop thtullj!ll. bul ,..., ploI" !oi (':Illgtu

.. "'"" ..,

"JIIPPOf't:d by ,"" r:obbn. "'" plate..oo. up nu>h wIIh


.. .-.op. n... Iftlgh. 01 ' M mul.". kcq ..., pb.c In
,....,... A propcr fii. mon> l~ ~ "" JidtpIay, IIO ."" pWc

__, sIlim...,. .......nIl In ,..., "'*

~ Ihc !'bl.. il >q>'M ,.bIe :Ind IlOl f,...rnro .x.-1I. t -and ,""
bo 0l0I1y mn<m:d froon the Wlletop.
'I'ha .. Im,,",,~ (n~ Ihc oId appt\Jlldl! ,"ou O"
'" do< ......... OUl .0 dwljlr l1li0 AnII bea ...... hor ~ b

_--nil

.. rrom

......,. _''''" luJf tIM: IIlIck _ 0(. pIrwood ullklop.


"'" an ,,-ri!lll gml'cr <kpd' 01 alt
)'OU ......",.
<lbriou<Iy, .be !'bl.. rrom whlch .m, muter h;m8> b
<riIbI rom""",,", 1. h .. ro be (1;11 ""
)'OUr c lI15 a""
C\IIIIiIIm, 1. hu 10 ..., ..cn"", ~ 10 ",ppon .I\!:

rrom

,1\;1,

mul(r And bcaus<: wc'n: "" OrI """'" klnd oi budfIrt,


1, ean', 00"""00 <kar.
Vou can bur a mClUntng pl1.c , of COli"" . Comm<:rdaJ
moun!inM pl>!C!I . bound . Mos. hit ""II~ .. h e .h~m In thdr
c:u.k>gs. "" do fulllinc 1001 de:l1c ... n ..,,,,, pb!~ .., ".,.
bad, !t<'n~raJly.
Il.n mr .nj.udc i5: Whr hur moun<JnJj 1'1:"" il )'OU

."o}
C
ID

-...

rrulI" onc1 ~Iy il 1"'" arc 1 hobby wood .....,rka. tD


nul<i"JI 1 moun'lng pb,,, an introduce)UU !t> .eehn lqUCA VI
an<! J'f'OI"'d~
wiU cnIun<:c ) ...... "'11 ,,"OO(/WQtI:1njJ.
Ano:! 1. con W>" )'OU .... mc<hlng you probably <Ion ', lO"t
cnough ~ pracUct .1-10,"",,"'. ,..0"'1ng from .;.c",'ch ,,'111
Si'" )'OU moun.1ng pIoIc lhot .. litlw J'fn'bcly 10 )'UlII'
routa; """ bit opcnlng ..'i11 toc cenl=<l OII thc bit axl . Ind
th;ot' . """",tiai. 1...;O sJ'" 1"'" I mounlln& pIa,e ,hal p""
m.:1y fii> ttoc ub6etop.
ln ,he ~ __ ~ 1'0 .n.- )'OU. ""P by ""P
""'" to nun I moonw.,; pIa,e y"" CiI1 rrulI.. M..... ar as
>II12ll ... )'OU like, rrom
("I'J'ft'I'ria,..) """criaI "'"
~ , :aotach wtw ....... tOlIIC1' )'OU ha\"C. an<! nWtc ltoc hit
opmins >Ii hit!: CI 0inUII ,." you _
1"1 aba expllill how
10 ...., thc """"'~ pIa.e 10 eu, ,he labktop opmln& for it.
CiI1

,ho.

"'ho,,,,,,,,,

'"

UNIV[RSAl IoIIOUHTlNG JOLATE LAYOUT

___ 11,.,-_____-,

[_____

~-4----:--,-...,

Mou~llng scre ...


hole, <ountt.,unk

IJlo"dla.

'"

,rlIo',\hkk wylk,
poIya.,~tt.

O<

plltnolic plalUC

Sti"lngpln hole

Making the Mounting Plate


Tbt .pproach ..."., ..'i11 Ix tu mat., plywoGd (W mcdiumlktUity fIbrrboard ( 1oI0f) lm>pbIe or J>3lIn'n, lhen .... ""',
." maI<c ,"" pbsric ~ ""'le.. 1l>cn: "'" oe>'CT.lI In""" lOt .1>1>.

Qty.

Plrt
Templ"l'

W X 8' )( 11\4'

JoIDf

Mounllng pI"le

]oj;' )( 8' )( 1 1!oIo'

Plullt'

]oj;'

- ""..."00<1 anii MOF .~ eukr 10 ......., llwI plastic."""'"


WU!I ' mdl, fufo::nmpk, lfyousand;m cdIIc IOO~

VI
OI

-...
~

...

!!

"
O

'"

Dlmenslons

dll. )( Ii"

0010.1

oi""lf
. Il0l11 ,,'OOd (l'IOduru

1IO'Jl. )'OU

."",'1

OO!I

les. liw1 plwlc, .. 1l)'OU


510 10 $15 ~.., of

,,"riti", otr.

""'lerl.l .
_ Il0l11 prodUCI5 pR>'idc
You """ joi dirttllQnS

lP>d .... rface<

fOr noIc

tald"".

ro. LtSiIlj;'hc tempLu.. l'ight on II

wan,."

'n II", fUI""', "'hen)"OI.I


nul:c. dupeo ulyour
nlOuntillJt plate. )\lU wm Ix ",",'n<led of ... h:1t bit> and

- Mr}.1k abo .. nsy 10"-ortr ...lth ......oo~


:lrId '" n:adily ~""'bl>lc: M pb,;ri<;oo R0n::5 and t
....Ii-<lonkr ~ IUppIkn. IL ........
aIM a> poIyarboll~tc . but II 1. more npI.
.iJKh -ihio:k pH:tt ... m ouppon a SCreo.millll I

....- M~-::i:.::"~'~O'~-.:-:':;:'~-:::::;:;;:

_ Phenollc
;1It dif6cull

1(Ui<k b,,'l\lngs 10 USC.

fim )'OI' nccd 1>01 make le",pl:l'.. If)'OU don 'j ...~nl
''', TO nukc ~ rnountiOl,ll pl:u ... follow ,"" """""""", ,
bul work with thc m"umln~ plate bbnk imlo:-ad of. tem

pIIcn .....,. pftft. II .. 'W)" MtOft8. '""'Y


~"ndHhld: plece 0/ Ilie ....1 paOo ",iU ouppon
18-pouo<k-t. 1-11""11 t:bok~

pl.lIe btlnk.
.\Ion:

1.. Sclea thc n><>Unl1ni p"'l" ",,,wrl,lI. The nu'<:n.b .......uy lI:ICd 1",""", Ib).. an: pl:t>tk:: ,cl'}'l lc. poty.
C2r'I)QQ:otc, :u>d phcnolic. In th= nut6hcllJ:

PoI)"Cafbo ..a lc .. """Y 10 work wllll woodworkl"l1


tooI!; :lOd ;s n:<>dlly .... iblJk .1 pbsllCII
.1IlI
lhruugh nwkJnkr ~ 'upplk'rl, Vln ... uy
unbrnbblo , k ... wl IkxIIJk_if
r.,hn" Uun

!oi""'"

fii'''''

Ioh:IUns-:md nay 5;l811111kr Ilie weighl of 1 NMmoIh


tt>utCr;

TbtnJ dK>Ia.

InlOmutlon .bouI Ilie ""'InWo :lrId >boia

""-1""" lOr ....-or1<lnfIthcrn Is In thc oppcndi1.


2. SelI.k:

Of>

dimenaioN lor Ihc

.h<>ukl L'~ . .." '~' J.'


,~.., ~, 00 , . .~ -'00";
10 "" .No:: 10 <Irop ti", .......". tbrough thc '-op
..l lhoLI!
. '""'''''''~ , ......."'" 10
.. loc Il", NU'"," '" 1
01 CUI
thc Iwl<llc:o bonom opIn>I thc
1UI11crS Umil. IIUl )"011 "':tnl Ilie 1!1~lt M snu.U t i
updmum illm<."R>k>n> Ihuli n~ ';ll"J. (rom IOIJICT ro lI'lIIIU.

JmlNG PLATE ANO TABLE OPENINC TO ROUTER


A. PORTrR-CASLf: "690 I VIHP FIXED8ASE ROUTER

Ut(lt. 'becl ""ndlts


wiN1I._nll he
rwter f.om droplling
Inlo pliu.

Plemy of duranet
btlWeen Ihe lable Ind
tlle hancUet. Rouler wlll
ell1l'v elear Ilie lableloll
D~n l ng.

Milh tilSV (IUfilroce

for tM handlu by
orient",!! t~m OII il
d~1 ilCrosS
I~ mounling IIlalt.

D. HITACHI,M Ilv

3~' HP

PLUNCE ROUTtR

HandltllOlKh
lilblelOP just
btfOM! rauler's
mulmum plun;dtplh 1. M!ached.

An USV .oIutlon?
Removt Ilie
hlndlu. A Iingle
screw secu"s
tacit one .
Rtmoval of IIte
'Outt. 1. now
tilsy. loo.

EV!n al mulmum IIlunge delllh,


lhere', plenly of d u raMe
tM-lween table ind hind lu.
IIlI lIau.e of hanelle design.
tht fOUler w,lI nOI ei.11y dur Ilie c.penU"l9.

;J>

".

C
..... pr.w:licol ""'IIa-, thougl1 , it ouy ~ ~.. 10 pkk up
.... rrom 11105<: maU-ol"tkr c:l.laJop.. 1 dI~cd jC>'Ct"1I:
~ ~IC< "",,,n:d nnfII'd from. sm:ill of . \, )( 10 '1
.ma ... 10 \arse of 9 )( 12 lndlO. lin. In minii 1IW
_ 0I2I0p offer ' U;I.bIe pbstlCllln ..om/"," 1QoI-sqU3ft
JIf<U. mc;ltl;nH !luI IhC}''''''' l i VI InchH
ar II ~,
a1a IIQUII"".
$o - . . . , thr 1U01Ier )""" \'" .,.......wIo:cd b u.., n;llIIer
......,... u.., ~ rrom Iundk 10 handk1 Whal's 1110:
. . . , . (rom thc bouom of u.., lWKllc 10 Ihc: 00.1"," r.:J 1110:
~. plun!!" n .... er.1x ~ 10 bOllom
... "'"~ ~.) 1I)'l1J II" ..1,h tI)( 11 '1 iJIcho"
Ia,w lfUkc k ......"v,nr LObklop oprnlnll (",,~1ud1f11!. ,1Ie
Itm) 1I'0I*l ~ obouI 7~ )( II 111<.:110. TII;' b Ilie &1" I
~"' bdna an "f'I'I'OPI"iJ1~ romproml'iC bct"'ttn Ilte !IIlC
~""IOUInII)"J'IOIIy uscd In n:>uler tobIo ond Ilte tIl",II",,1
lIIHpr< piooitic pWef lnOIII ronlntonly .'-:tlbbk.

...

...-.~

"1"''''

1/1

....or,.... '"'"

j. Cui Ihc pble l empblC.

~"'ke

,he

l ~mp b ' ~

OUl

tr. putk\dloltd. MDIl OI' p""WO<.Kl . U.., ""'1cr1.llh~t'.


. U thIct.

'ro...

5mootll mIII marlls


tII" I" mlllill" eclgH. Attv
nicb o. wa.hbo;lfd!ike fiOgeS wlllitleilraph OnlO Ihe
plulic mou~ti"Q pl~tt's edgt~. 51roce 11's tilslt< 10 file
or Sind Ihtm from MOF IItiln from Kt"/'Ilc O< phtnolk,
do thls co.mtllc wo<k on Iht lempllll .

MANEUVER ING ROUTER THROUC;;H OPENING

Whllun ....Iong

openl,,!! wlll
KCommod,Ut
mo!.l blg .0Ult.S. It
will NOT offt. usy
p.lSS.~ 10' ~I.
Ryobl' s RE-600.
I 2'A"

lor "'Implt. NS
lIulldind hilndlH
tll.t WOII'I P.iOSS,
dilQOn.llI.

even on I

an Ilie

, ~bk

..... CUC tlle m,.. elial tu Ihc dlmcmm

)'0\1\" iIC, \k(I onlOr the ,no,mlhlj( pl ne


RounrJ the ':0'''''''' ,"",,,,,. I pr>Cunl ""...... lOr thiI:
'1', elllii<:r ,.. ""'1 Ilie lohkt.'P "penrng i( 'hc apen...:.
emne", ."" radi"","",. SqIW'lnSl 'ht: rome", ha. \1) " " . . , .
wllh a ehi... , n........t 01 roundlna .he l~ m pLole romtn
ean bc dof>c (N'I >Colloo:uy S>n<lc bUl Iilke W u'"" I ..,.
pl.le 10 Rulr,le I ...... e "" p'" uem bil (Se<: "1Iorq
Temp lo,"," OII p.1JIC 6 for """" Inrorm . u"" OII rof'1It:I<ou n<llnJ ,enlp1"",,)

4. D rl lllhC moumin8'~ hok:5. You w.... III


bc . 1I1e \1) U$ Ibc Icmpl;uc ' o lIUi<Ic the: dlilllllJl. 01 tt..
mounU~rcw
and 'he: """ing 01 ,"" bi. optttq.
Usc Ihe ",u,cr', belory boucpbtc '" ""Ilem ~,.. tt..

""Ia

moun.ing;ocrcw hoIcs.
R""""" Ilie ~pl"c from Iht: f<I<IIe. lJiIC 1 ., I ~
g;r.Ujt(' tO scleet 'hc prof>Cf'6ir.cd bit 10 drilll"" nlOunlin8SCf'<"N 11<.>1",. Wi .1I tbc drilI idttIcd, ~k:k Ibc: bascplolc 10
Ihc ICnlpbte . Althoul#l tbc bII opmI"II
I>c lbooIu .. .,.
concentric wl'h 'he bi' uis It 1"" ....... , ,o ...., 'e"'p"lr
1I"kl<;< .JU.."..r" IIy. I. dQc)n , Il... e 10 hc cind cen.e. <)II "'"
pIole l'hcrcrorc. fU" can c)'d>aU Ihc rout.,.IoaUon ou thr
pIl'c: Apply ""1"pCI '-"PC w thc bo:Iorylr>$pb'c:. pOiIItiolt ~
.... Ihc 'empLole,
It 0tmIy tu.hc <cmpbtc.
ru~ Ihc !cmpl.! ~ .nd driU bil 10 Ihc driU 1'f'C'lO. anii
b<w .hc moun.l"lI"""'rcw lIoIci rue OUr <imc; fICI Iho
hoIes ""ffcclly JIO"llloo>e<l 1'<)' oM ba,,;q>Io' e otr 'hc ....
plate 1'hen. sr"'lI!I<";r.S it ""'Y """",. counl~ Ihc ""*" il
oM ''''''Pb'e.

m"'"

."<1 1""'"'

WhIIIO do1

Un Ihe fOUltt try Iht


mounlOng pilIt. Ind
man,uyt. on, p' unll'l
fOd Into a tO"'ff.

Tip

l~t <Oult.
so lllt opposllt
hlndlt tiu ..
t~ tablttop.

5.

LocaIC a n d bon: t!le b i t opc:n lnjl.. Now """""

' hc rourtt ....,If "" thc ." mplo' e. TIri. io " -hy "'" cvurrtcfsunk tbc !Crn>' holo. t''''' nn.J 10 II<" the SCf'<"NlI ....

ctIOII8h 10 puii tM t(mplale Imn

pooi'' ' ' 00)'0\1 an ......

..Idy m:uII the bit opc:"ln~ . C:cn'ef.

a",d; I v1!:"""1ng bll In oM roulcr'. roII<t. IJon1 ...


'" thc n><MC'f. hul "'I~c:r '"m Ihe hil hy hand. 111"1 bourl!'
....."'1"11 oM ,cmplotc .
RcmtJ,,, Ihc .....1.,. In,," tlle lem plole.and hnd bact III
.1", driU j'If<:H. Il..: a c""Ielin ~ pin ar malJ.di:amc1c:r bot ia
lhc driU prcIO dludr: 10 111;11' tlle wo",plt ro. 1Ioring ....
hit 0"""1",,. 'Inrcn ' 1Ie: cenl.,. pin pOim iJ righl Ofl IM a .
.ermln:. clamp Ilie won:pltte . TIten .wi,dt ' o ~
I hlncl>diltmctn
btt OI' hole saw and boI'C thc: biI
opc-n11'l3 1n thc t""'plate.
1kpcn!IinfI .... Ihc bit an<! ,cmpb.c guidc rombiru~
" ' " WIC. tiu. ~ Imlpble apenlng ""n bc lumed 1n\O I
mounllngplatc tii! apcn!ng rmging rrom .... Inch diamcIa
up 10 futt I I'> Ind!cs.

TMn movt Ilie routeo


biltk .1000g tllt d,altO/lal,
so Ihe hlndlt Is
.bovt the lablttop .

Font"".

6. Locale a n d drill IM ~l2rt1"s pln h" le. n..


... nln8 pin iJ callcd _ _ NI"II pin benu,", It hcl~ 1. Ihr
beglnnlnll 011 CUI lr ruknun ro. the "'''"'Illcec " .......
)'0\1 ,,'" rou' 1ng _b piloted bit bu' no Icnee You bta
tlle
nr~ "pin" tlte pin . tlten "leve. II Imo ,1", bll
Comrnonty. ' Slarll. . pin il" ~n ""~ .... mc:tll Of
pl~.1e pin p,,*,,"1ntt: rrocn the ll'OOUIl,intI pLole 2 .0 ~ Indl"

w,,"'

Rigllt tlle ""'ttl. "h.ng tM

second lIandlt tiu .

... tbc bit. Thc posltion I n:Inlmcnd '" shown in Ihc


pili< Irfout dn",ing . ~I.r1< Ihc loc,,,,ion on lhc ",mpl>lc, Ind
*il tht

'Mnc1Hli>mcla bol~.

7. Mnc thc mountlng pla lc. (Joc a ""uplc o( >lnp>


0/ """'"' taP<' IQ bolid lh~ u:mplalc 10 lbc p/llMlc rOI'-'"
odmtd """ Ih. mowlIhlj.l pl.:/le (( Ih~ p1:L>lk 1. prow.:tctJ
b!"....tin3 p.opct. k:lvc . he p.opc:< in placc.
/oJ. tbc dliU p..."... <lriU Ihe noountlns .....
hoIes. Ik
arduIlO <:mI ... III<" <lriU bil In II>c Icrnp1.11C5 ~ukk hoIco
")'\lI f:tt II>c bob in Ilie pl>le pcrfcctly pO<Silioncd an<l
_ tI))"OU <Ion', cn><k Ihe gui<k hul<: .
DriII tlIc >lm!ngl'ln hole.
XI lip ~ur roula 10 ",ul thc hit opcning. lIe,,", .rc'
"~lnS "'-""bilUlit.>ns u.> cho<>o;c r",m;

"'w

. Iilr +.-iDeh opc:nillll. """ ~ind, >lr. illln bil in 1

ilctKlbmc'cr lIul<k hushing .


l~nch Qfk'nlng. usc ~ch str:Iighl hll In
~i>mc1C1" guidc bushilljl.
.fo.>r. 1\4-lnch QJlCnilljl , """ ""ncll "' ....;w., hi, in
\~...,."cr gui<k hushlng.
for. 1~ ..... h Qfk'''inlt. usc a p.on~m mi .

fo.>r.

U)'OU W>nt .0 mac. hi, upenlng ,,,", will use ,cm


pilt<gu;dc:o conrlJ!ure<l un .he I\>nel'Cohlc >I.ndar<!. 00'"
'I ......... h hale clcar through Ihe moumini\ plate. Thrn
.ndI tO * lMh M... igh' hi, in Ihc ~nch Hulde

IotIImB, ... d ... blkL 'Ile huk . .\le",ure It..:, naf1!lC on


.... bu>ltlng nd mul Ihe ... blkl IhOi dcplh. 11"5 um. Ur
DIat Ij, Inci!. but cl>i(.

Router-Mounting Screws
Make Suie you h~ve reuonibly becfy serews
1I01d.ng the route, ta Ihe mount.ng pl"e . Many
olde, fOule,S had only IlI,u 832 !new, hold"'g the
baseplate CHI. Tha! was fine for Ihe use Inlended.
but when \'Ou hang the 'out.r rrom Ihe plale, you're
bono. off et\l>", dnlhng oul and tapp,nglhO'" holu
10" blgge, StZC o, drtlllrtQ and tapping .n1lfely n.w
holes The PonetCable bchemOlh used In the
Rodale DUlgn ShOpl route. tabl. nas fou. "';nch
.crew! hold tng 11 10 th. plate.
By aII mnns. use Oalhead screws "nd COunlo,
sink tnem sa Ihat Ihey are Just barely reccssed.
(Rec."ing 100 mLKh noI only weaken. Ilie plate. ti
Cre"les li coll.etiOn poInl fo, chip. th"l wtllinvarl
ably tatel> youl work and 'Uln your CUI. I( nOI you,
fin!/f's.) Flathcads !I'v. th. but Ioad-sp.eadlnggrip
and are 1...1 hkely 10 crack llu! plalo and puII
Ihrough. Oon1 USt roundhead SefeWS; Ihey requ". a
nalbottomed eoun'erbo.. Iha\ ean se.IoLlsly com
p,omt'" the mentllh of tne plai . The eoonle,bo.o
eollecl a 101 of ehlps. 100.
Th. StluallQf1 mOSI IIkely 10 IeSI the s'rengll> of
Ih. plai. and mounllntl< '5 when you make" mis'
take In fud dtrecllon. A 3horsepowe, ,Out.,
sucklng a "-Incl> plece of Qilk In,o il Y,-;neh space
IMolwun Ihe culte, and th. fonee can ereate an
amazlnll arlWunl of prenu,e. If you, ,ouler Is
securely mounted. II>. rene. should IIM! enoullh 10
allo ..... the Slock to be plueked fram \'Ou' linge.s ~nd
Ihmwn a"'<lSS th. ,ilaI'. I( IIu! muie, moun" gl""
fi'st, you could end up wilh an ang,y 'OUl.' eomLng
out from unde, IIu! table afler YOLl_

. ..

-.'

\ "r. .:...
"

1:"'''''

... J\.~ "" .....

OiRennt eomblnations of tem plate "uldes iln d


bll~ enable you to Iransfo.m Ihe tcmplat'l
IIHn<h-di.lmcle. bit o~ning Imo Ont of a smalle,
ozo .. hen maklng I mounting plalc. Vau can cven 'OUl
i~ .d bll opening Ihat will accept templale
..S<I.iS s~own htre. Mtt' routing complcttly
!iWouIJ~ Ilie mOL/nUng plate wlth one blt/gulde bu~hlng
<'!btno.tion. \'Ou swhch bllS 10 ,oullhe .abbe!.
IIrllght

A duplicate of t he mountlng plate te mplale 15


p,odue.d In I ,ingle circuit w1tn li roul., and nush
trlmmlng bit Bond moun!lnll-plat. male,lalto Ihe
lempl~l. wlth ea'pet tape. Wltn the blt\ pl!ot 'idlng on
th@ t~mpla!t. zlp around th@ undwich. trlmming the
mounting plale ~ush wilh the l.mplaLe. as shown.
Universa l Roul. , Mounung Plate

167

~1nalI)', .... 11II a pancm bit OI" nU>IHrimmlnli bit In l"",r


..,....".. lrim
""""'Iinti plal( .0 !ii4. Pry "'" ItI"plIlt and
1"" mount __ plale 1pat\: thIt le " ......, Ihor m:o'll<ing ""pcr
COft>Q olf "'" moonllnll pI.1I" ",,,xii 1"" plale lu thc: """.,,.

1""

8 . Mat<.. lhc: tartlna pin. M. notnll'f"'iooilly. II>c


tommL>fIlIWIIbtadon oIthor ..;ut!na pin b ',,><>den
""" ou """:al .... pWtC pin. for Iru. plal". 1 usnI a I \<..incto.
Icnph ul '-o4nch Iwdwood 00"''''.
CUt 1"" pin 10 ...... h . 'Ll11h ueilky kni~ . J<:On: ,"" pin
dct'pIy '. Inc:h r...... <)ti<: moi. WIIit.k: 11'11: pin r...... thc: moi
10 11'11: "'~. mludllll 11'11: dIamn.". md lQrrnInw ohaM:.
I\:tiOdIolly ."'" ' M AI ul lM iIwU: In tbe ..... nIHM hok
In LI ... lmIpblt.

1. Tnce lhc: mounlinJ!; pble on tbe lempblt


stock. Mall" 1"" framcU kc lemplolc frum I-W>ch p!yto.'1lOd
.... I.-..lbo:oni, lor lhc IIIOUnllng pIa,e on 'bc .""'.,..
srod<. ~n<l ,""'( "ruun<l i, .,..;.h a .twp pendI. II' "'" pIar
tu. fOllJ.dnI comc-n;, lIS<'. <lr.dt ..... n's rin:k l"",pI.1It 10
locale
ccnt<:rflOn1 of cadl oomer'. radj",.

1""

Installing the Mounting Plate

2. 8um p up lhe .cmp lalC oulllrn:. You nced ..


n.. kc thc 'c",pille Opcnillll WJ!cr liwI Ihc pIo'c 10 X1XJUII
for ,"" hl.'iC of lhc ron' ..... )'''u 11"'"' ti) ~'U. \hc WlInop. OrA'
l!nes on Ihc tn1'ptlte >Iod! pa II,,1 ' 0 IIIooc: 1"""'" from "'"
lIIOWl'irlII pblc. ~ diSlancc .way rrom Ihc pLtlc uac:q
dw )"'-' po51On lhac n",,' ~nes is II>c <h/I'1:-n:""" bcnI._
thc: bIl', 1':I.di....... <I lhc b;o,;cpLt'c <liU>, ...

""""'nIn "'"

<JraW'1lII Roulf~ Tublelop Ope,,/~ u:llh /lase<.uldl"l


T""'pl.ufc If "'" C<>mCrs an: round~ "'" a comJUl'6 III
&Ctlbc thc:m. plWll1n1l on ,II<: corn .... ccn''-'''J>OIn ...

,."."..,'. "" q"""'lon .lpl,1'II: _ ling plai" m .... AI prop.


eri)' In thc LObIelop. 1L ha>. '" "" dn.J/l1Ub " ilh "'" LObk:lop
""d.ct >li ...0<1< doo;n 'l 11<'1 hong up li ,"" plale S hgh Of
Iow. IM~" ... . , . . ~'hat: ' 0 ",.eb and >lop ""'"
hd"tl kd """""" 1. IL ha!i 10 "" !iahl In Ihor 0JlCfIn8. It in
kxc, III<' pp bc'I ...."..., plalt Ind lablelop filI5 ..;th dust
Ind dJlpo, hln<k:ring 1.... smoodI 1IIO>'Onnl1 01 thc .........
pcriupoi 'hrowlng uff """"..... "'''''''''''''', ' ......., pbu: an
>bIr, pooltlon .... hen ,hc rt>Uln' '" i"ilchN ono ag;oin
Ihrov.illll off. prisc 5cIUp. If ' hc li. is .oo Ilght. )'OU 1n3t'
nOI e'''''' lIiCl ,.,., pwc In,o thc upctIng. ' f yuu 00, thc pIa'"
m'r bc dlslOncd.
So lhe mlI quodon is:11ow do I ochit:t" 1"- ~i'ld" 611
Thc ........ Uot: ,.,., rnounrIng pb1c u:m.pIatt (OI' "'"' "'"
I1l<KD1'I"J; p':lIe) ." malle .......... . "",pI:l1t. Thm ..... II~ .........
"'mpil,,, 10 rou' tht I>blclop opming. n......, ~ 1"":>
>Jl'f"I'J*''''"'' tI"" "';1I "vrk. In "'" tir$! " ' IJ"",""h, )'OII ru:aI<c.

rcmpb'c "",""", ..._

"'" """ ..... ~ ....... In "'" !U'OfId,

1-"" nw:c a ,,:mp""t ~I"" whidl ''''''f'bIc lIuloil' ridc!I


, lik" Ihc second app!O>Ch, but mII doo;n ', """"')'OU
"'il!. To me, h~ . dt.. n':lg<: S
)Vtl ..... . 11<' nlOUnting plale
i"dl' 10 gui<k thc ro",.". os l' cu .. 1"" l..... pillC 1lKn:' .n:
110 pcndlily""". no rl\lMrallng eom 10 100'" 10 1I0e. Yoo
just ltUidc II>c rou'C' . rou"'" .h( m""n' lng pill~: 1. cuI> ,""
perf"'" tempLt'" 11",1'11 prod""" Ihe ""'""'" iii.
Tht firsl 'PPro.1ch S not wllll01l1 adt.. m.gc5. of
cou~. It >110"'5 Ihc !Ou,,,, u-, ride tll""',1)' on ,I>c tabk,op
surf""" os Il cu .. lhe ol"'nlng.ThI fforWi Iht I>oc .uppon
and xcwxy of CulLlltJl deplh . lt can iJc duoc ",;'h any
roul~r and .. ",ighl bi . )'0<' <.Ion '. n,,(<1 an uoon"",nl uf
I(nlp!o'c guilkll and """,,,,,,1 dlffcn:nl >lrA!tth1 bl15. II Ic:o>
oIwi<>u> al"","""!!" b .h.1 ,ht IcmpLtle nccdo', Ix OMI)'
1inWInI. ~ bt1I<' radl .... of 'bc ro\I1C' 1...., can ride:
".""1)'
nlgc ",itl.oUl l",n."II"l1 "'''''Y Illlle .. w m.rI<
In'o lhc cu,

,1.

,"''''cd

Using

il

BilStI-Guiding Template

11ti>.ppruach an bc """" ",III! ~ny rouler. O"Nb;oscd o.


piu"""",. It "'" ""'" bc """" ,,'llh a laml ... ,c ,rim",c. In
bct, ,"" ,rirnmtt", tmallt. baoc:pillc ",Inimi""" Ihc .b.l' of

IC'rtIpIa'" nccdctllO ~ukk II>c cut.

16a

R.... I~' ""'9'"

l..Jtylng .... 1 I bltsl'l u ld lng tlmplatl alls for ..MII


IloNI dflfting looIs, lik, I comp;lSS, d"ftsman's clre'ttmplllts, Ind. rul<! . Aher lr.c lng """,nd IIM!
""",nllng plAle on the lempl", "ock, 'r'OU .... ve 10
d"w CUI I,net, offHt from the Ir.ce<! IInel . To "",ne!
Ihe lemplalt\ eOfne,S P<OPerly. 'fOII m"st
the
COmp;lSi on the CtftlerPOIIt 01 Ilie mouming plate'l
c",ne' lre' , U 'hown.

''''ing

3. Cut OUllbe Icmpbtt. U"", a Pbrr _Whlk,..

.,.,;.1

I CUI liw " .. I>ik:n, ~1Ik: rippld and !'OUJIIr


......... ro .'lhouldn't l ... nskr 10 III<: rout.". cut (!houh 'II<)'
woukllf}ou ....,.., n:*~ a '<=pIa,t . . - o,pIRu: ....
,,,",pI>tt .... bc. ""'" .11<' rout.... lw;q>latt).
wanl ' 0

4. TC!lt ti"" I""'pble. U"" a J>Itft ul ptywood "'"


51: of ,II<' ' "",plll" ~'Ion ttoc I""'plale on "'" 1051 pand
.00 ,,"'mp Il V... 11><' ro." ..... and a .I.onm str.tlgh! bit 10 CUI
WOO'"<: l.a) III<: """"'ling pLt'e ....."'" ,1><: 'CSl
il>.,...
sI<k nlllI" >houkI ju>< line lip ..11h 'he ouuI<k nI8' ul ....
llro"" ,, I( III<: 1.... COl' de""""''''I'''' ,1t;Q II><: ...... platc is WO
blH " .. ",,' ~m.JI,
,II<: " 'hok: JIf'O<'D'< ,,, mai:e and ....
new lcn'pLt'~

<U,

"'1''''''

lOUTlNG TABlETOP OPENING ... ilh hse-G .. idinv Tem,late


B. BU MP UP THE MOUNTlNC PlATE TRACINC.

A. DETERMI NE THE OfFSET.


8a1~pl at e r~diui

Round corne"
witl> compa .

- hil radiui _ off'~I

In Ihl. example.
r -:y,." _ 2' l'oo"

JIi. " hit rad.

Line !ra<~d from


mountlng plMt
Scrlbe IIn~,
parallello
traced line.

-,,<""__,

.'

l' bil~plat~ rad. -

> .

Templatt
stock

Offset

Centt,polnt.located from traced line


",Ing drah,,,,,,n's clrcle t~mplate
Off.et
C. USE fINI$HED TIMPLATI' TO ROUT lliE CROOVE IN THE 1:ABLETOP.

' ' fi

Tablelop

"tLJ
..

f'.---_fi

D. S!<W OUT THE WASTE.

t- Tablelop

1__"':::::;;~~....~ ~".,jli.

hole

S. CuI thc "'hk:lop openlng. Do th!li 0Il1y :ll't~ r th~


Ili sll.C1l ~It'. of
"""'" PosilOn Ilie Icmpblc 0Il .Ile t:lblct<>p. ebmp II
u:jC lhc ro",,,, 10 ~ Ilie I.bietop. Thb
pO(II'r "'Clluwly bct:om"" Ih~ r.lbbct Ih;1l suppons tlK
tii <IcrnonoIrlt .. th.l th~ Imlpbl~

.....mr.:u>d

......ungpbl~.

Cu! 0111 'hc "'Ulc 10 eomplctc Ihe opcning. li"" ... hcr
... wlguitk II """'!! II'" Inn~r ""!!<' of 1"" gt'OO'.... To "an
.. CUl.drill pilot h<:>1c for 1"" JOlber p w b~ . W"",,, yuu
.. donc.lhco PUt( lhoultJ JUSt fil .Afier 011 .
ldU:d It.

}')Il"'"

CiIIkI.I .... rouler againsllhe le mplille's inner ed\le


IIIg_11M' lablelop. The C"t Iln't 100 heavv for ;ll laml
lIIIt trlmmu. If VOU have one. Tlle " Imme'" small Ilze 1.
l~ ... filln

Ihl. ';tuatlan b&aule tlle lemplate doesn't


10 III' ,o bog. Her~. Ille g,oove " belng routed in a
~ ~w eXlOn,lon "'bltlop.
_

Universal Roule, MoumlnQ Plate

169

Using

ilo

(;uideBushing Template

I likt 111.1$ '"1'<'031:11. , ''' I said, bea....., IM",. bo opp<>nunlly M-em..-IO e=p In. lfyou "utc "".nul'r. JUlI ""'.....,
lIiCt pnfcc. rit.

'o

1. Jtout NI intunal tempble ""lde<! by the


n.u...,Li"K ploi... u.e. pictt 0/ ~ ~. MOP'<>r
~ lOr ,..., ttruplo'''. n.a.,'. IlO l:ryQut worI< 10
"",bm, but......., .,...-po....ion is~,
J;n;t bono.I thc: n..,..,.ing plate ... thc 1Ctnpllle .I<:x:k ... ,.h
carpn t:ap<', ~ thc: carpcI bpt' abo .0 bon<! thc l~mJlbt"
srodt- pank:ul;u1y .h,,!IeClion !>mo.1I .hc "",,""11lII pb.r.... ilittc ,,(
m:o.cNl, 1)0 this C>O:'n "'n.'Ijh )'OU
""""JI ,IIe '"",pb.,, .. ud< '0 .hc ~TIIC apc:ndabIc
"",.mal "roI~'C" 'hc IOI~ 'op, TIIC ClUJ>C'I topoo
bet"''CCIl II ..... thc tcmpble u.:p. thc: "'..... c. ,,'hidI jUIpOIU
thc: fIJUIn, ftum ohiftl1(l . . II is.,.. frtt 01 ilie """JIIa<~,
Qu,A. 1'1...,., "",' n "itll t..tnct..o.O tempbtc
Iluidc ond ~nch ... raight bit ,Sa lhc pIungc dqoth
lhc bit ",iII, ..'iim bouomnI apASl 'hc swp, juM bn;:aI<
.hrough.IX' "'mplo't.wcIL Inl".IIe """"''' """""III..
t:cq,ins.hc u:mpl>." ",kIc liglU "II"'IISt.t>c m""n,ln8
plate, """ :oround i' in IIM: dirtttion IndIc.led In 'hc
drI"'1nfI !loulf", t/}k1Of> 0/111"/''1( wllb G"f<fe.U"sl1/,'l
TnorpIal~. ,,",,,ke """"'".. ~, plLUlSlllll Utllc: Ik:cpc' 11.."""II d",ui', LUl,il 'he """"'~ 15 OI' frtt. Undamp lhc W<)rIL.
pIc. Pry lhe ,,1011<' fronl ,h" "-'bIe.

"""""""'*

p>n nwnhcr ~2021 (You an aIMt 1IK' ~ .......;., bol


in. i1nch-O.D tc:mpl:l'c jltJo<k T1ti> combu1:l'k>ft ,o/wiouII)',

ticld ............." 8""""" )


Sa 'hc plunllC deplh carcfully.Th~ dct>Ih o( ,"" WOO"<'
)"" ~'" Ibou. 10 ,oUl Iohoukl t:nCIly nu,m ti", ,hid<nQo li
Ilie moumllL,Ll " I;ne. YUll .1 .... m~>I occounl lOr .he ,~
of.IIe IcmpblC.l0 du Iltl., ..:1 Ilie rout<'I"lHl .IIe .cmplm.
~nd go.:ntly bou .... ' 'he bil ~'Ithc WO<'I<p,ccc. _
....
con",. oI lht n"",,,.ing pble (>It thc 'um:'\, and drop . .
dep.h rod <>ntU II. I,>ei< ."" rod. You .'" rnt/y W <OUl
Kcq>i"8 "'" ,empa,e ilulck tl/tht 192insI thc tctnpbI<.
mut around .hc inncr pc:rimc:tcr III .hc dltc:<"llon Indlr:lLui
in .hc ~ M.u OIC:VCnl pa>OC>, pNllIPnlI: ~nJc: dftp<f
lOt <:adi d"-'Uit,
'hc: muimun> dqoth is arnJc:y(d
Undarnp "'" Icmplolt, "'" d .... riie dtipo (rom ,1Ie lfR"M.
"iIl

""'il

""P'"

Use Ihe mounlillg pl.11 10 sel the phlnge SIOp.


Ant' bouom,ng IM bil .\I.llI>t the wo,k ($t.lld Iht
rau ... , OII .h tmpl ..... nd plunge II ~II .1Ie bil
louchu .h. l.bl Oj Ind I",kl"ll the "'unge, hold Iht
pl"t btIW II .h. raUl ..... IUfltl ,"d 1'" IHpth $'OP
rod, U $howII. Wilh tIw:- ,,1.1t agllll$' U.e ""....1. nIl
Ih, rod OII .h. """t Ind Iodt It. Now.1Ie mu'v wiI
t UI I
1$ dtt" 1 h, ptaltls Ih't k.

..{!...
OI

\1'_

.!

mlOlI .. lOguide-bushlne I_plale, use Ilie


~" TornounUng
pl.te It$eII as. Ifmp!ilf , Bond M 10 tIw:- I.m

S'''''''

pIo ...
and rout counleo-ciotkwi...."",nd II, Il
lhown 1Ie.... . Kttp tlle Itmpi,o.e \lulele 110"1 ag,JIIIll Ilie
_ mlng pl bK.au ... 1he "mpl.te will "" ,uilled il
Ilie \IiIide drifts aWIY from Ihe pl.le .

2. Ro,,' Ihe: platC,s LOI.pon rab DeI In 'he:


IIIblc:top. 1U.i<lon <ilc .cmpl.' e OII thc """n ubk '''P.
Camp 1 bclng 5u", 10 posIllon .hc ebmpo whcK .h.,.
Inlcrf~", .vilh 'he """CI' ... ,..... fc..d It :.uound 'hc
In~lde cdgo: of th<: .emp!;"e:
Ow!ge Ilie plUIIIIC """CI' ""'''p. Ono
bit Ut lhc <:<>I1n. :ano! in>talI. I ~1nd>O.O. """plate
lIuidc In <hc: ~pIo,e: I'onCl'-CabIc """'''' thd 1\Ikk: i ."

_f,

......inch

"rai!Ih'
I 70

ROU't' Mag,c

Groo..lng Ihl ULbItc"" is I I..u ICk~lh 0f>Ml!i01l tNn


rouung Ilie l .. mpQie. StI ."'" n>UlH OII u.e ... mpLII.,
with Ihe gulde <oIIiI, tight ~ill>l u.e leo-npl;ale~ \lulding
tdge. 1'1.... Ilie bit,;;Ind \Iuide Ilie _IU dockwlH . 1f
'/'OU do iei Ilie .ou.... drift .way rrom Ilie \lulding edge,
'/'OU'I mf:rely "" CU!llng 111.0 .h .. was .........

ROUTINC TABLETOP OPENINC Wilh CuldeBu5hlni Templale


A. MAKE AN INTERNAl TEMPLATE.
Templale blank

JoI."-o.o. g" ld~ bu.hlng


T~mpl a t e

..,ounllno plate

Sc.ap 10 p,oleCI
wo,k su,lace

Moun"ng plale

B. ROtIT THE f>LATESUPPORT AABBIT.


Tablelop - - - - - .
I !4"O.O. lemplale

ould~

~ ...... .

.
,.::
:

: 0

... "
"

Te mplatt

C. CUT nit INTERNAl WASTE FREE.


_~_~

waue j

l
5aber saw blade

___ r-

..-

Tabletop

II

Tablelop
J4"dja. hoit

Un;V<!rsal Rouler Mountino Plale

171

3. an tfM.o ..-asI" ou' of tho: ""'letOJl <'>J1Cl"~ U..,


a .. ha _ . br ,his ~.CUlting n.><lIIy ...... oM Innrr
lohouIder of oM IIJO'I''I:. V..,lI..,. oM dr:uIOI jQb
drilI
~er ........ "' nch comc-r. .. "",",'n In ,...,
dr.Ning and phoco. 1ltis ...,.,.. JtlU .,..., in>o:n .1>0: bb<k In,o
oM
and make a .. f3!&ht ...... f...... ooc concr 'u "lOIh.".
""'" ptocUlklK of W " " " cut wi/I da""", ... how " ' Ik
oM pb'HUpJIQ<I robIxI it_lI ,.... do cu' ..... ' :II ,1Ie: 1I"'J<""lI
ohouIdo:r. 1hc r1I:ob<1 will Ilo: J.... u",d", ~" \neh wiIk. whleh
k. N. mud! A fPKI width lOr Ihc r.o.bbet ~ '. i~II_
Ti,b ,"" ..-ut" ro:m(r\-.;d. 'hc: """,n,lnS ,,""e ol't""kl n.
p<Tft1)', ..1'okb is .0 gy, JI1>t bit han!. Vou wlU "" .bIe 'o
so:t i. \n,o""" OJI"IIing, bul )'QU'U probably "",.., to ~n .. ck It
,,-itb )'OUt" f..c to .... t ie.

j(,....

"'*

Using the Mounting Plate


No """leub. ,<kk '" im"OI,', in usins ,..., mOUtiutljj

1'''''' You ~mply dri,,,, 'he m""n, lng ..,R:WII,o,,*,, Iht


.pp"-'J'l'Litle holo: InlO ,lIe """e, ~ ,\I.ncu'-U' ,'''' rout ..
Ih'''''8/o .h" ,"hIe,np n".,nln/t. Ind scaI Ilie pble Iii Iht
r~,*",' Chuek bit In ,hc colici, plug in ' hc: ruu,er, ono! )UI
.", ""dy fur "",,,:r ,.bie: ......n:
,,,,, "-dljhl "r,h" roulU' ...iU kcq> ,he pb'c: in pbtt.
A hig O<h .. nLojie ./Ils mounWlll pbt~ lk5ig:n lI2!l OO"tl' t:he
oi<! bol.<:<J.t1>-t1\c.tabk.10J1 """,nllnll """"""'" >tIfbco:!; .oM
t'O'" n'tl 'o <itanll'" bi, . Ti,h Ilie roula lOOUI'l'cd ( _ /)1
....... pcm",""",Iy) hU"Ie>,b 'Ile W:lIo:IOJI.)'OU t>a>-.; ' o SlJ\If!I!Ir
'<1 d"""ll" btu-. Qttm, )'OU C'af"j ' ..n: ...haL )'OU '"'" <l<q.
"""",.... 'hr IOhlrtop P""'~ no ",indow to ,lor """a.
dc;lr pI;<.<t1c mounling pIl'c, ''OU QII iiI:t
Ihto<o&h 'lor pLa'~ 'o II """"'" )'OU,., ... u.. ...~
~""" bc'ftrr, )'OU an puU.1Io: tuUi.n up out 0/ tllo: ubktop
anei lJI'" )'OUndf cur Xtt56 lOr bit cl\an,Jtl:s.
Ilcmnnbrr ' o puii 'lor pI"II A..'O' .~ )'OU dun8o<- loii>.
I C'af"j', 'blnlt of. >inp. lmunc:o: in ..-hk:h fm:1wId
OII ,..., rou.rr ~ il .ppr-opri;o'~' In co-rry optrolIort tha. ('Om(:) 'o minii, )'00 """ dthU" "",..Ing pin Of
I'ntcc:. r\.,., ~" tunplltc lukk, Of .n O\-nfInd pin, '"
hdp )'OU lJlIido: and C'<><tlrol.1Ie "'Mplccc
I'c:n<:<$ ,lut caii bc ~ '"'" CO\"C~ In otl>U' e""", .,.
"llIl1* s...
1toI .".1'~bic:- un ....11'" 183.1Jcndo.
TOJI Ilou,rr 1\ooble' OII ""'" 2Oj. floor.St.ndltlJl Ro\ot
TIbk' OII ~ l12. Ind ' SpUI Fnw;:c ' (NI P'JI1' 2371bt
JIOIn' """" It. ,Ilo:
pin )'QU nl:l<k W'lIcnco.,r)'tllI'"
rou'lfIJI ..itI! I pllotcd blt 1"" no fcncc , u'"" ,"", .u"l"8 pin.
~ 'hc: ..'Ofk aljOiilSl ,Ilo: pin , ,hen ' Ic:,-.:,"1\ In,o 1/1(, tol<.
""'" pin Oi Iixo:<l, "" )'OU can br.oe" 'he \0"0'" IJVOln>l k
-""""""1)' MOI't'<n"Cr, ,Ilo: pin lIi,CS "'u Ic: .., ..."", multlpl).....
.110: 5C1nlf{t1l of yuur lIold on ,ioc: " '<JUd .M damJl"nIng tItt
Clt1tc:r's en~'ln_ (1f)'Ol"'" "MinII \O"ltlll"" 1 >!'''!ni pItt.
.hen ,1Ie spllllling bj, b )'' '''' fukrum,)
Oo.,e 'hrcng.:tp:d
W()t\< .. In nrm!'Oll!act \O"i.h .hr pilot , , he pin li 51'Jl"ri1L1Ol". It """,., bun ..
kp'hc ''-o'" og:o;n;. 1 hrouKh<>u'''' much of e"" cut
pOSSible, hUl )'Ou e",', al .... ),. I<c:cp 'hc: """"':t.pInsI bodt
'hr pin .M .1.., cullcr. '0011 proI>oblr IInd
Ir)'OU!'OII",ra,c ()fl kplnll ,lor ......n: 1jOI'n>' ,1Ie pin .h~
.1Ie cu, , )-ou11 <:o'2Sion>llj' lc:I 1, JtCl ' '''2f from ,"" pikit.
k::I\';ng "" unllnlsbcd f..... .1Ie cut

"OI' wi,h ,...,

""'' 1\11

"",=>ion

""""Ing

..{!..
OI

...

:o
O
a:

"Ull(."

C UI Oul Ih4! bl oc I< of '"'ilSlI "'tll il Sl~r so". "


you elrltl Llfge' clllmeeer IIole I I uell cor ner, IS

iM .. n, ~ou slmplv ""ve 10 mlke SCtill;II, eu,s ftom


COrner 10 (Orne.. CUiele Ilie Si" ;alon; Ilie Inntr eclge
of Ilie g.oow 50;a 'ilb~, Is Itf, 10 IUppott ,lIe
mounling pilIt .

1 72

Roult ' Magic

.00l ,1..,

,ha,

'o

Bit Opening Inserts


ln ltrehanguble inserls sale the
..ounlin" pl"'le'5 bil ope"i"" to
wh,l Iever sili! bit I'0u are usi ng
10 keep rou rouli"" sdely.
IIow 10 make them for your

roule. ubl".

'"

is ,;a1c!y as much ... $I'''''Y. You


bl! opo:nlu,ll 10 .h", mounl ~'~ pl.;U~ ck>locd 00"'0
.ruu.....
bil ImI .. c k...,Iy .... f"OI"lbk.Thi. p""

T:

~
ii

,t'"

...... 1"" "'''"'I'k:<:< rrom (11" 1'1011 111'" II><' bl. Ofl<'nlng,
",,"",1I1h<c <'tIp:, m'l'h<: ~t~JII~ ,h .. cut.
Ir )'00 ....., "PI'nnl up II,., bil hok 1<1 a.:c:um,"o<!;uc a j.iIdI (OI" la","" ""11<'1.",1>1011 hoil, oon', .ht!11 O, \'o.lnch
.....mI bil .,.. \<..lncb m ..;gttl bit In .tu: roUIC. I nd upo:ct
10 """ tp'UO\'" ... ilhou. h....:anl OI" h."lIup.
" l'OI'>ibl~ fOIUIK>n. """""laiI)' 1t}'O\I
a mountirtg"
pilit' l"",pblr. l~ \0 knock oul 5e>'Cr>1
nch ...."h
diIIm:nI >Itt ol biI opc:nl"4l.
!lui :an Int""""'1Ijl :UlnTUln.., '" 10 lI\alee a 5~
~ plaI" " 'lth a oct al bit opefIlnj! ut5<:m. TII<:
............ uc ~' n In ,"" d ... wlng IlII Ofwt'fna Inu-rI
11:1<*4. I maok tI>(, ..... _ . . , In 1"" phoIo rrom ~och
_ XT)'Ilc '"'" NoOo." 1111 opmlng In dl<: """"n';r\f!. pL>tc i>
)'1Inchc> In diamClc:r. blJ:lC" cno<$h 1" accummocb, .. u..
lIrp plIId-n;,.,. In aJrt' bit coIlectIon. II lwI a Io-indt_ido: X ~ .-.btxt arouOO i,. "Thc in5o:ru :an: 4
. . , '" diamctcr ;ond ~ Jirnibrly .... bIx1<'<1 K> tM Inooen
1II .... 't.. iii. opw,,"- onoJ ~> flu.h. "'" biI opwinp in
.. ift>a1. :an: nu,chnl 10 1Iifkrm conunonI).. uscd ni,
_~. I~nch. I ' .Inch. ;ond 10 OII. ,.,.., J!Ol """
kIIod DU! and ... bbc1<'<11i)t ,(1tIpLo'~ IIIlklD.
BoIh ,t.. MOIJn,ing pQ", . bI. opminB aOO .hc lIUCI1S

il
IT

-.

h;t,..,

pb"".

1haI.

It

Thi5 mi5ma.ch of bit 10 bl. opentng II trollbl .


W;,h" smllll bil In" I"ge o""nlng. IM wo.k un Cllch
It.. b . sH:le ollhe bit openlng Ind gel hung up. Even
worse. 1, could liP 1"'0 It.. "old . II you "" Iuckv. II
will only ruin Ihe WOfkpiKt. BUl .. olng In Inse" clolu
down" hole blg enough for I poonel ."lse. 10 pfO\fldt
nUrZero dUflr>Ct for li !oIlnd! CO'o't bit (lnJ,I) .

:an:

rut US"8

,t.. s:lfIK ,n"pLolr

In fKl. )'OU can lOC<><<>-

...'" tbc.- rcquirCd ""roc<: In,u ,hol: ftMMHItlnil"pI:o'" ,nupl:o,r.


mus si... ~ityinl! "'" nw,,,," <Ji ~ ,h:II ,hc bit <lfXnl"ll
is <'C<lottI"I,,;,, wlth 'M bi. nil.

'"

tiT OPE"' I".G I".SEIIT LAYOUTS

SECTION VlEW
812 flalhead
ma(hlne

Inotn

K~ ',1.".....)"1.1
.'

'.

Mo"'I~k

lerylie.
pOlYUlbonalt.
OI phenoUe pl,Ule

'"

\....
3Y!" dl'.

Mounllng' strew hofes,eoUnltlSUnk

1It" dill .

II'" d~ .

~"dla . (IYP .)

Making Bit Opening Inserts

..
-.(!..
OI

"
a:
O

CUlting Usi

lI"' iOj! 'hc .""""' . doc:!> ro" .... 8O',.j "n~ )UU lh<> ho'"
"""""1"11 pl;Il",.... uP ,,,
,hen. S<I nuI Jh(
pla'" al ,hr ",nlC It""" )...... nuk" ,hr Inocn..; ,.,., do ...., Ihor
"'rne Icn'pb'" IIc"'........ " ...... kc ~ plaI" ~nd.n Inocn

Put

:Itt'On.rnod.a,,,

1. M3k" lloc mo""lIng.plal" I"mpla le . 1 do

nnw=r

P\;a,,,

Rou,rr Moonlinl!
Qn p;ow 16) FoIk>w Ilie ~
oull,,>C'\I ' hcl'<' lOr "",ti"" Ilie IC'mpbl"
Whcn )'OU bort ,!tc iii, opcnlnr. In Ilie leTIlpblC. nul<e
ItlC
4i \1 1nchc::o In diamnrr, "'" 1 \1 1ndoa To eIA
ltoIo: Ihlo b rw: and h.n,., It ccnlcrN pt:fftxIly. ...... """er
and Il"MrImd (1Ile TI"lfnI1IC'IIb>cpb'c .no..."
39 Ilo
Ilfn' lOr 1hIo """""llon) Of do It ar. thr drtI ....,.. ..1111 ny.
",lItrr OF hoIc ;,,,.

""""'' II

lin.,....,

2. Make Ihe moumlng plale. _


lbt diI'l'cIJon
In Ilie "Un"TnIl 1l00lrr Mounlllll
du",rr on .,....,
16) lOr using 'hc ' '''''pbte ,,, makc IhoI: """"'Ii"" pblc I)rill
:and countcf:.lnk ' hc .....-u~ ......, lOr thr ...,..ler.
.nd nU>IHrim Ibt plaI" 10 dupllalc Ilie lempolale
lIut >lUp Ihc dirn-tions In lhat. ch:qMer on IOUI~ ,hol: hi1

P\;a,,,'

""'"'"

I ....cad . ... ud)' thr

}f;" )(

m-inII "'ating 81, Upming l _

AS ..,.,..... lhen: n """ A. ...... I lo-<ncbO.ll.lClnpbIc iI*k"


~ """ I..tnm suoighI biI 'o ..... tho:: ~ """"h

Matul,1

8" )( I 1)t" Cfe acrylk I

lI")( 12")( 12" Clu. "rylkl

Hardware

ho,,,

10 do Ihlo 1" )'OU. bul


",,",p )00'
~I Ih" ......
an<! ,um 'o ' hc ~'cp-by-6l..., 'elIl !)II nul<inII Ihor u..;,-.,n;aI

Qty. Dlmenslons

2 b.us flalMlId IIIKhine K.ews. 8}2)( \Il"


\bol JIoouIj/ ,CI " _ _ ~ , ..... I"HrIJ (rom " iIIo>d

,III< wc
I ~"""" " lJI$o _,~.

lhc

-Ins pb.e. Not~ 1"" ftd dln:alon opmfio:d.

Thm swl' ..... '" %-inth M... lglll hi1 In 1"" oan", la.
pU' e jIIIIdc 10 ...,..1 ,/)f ~p ...
.no.m I!
...n II of lhr w-i"8.
i\.1 .hh poi"'. JUU .... n I"T .... n 1"" le",pl;l1~ .....

bb<:'."

moumln:jl p!>'(

3. OI I Ihc huer bl:o. .. k. 1lM: inxn mUM bc rnaIr


rrom Ibt.tall>C' m>lu2I U Ilie mounlUlg pl:l\e. 0b>i0usIy:
you .... n' ~lIxh 'he I~mplale 10 a omaU "1 ....'" ..'orl<pka;
.., ~"I :os .......,. i....,..~ "" you "'.nl rrom o"", ia'll" ...-.n.
pK<:t . 1IofKI lbt 'cn.pb .c ' o .h<: ..'Orl<picc~ ... ith c:o.~
lapt", ~J you dld ........ klOj! Ih<: maun, lng pl.,,,. Uc !ltt
"'pc ta hood Ihc "'",",pin'" 10 .".ne ""rAp Thc "''''p "il
ptOII tbt wOtl\ ..,tf:ICC llIpinljlhc w"rI<pie . 1III loCllp

IOII<1h.,. k""r Ilie ,,,"".. bb,,~ fl"O<l> ~hing "-, l' I:! cu,
~; If II wuIIIll ~"Ifi , 'he "",tct bit wuuld g<>II# It. and
tII~ "'''' l '

1IeI "I' ,he ,,,,,',,r "';, h ~Htlctl-O.I). ,,,mpt,,,, ~ukk

lIId a IIo.lnd, ..... Igh,

1)1,

ICttpblj( ,"~ '~"'pl"'~ JIUld<" 'lsht aplIOIll>!; in""" WlI"


oi the tenlpl, ". r<'>U' OUl ,I>!; Iruen bIadl<. n.., plas!k~ 'yp~

c:dIj' uM:d for """,,,.inil pll' .... '"'" aU ''t"I'J hanl. A """,,,,,"
1ltOigh, Irit '" ,hin .n<! ronliaIUC"''Y I",U. So 1lllI"
!IuJIow C"". Of' !...... rilok hrnkIn& 'he bit

"try

II J'Uu an:: nukng noon:: !han OrI<' irucn-and )tJn:1y )">II


""-pry up II>!; ''''''1',"1'''00 n::p<.>6IUI1 1. ,,, cui 1"" " "',,
""'" n.., carpc1 .. pc: al"7f5 s=ftt> tO stlek 10 1"" WI'OnIl
pul nd " '''en i, d<.oco, !'OU an'! ~Iy pcd It "I' an<l
It1pply It 10 Iht riJlh' put. So you 6huukI r.gun: " 01 uoln&
"'-"" ",np> ,rI "'pc: ..... nch ll<'W imoM.
4. Kahhe.lI ... Insert blall.k" Ud1 iru.c:n muSi bc tabbriO'<! ... Il ,,-iIll>CSI in' o 'bc """,n.lng p"'le. n,( \kplh of
th< """"" .. cmlcal. >In you ..-;mI 11l( InS<:f1 "";,h<:r
IUndlng pmud o( thc plall: . - IICI'tlj( f1.'" ",,,,,d . Iim"", bc

Jl<IftttIy nU>h

TO hold .h.. I"sen bl."k for rJ,bbeUnll, . n,d, iI .o


1 2-inch"Squl"e poSl w l l~ C,.ptl tlpt . Cbmp It.. po"
In, V'Ie , ,nd you h,vt un'tstncttd .cu u 10 Iht
bLonk\ tdgo. kaust of IlS comPOl" I Zt , ' l.m'OIlt
lrimrnt. II. dlndV rou'.,'o u for ,hil job. Ust 1
... ~!lnv bi. of COurlt.

MAKING IIT OPEHING INSEItTS

A.. CUT THE BIT 0PEH11oIC IN THE MOUNTINC PlATE.

~ dll.

bll

1\4"0 .0.
gu~ bushi"g

. ROUT THE ItABBET AROUND THE oPENlloIC.

I \11"0. 0 " guld~ bushlnll

!IIo"II"," bit
1\4""0 ,0.
lIuiOI' bUlhlnv

____.l---with

Ttmpb't

Ruu~

SUI" 10 protK' wa.k ,,,,"Ct

" Y,"" dil..

1, .

]!h"III hoIe

c. CUT TH[ INSERT BLANK.

..

y..-o.O. guid. bushlng

~ ."-du"

rlbbe.

Templl.f wII~ 1
41'>"d ll. port
4" dll . c,.-clt, wh,ch r itlds
a \4" rlbbtt betwttn 4" d;"
CUI.nd lY,"" d ... cui

\1."-o.O. ou'dt bush1nv

..,
""1:___

Se'lI>'o P'OI.CI wo.k .urfatt

Ttmplltt w1th
' 41'>"'111'" port

4""d l disk

SI\opmldt tdlle
lIuldt II bondtd
'0 bllt~lt. wllh

In.trt bLonk

Ci'1)I!1 taPI! .

~" .abbedno b"

Se,ap tllmptd In vise


(bond In.trt 10 """P
wilh earpel tlpt)

(
Inn'l

W rlbbt.lnO bil

'" Opt"lnOln ru

'"
.,"ii:
O

';}

-....
ti

IIOTTOM VlEW

1'1dli. bi,

"(
~nk l \.
l'I. " mllghl b,l

\IIwldt)(

MountJnv
plalt

O. 1tA88ET THE INS(RT 1lANK.

"

WUlt

Se.. P 'o prolt"


wo,k ,urfact

175

QlUd, I ",bb<-tilll:!:>il In IIM: rouIcr ..... k" ... "')'t1U hI,."


'M 'J>proprbIC [>1100 bcarinl! ~ .. mal;11lII I 1oHn<......io.k
... bbc:I, Set ,"" cullillll <kptll, uoiIII: ~ fl>(lUn'iIlII pbtc',
",bb<-t, Set lhc mounlln& plate on ItIr ~IC . ..... 11 1""
~ rt>nned 1' 1"" ... bbc:I ha;io.k tIM: hit,,, shov<n, Set tIM:
hcigh. oflhc "u 'ocnnlt' .... UIl .IM: ~oltbt na..,.
1()'tIU "'''''''' "'" , ....1I1cIm<:Y from Ilie Irutcn.1t ,.;u not

n...t. inlo tM mount"'ll pbt~


lb: dao<in .......... I ~ ftljp: paI<It: MLId< '0 ,""
"""cr's ~e nu. ba1 n.omtlll, bul )'OU m;/)' l'InII It
hdpfuI in k~ Ihc" routa Mady un tlle wun.J>ica Thc
irbcn bbnI< .. .smaILarId J"IU hI,." ,,, ...'Uf'k il>
~. To
~ I.bcbbnk)'CI rninlrrIiz,eu.", 1wwlIInII.:IIlek It 101 bk>d<
01 Knp ..'OOd ...ith CIf1X"I Dpor You am 1m(>l'U'l""hc hund
Il J"IU ......,.,... ,"" bbnI< ." !hc I>l00.... mornenwilj', U>lng
Qbi<'k-Grip clamp . ~ Improo,-nJ boold, 01 cout!iI', n'l':U\S Ihe
Imc:n ",in hc lurdcr 10 1"1' otr u.", "''OOd ..' h~TI d~ routlllllls
donc.) ClamJ> u.", ""OOd In ~ >"I)IO, . rId ro," thc ... I.lC\ an>UJ>ll
'Ile Imc:n.

"".iI\:

5. DrUl ~'O .. nlt:tSlnk. ami "'1' tiv: nu.lnIUII


1iC1"t-..... 00"". kt:l.:lining <i<''''''''' an:: nftdnl 1.0 kttp d.e

.
-....
.,.
II

lrucn in pu.:.,. Si"",", Ihc",'. "" .-dgtll on It, u th<n: Is OII


tM n"",ndng J>ble, th<' routcT& .ibr.>tion!o ..ill 1"""'1" It ."
pop OU' of pbcc_ n:2l disosI.cr.
1111.: ...,"'''''' "'" local .... In thc- ......., beN..,.,.. tll<' plate
:I"d thc Ins<!n. '" >hown in tII. dr.rAing HII Oprn/"II J..-t
LuJ<ftllI. M )"OU (2II ~. thc mOUl"irl@ pb." has ~
llOk:!c, ......i'" "'" Inscn., hin, onI!' 1.... cmocmIWpn!
noIcho on tIM:.,.... Alt an:: iliShtlt' countenunk..
ttcousc thc- hoIcs in thc .......... ing pbIc '"'" tlppcd (!I()
tbt JCR;'A'S Ihmd Into Ihcm), .hcir daIrlCICT t... 10 br .,.,..,.
",,,,,a! ..11" IIM: tip 10 hc lO!I<d. 0ICCIc tbt I:IJI; Ihc sIIc 01
tIM: hit tO UK" ...in hc md:>os!itd OII il. li)..... ..., LtSir1t! Sj2
tcn:"WJ, u.;c "'...s c:al1rd I -29 bil . (Yoo an bir)" 1Il<' tip or>d
U.e hit 31 """" hI~ 51 ..... .)
Tho: t"aliIc!Il "111)' 10 bon:: tll<' hoIcs Is an tlle dfW pm;.s. fi'
II> inIcn into u.", 1I>OUI1""fI: pbIc, ond p<lIitlon ,bOi ..un;.
on 1"" dr1lI 1"'"""' tWlo: DrilI thc t...'O hoIcs, lhen
tl""" .......... thcm 1tcnIo>.., t"" iMeA . Top ,Iv: hoIc> In ,iM:

~ '*"'"

II

~ pb'"

1_

on mnI!

"'1' "'" 10und

In tht

CI

""

t""

Ippmdis. in
brun: "Cuningll"""d. un 1"'1" l
lJx ,"" Imc:n tt... ', hccn drillr-d .... I"'''Ctn lOr mi ....
.Jimil:lt ..... chc> in "")' Olhcr Iru<-ru J"IU "'" n....:ln~ lttlT',
tiM: ,,'u:oUon: TIIc h:oIf-holo: DO" .....mIII tiM: 1......,
p....
.ido c~ for Iho: SCn:w
ll>c >Cn:..- """" nc-nb.
.!okoI\h 01 ,-"",,!XI. 'o lIokt
Inscn down. IIm prccito: III.
~' I lh:tIlmporUnt~. Now il'! dam"'ro to ""'" Iul"I
holc. 1t J'ontner btt ,,;11 do it, 00' t"" ...on ', nntl -l9
~. II ,..... ru ... cll Inscn lnlO ,IIC n>uun~ pLII.t 0<Id
tirUl .11 of ,lH=m, )""U dislon th~ n>OIlIl"~""'I~ hob,
m.Jdt>M. II>cm 1n>J>06Slble 10 "'p. So
""'. A ~It'" "OIt
"';'11 Ihc ~'()ml'" 01. m" >houkI do tlIC trieI!,

""''''It'

""aru:.
,"e

t"',',

..

6, ~ th" bit opcn.ing in the Insen. lllc lIN .."It"

..,.n. . ..

1<) 1""" t"" lJ;t opcnings is ..;rn I.hc


TIn. ..-ill proo,idt
truc ~n.>eICannCC l>oIt In thc irIonu.. ,",OUlII. tbt pbtc ..
tlIC row ...... 0. ....1< tbc: lJ;1 ) ..... "-.ni to u>c in t ...... n>bI<T'.
CbIkt. ~"it 2fI. in>cn in,,, pbcc- IOd dri'" in ,1Ie ~
..,..,..... turn on "'" rout ..... arid [>I~ throujth 1IIt
Iruom. lIc:ntIoc ,..... """ borinI! pllstic.,..... necd 10 ......, il
~ ~ IOd mnctin8 u.", biI. :opIn IOd . .

....'u <hc inJcn is J>I""'lI'I'n1.


Rq>nl lhis
J"IU doi",
For ,.".,.

proce!i ..ith 0100

b""" opomirtf!:l, I>oo"c

biti arid Imens, II

lhc """'" un ,IIe df'iI

1''''''' DO" ..it.... rout ..... ond 1.........,1 To mart t .... lrI!n1 C<"D~ nd tO do k>r riliM:. "f thdc
In$WI it in ,IIe rnountir>g pbt".ll>cn u>c y.

'crpoln' . ..... lell


.~ ,

~ bII., churla! In tbc: """er 00' lUmN by h,nd, to


dimp!c tiM: m.cn
I( )'OU ' - thc drill 1'''''''' u.>t l'<>roIncr bit Of ny.
cun..... w bon:: thc _
10 bcgIn.churt:l ",cring pin OI."
>n\:I..Ikli:unc..... lJ;t III tloc ch ....1<, and lod 1hc q .. i!llw.t """'~
"'" ln6m II<IIf;ocf. Unc up tlle buen', CC"tcrpoint ~
l1IKkr thc 1>1. uIs, <hen cbmp tlII.: loucn. UIlk,rl: tlIC quiI.
ontl_ltch 10 IiM: b!1 10 I!c usa! tO hore th<' bllopcning.

I( J"IU "''''" tu " .. ~c ." I"""n for ..., npbtc guidc:>. 1hiI il
t"" appro:adl to ....,. AfI ..... tiM: """'n .. aligtICd on tiM: driI
1''''''' I:lhk, """" . \'J.HndHlcq. rountm.ort: for 1"" lan.,..,.
IUitlc: f4nw: ~n(( I Ih l""h !'om.,..... bot. Thcn ...i<dl 1<).
l!<Hnch ~ b1. '0 horc COIl1P""~1t' "'rtJt.I8h I.hc imm.
I()'OU u.... 3 mut.,.. outd lnUnmCl. )"tIU -'liIlsboWd ....
~ drill pn:so; lu .,.,." a hok In I.hc ino<n b ."" pm:.. pul. For
.IIC ' ..... u'ld 10 j(Ui<k ~.,. tI>I! '~ COfK"CfUfic ...iIh thc cmI<1poInt , Ihc p/YoI
l>CCds 10 "" pnpmdIruI:or 10 t"" imm.
fat.'C. A drilt pro::a; ,..;u ~ lIUdt a hoit ~. driIl pra!,
u>c driD cquIppcd ..
rw-<II18k gt>I<Ic
Wilh t ...... "'"" hoItdribed.hond I.hc in>cn w. &irIr liwF
;cnp. ... hi<:h CUI toc danpa!1O
1UI.'bcc, Sincc tIIc
pi"'" b in tbt...--r, )'tIU IM'ftllO moun: ..... 1< """,,'1 _
b CUI coonpIcIdr flft 01 "'" Imc:n. And. fi
COUtIif. )"tIU dan', ....,.,t u.", lnKn 10 ....,..", citoo,

""k

i,"

t"" """'"

""""" t"" _",,""

AdjuOl thc 'nmmd

C.N'I co"n ll lnll .re In ,,,," In.l" u.ing.


fO"nd nle . Ml.rk Ilie loc.tlOfls of Ilie nHdHl countt'
,Inh- Iwo In ueh In"n. A cObplt of 'Wl.pt, wu" Ilie
ni. wlll fOf'" tlle profili! needed.
I 76

ROUIer Ml.llk:

....11",.....

""mi W ,,.,.

~ )"tIU

1.0 ,,,,, ~

raditJt., IOd ....... lIIr

routln!! l1J>bc:lC'l.l op<:ninJl for


1uJIr1-<l"""""" d n :Ie

talt

Iiflf.
C"((in!! l",.. inch <lccp. 1"hcn ..,.A<ljuot t"" t""",",,-"I to n ..... thr
pblc

>houtd ....... tbt

~""upaUnw..

Router Crank
Adj us 11he plun"", rOUl e, ' n . . . ._ _ - . . . .- . - ,..~
ro ur rouler la bl e Ih e u me
Wil)' rou a dju s i Ihl! bla d e
hel ght In yo ur u ble nw:
by turn l" g il c. a nk . !t's
fU I , s moolh , precisI!. And
when )'OU mak e rour o wn .
Irs economi a !.

f i i ~ ~ ....

clldw'. '"'" p.d -~ i.s 11131.

_""u In a 111*. I he plul1gc """a pl'O'lidcs 1"" mnns


alju>l bit "l<nslon '''''Y pl"'dli<'!t' and "'n_ tIM:
.Iu., plaJ!:"'" m""y
""'I..n.n.. bad

I<l

1lx~b:lsoo

_~

il dat, lIIollmcd In l ~ hlc, ,hc plunw: "',,";, can bc: ...TiSI


OIcad>t:. In adl_.
10 "".e"", ,lIe bi, lQr cut, )"" IMY nccd 1<> ",-isi )'<>UI"
WTi5I >boul 20 ,o iO tim"". Th"" H) ,,",'CI" thc: ro.otc' """"IIh
10 ~ .tIc colicI SO }'OU an ~ bib. )'OU h>,... 10
.... UtIl '.... ri.1 .nod~r 30 la 40 timcs in thc 0I1M:r dilTC_ . 1( build",g fo<'<2nns lil<c ~ ._ I!I ....., 01 )"'"

tlci"J" .
+"1\<"1 knoh ,1>;0, ""'" _ _ _ ..... un ' , blo._ted plungc ruule ... lrulnd 01 JCl'in!!. )'OU k""" 10
ltI'bI. lh~ <k,~ !!I"""" )"QU c ... nk 10 .."""" Sud<knty, "'",in~
ond """'cl'injj )"011' ...1)k.moun,n1 ..,...,.'. bj, .. as >implc: as
...,.". ar """'ring ro"'"
blodc.
1ll1>
01 ~ CUI""pU """'s obrioul ond sirnl~".l

,"bk _ ".

KtU>Iy_"

Ioo.l~"

...-n

obouI k, ,..,.l _
',
h ,.uukI ...
1 h;od dwlC<' w uy <U row:r laIJIr: huilt b)' l\l<ISIer
1O)(Joly,, ~ Nk:" &'IJtt Nidt. """er ...,.. ftnnl ..-hll cr~"k
euctI)' III<r
,"o.-n """", ....J 1, " ",,'ni ,h.,
_

*"""

u.. """

...... >lkk ,.. cuo*l bc: Oh .",., .,,..... aIm<l!it 1IUjIIc:d,

'wo ......l'O' un ,bls. "'" can .... kc ~ tia

eo.sr.

,,,,,,ro

oaciIbry 1JOill'. h",',"~, it . [( noi . 'ry Ihi> IPlmO


lf I>op-mad~ , ..">!ion 0<1 thc bmiliir

"<lOC

Now)"OU can JIO

'u'" quickly .noJ 1..... 11 ~ on )'OUt ...... 'er, lUW1 i, ... iU ........
ob)' bul ''''''''' os >Ild: as Skil'. , OII. )..... ClOn mUc. ft~'u",
,,-i,1I =c, . nd, bdon: 1nsullin8], OrI thc: "","er, )"" ~.... ,
.... pl:f~unc 'he "",,<1"'5 adi.........., mh:atLi.vns n.m yau'll
tuve .omctlll"ll. Bullhe bel o(lhe .... 11 .... !I.tu"he ",ule.
Iu<:lt l5 lhc linchpirt. It thc: pI..-.w= """"'""~ Is .. K:lty . OO
.11" <lc l" h..stop rod II mloaJigncd, no Itnob OI" cr.mk ,,;$1 bc:
mhle 10 n",~e iii. adlusuneflls
Sa .."', ~.", IlQd.nno.. dichiI' ,.,Inds oii 11", " .. y
'hrough.n." JIOOd """'"' Is. fOII' bit odju>tmm roublcs an:
Thc ... nc-1I b. fOU P'" 'UD( 'hl'
of r"" ....

"",'e'

Uslng the Flxture


Whlle 1, Is simple In CO<Kl'pI. ttlls RXlu.., ncl:<b 'u bc: nllN
prct,y pn:riK1y 10 thc: rQuler i(j, l5 'O _
... lk:k ... )'OU
" "'111 il ,0 . l'm goinB ' o flIp-1lop tIM: 11$1",1 choplc. IOtm>I In
,IIi> Inst:lna, bcauoc Ilhink 1<:11inl rou bow Ibc: b'un:
..."Orl;s ",;ll m:d:c i , casie< lOt ,.,.. w u n ~c<>tand why )'OU
~ ' " m:akc

1. ilie ""'1' I <l<::scriI>c b"'o....


...1 lhe cnnk i.s i> ..."<><I<icn roIum" bom:I 10 Il! (JO'n Ihc
l1IU\er', bc:ijd"It..stop rod. A nut 1$ epoxinllnlO Ihc cnd ci ,bc:
co1wnn. AnII uI cuonc """"'. 11101 c ... nk al"" thc: coIum ...

'"

::a
O

c:

;
...
~

AI

CT

I'D

""

ROUTEII. CRAHK
EX~OOEO VIEW

Cunln, List
Q t y,

Part

Column plin
C"nk plale

Dime n sions

Ma l erlal

Ifo'x IWX Il'


~" X I~' x 414-

IQtdwood

Ha,dwood

H~ rdw~re
I <oupllng nUl (th'ud 'o milCh , .... , of router'S
he'\Ih"J1op rod)

I plulle kllOb. ,I-t" dlol. X ~"hlgh wnh 14-,20 Inse",


ifRO ....4 r.om Rtld TooI SuOPlv Co. (800-1H 0421)

S.ove bolt

I n,'head 510111 bolt. 14'-20 X 114'

Column

Ihc: nKl umilit .';c,.\., ~l!'Iln .. ,1Ie )l>kc: "" Ilie motor Now.
)'011 c r.onk, ,1", ",oto. " '111 bc Il,hen IIown II'N: "''''''''' rodo.
1, ', )11>' lik<: ,1Ie c:om.mc:n:til :adju,unc:nl fUlI"",, ,'OII an
""r, ""c:q>I ,11'1 )'011 .'" cr.onklng. 1'IOI. '''i>I,rts,Cool. l\Uh?
!lon' , ,h<: COffimc:n:i>1 ~
a c:nnI:
uw.rn 01 a lotob, )'tIu . sk? WeU. t>.kc: Iook al 00..' thq- ....
eomIlUClcd Thc 1)'pk". 1 uniI ~ I>om:k/Upc:d pluric
,1I..,.oKkd In"," !oI1I<.:k IMIII an .Iuminum tubc:. Whcn
,umed 0<l10 ,I>c hc,g!tl ....", rod. ,hc- onIy IhiRJI keq>lrtKlM
.ubc: "" IiM: Ame axls ... hc rod i> 111:1. p .... k Inscrt. Put
c:nnk OII lap
whe,n )'Ou .. an !Vind,,,!!, Ihc ,ubc:' !tLJinI
1O ..."Obbk:.nd " 'hlp ami evenu Uy p;>p rigii. Od.. ln>tf\,
So he, ..... the ><'<-",," '1> ~T.nki'lJI "ti,:"."., n", .-.:ut.l:
rolumn has 10 bc dusc:1)' flllro 'n Ihol hci:gh'-6Iap rod. MoI
thc lonJI<'r ,11:11 rod ",Utc betler .1", UniI ",m ...orlt. Ika,,,,,,

ha."

Whr

it,

Couplln\l nu'

',1Ii,

Tu """ .1", fi ..'"... ,,..... ~" thc ...", "ut>. OI ;am nod"
rrom )'OUI' I'OI"""'S hdlCh'~"" NIl, ju>I as )'UU Ilo " 'hm )'011
nttd 10 puii .I'N: molor of( .I'N:
rods. Orop ~ /1;01
w... h~r o.'cr Ihc rod, and ,,,rn ,"" 6:.. u",'s no. 0010 thc
Ih ......1kd rod. SUn cr:tnltJng. 'urnInJ! thc
_"11",,10

"'una<'

n........

oIlhi>.)"" .....y

"'Ul' ", ~..,."'oJer "'1'''''-"l1JI ,hc ..ucle n.td

"iIh a ~ OIlc:, Ihou!d1 )'OU """'1 Ilo this un :alI f'/utIII<'


rotiI""'. (lf)'OII "",,', rond meuil: ' hrndctl rod In)'UlU' Io<:ak,
!'OII CIUI onJer il rrom 1l,-" dTu<>! Mll'l'ly Cu .. i!OO-2Sj4!l I l
...00 if ,..... an: IIO'JljI 10 ... pl.cc Ih .. rod, whr noi.
rq>bcor il wlth a ... nctt rod, whlch ... itI h~,-c 16 ,II~. pc,
ind!.. 1lK 16 1'" Ilo ml/y handy oIncc II mea"" In (MI' t'Oluel

\ahi<: appliC3lion, ,h., cacll full ",.'011111,," l>f II'" cr.utle


1\ h.If~"m m,"-.::s ,IM: hl,
~" lndu, qua"CNllm tnO\'tS II '4< 1"'-"11. Such pm:15,ool
1'""" ..."m In IXkk III" roti,,,, modllklt,lon, ",a'" ,he
r.:", utt: ' Rc:pbdllf! ,hc111",adc:d Rod ' "" p;!J!C-' 1111

dlanfIoi .IM: hit ctl~ k. incll

Making the Fixture

o" Ulbl.mo ll"te d rOIlI. r, ,he c.ank u~itu bll'


ulenslo" adlu~,men" , No mOle w.ls. W!l!ndll"ll. I,"s
....w IS UIY IS adJusung VOU. lable nw"s bl.d. , Ju"
'u,n , .... , e nk Ind wa.eh lhe bn move .

178

Roul" "" g,e

1lK nitic::al c:knIc:n. It .lutl roIum" lr ,..... ..'C """ Ia,hc- .nd
IM :q>fWOI)fble 1<rw:rw-how, )'OU C2rI ..... kc: ,IM: erant rolum~
hr bori... II""-"'><Ji> .......cr o.kn>.-.:I on .11:11 nuehlne. llul r m
I'lOl. a .umc:r. '" I had In find iII1 all"""",I." 'PfIro;o.cb. Yoo
mIjtht 'hinI<, ... J diIl 'Iii Ilrkd il. lh:o, ,hc liriII p"'" is ,Ite
righl .001 for bori"fll .hc roIumn. llul in>Icad. _
Ihc
aPf'l'Ch I ....,Ied on alt .... a c:ouplc o( false .nru. II', a llil
of 11ut. tOIJI'" ",,"pC, I !hink.
~. )'OU ,.,.. gruoo...,. in , ..... pitt<:s of ...'0<)(1. Ihm
glue ,Ilem ..... hcr. n.. ~..,. combine 10 form a dwtnd
for thc hciJlhHlop rod .nd a rc:oto6 k>r thc nUl 10 makc ,IK

.00000R CRANK LAVOUTS


fRONTVlE\\'

ENO VIE\\'

SEcnoNVlEW

1"

CRANK Pl..ATE LAYotlT

'"-.dll. x ~"-deep
!>ole for column
C ~nn~1

for

helghNtOll roci

Y,"'"d.

EpoxV n\ll In 'uess,

to.." -.di&. mouml"9 hoIe


for crank hlnd~ (ouniersunk
fa, "av.boIt Mod

cOlun,n fII """ mut"", J'O" rtp k down ...... ch:amkt ur ruun<J.
O>'C'

'''''~,

1. Start b )' meuurlng y<>u ....... c r, TI'e wlumn


m.... "" Iong ~ '0 citat ."" ,op 0I.11e .....,.or an<! tlle
IXI"'W mi, il l pn;tjf;W OUl of IIK lop o( ,IK nlQolO<' ( 1' ,""
aank hl,.: """ P'1""" ,RJ Qn """'" l'OIotlon , 1, ....w "" ..
ne"l""""" 'o u>c as o ,,'n.t00;l1"3 knob.) Thc coIumn
n,,1SI ' o ~ tu acrummo<btc """ . hrn<ktl lOd. and .1Ie
di. rnct"" oIlhe hole
mat<:h lhe dbmct"" 01 """ lOd.
(AS I cxplaincd nttkt, It this hok is lou m..:ll ~, ' han
'hc !'Od.1"" wllok rnutk ..mwubbIc wt.m )'DU turn II.)
PI",*" Ilie routct un.~ thc mocor bOllOOU an , "" b,ue,
and lod, II Thcn ma:;urr fron. Ilie yotr dtrough whlch "'"
thrnd<:d lOd p,IS5C$ to .he highc!it projn'tion On Ihe l'0I.II''''
Thls IS ,'''' minimum Icngth 01,,,,, coIumn A"" .....-,'"
from ,1Ie yote ,,, Ihc lOp 01 "'" rod. Thl~ is , '''' minimum
dcpIh 01 Ihc dcaf':l1KC hok ...., ... uot hc _
In .hc
coIumn. fnilly. USC di.ol .,..lIpom. 10 m~", ' hc dl>.rnct"" o(

m""

,'''' 'hlndnJ rod.

2 . 8u)'" COl. pling nul. Tltls" ... extra.!oog nu, ,h;o,.,


.......ur u..:d 'o ronnl "''O 1'0<10 ,h;o, h:t,.., ,"" "'RK tJore.l
I

Mus .... VO ... ro .. '.r for Ih. ('&nk . Plunge ;IU fI,
.. ~ wlll g<>. and musu,e ,he ,od from Ihe yoke 10 IlS
ond, n sl>oWft, A1.0 mu.ure from Ihe yoke la IM ,op
oflhe mKhlM .

'*"'etI 'o u>c thb ~, nut 10 hdp domlna'e "'ObbI<

,"ou, \ocaI bani .....'" .>1 .. ", wil1 ...doubtcdly h....,.:oupllrlJl nu .. in 'hc Ihe Not1Qn;o1 Cou1e . h"",d ",con !lut Il10>'
phmlF roulel'J.-"" n~,<:abk 10 lhe ane cx~1on r ean
,h lnk of- h;o,.., met"" hci&ht ;oo)jus'mCflI rods. "")'OU ncetl

Raul., Cntnk

1 79

"
O
C

.,,.

p}

-...,.
'"

COlUMN ROUTIHG SEQlJ ENCE


FIIIST CUT
SECOND

CUT~::::::::~~;~~
CUI lenglll _ I<!ngth of nul

iiI eI'-tt" _

fI.,,,...n,,, ellmt",lo" of

COUPlJNC NUl"

THIIIO CUT

nul

HElCHHToP ROD

FI.,t ..."",
drmtnsron
of nul
CII1 1<!1'I9!.h - "'!\(III! of nul

""

.
~ V-9_il'l9 bli
CUI

d~ptll

_ Y,

ouU Id~ dl~-'~'

of nUl

Ou~ldt

dlamet" of nu,

a m~"ic rou pl ~nUl . Can IIlnd ......, Ioc:aUy? T'1' R6d Tooi
Supply Co .pln. "'h"" I ""'m '1 Iookcd al .....,.,. plUllJll'
n"'I~', I con Icli )'''' ' lui ,tic: Ililachl lot 12V ,ak"". n MoS
111 ..... ,1. Ih~ Itl"Obl " I!(i()o ... lot 10
0lId ,..., biil

''''''>d,

1><:w..11 plunJlll" an M Illtuod.


nlC poi"1 11eft: ls ...... pIy tIut}"OU m ....

h.md bd"'..,

}"OU

tu.,.., Ihc: nuc in

nuk.. Ilie ""'UD"'.

1"'''

3. Cm th~ colum" pUc:.. SUn "'ith


pktts ~ X
I h X 12 incllC5. Good. lihl"l"'inc<I hardwood Uk.. clle...,.
OI'" ..... plc:. Ahcrthc coIumn S ~, Pucd up. and rippnl
""" ...... tt:<! tu ilS final "diamnn; )'OU an ctOOfCUI 1, 10 "'"
prupn lenltlh for)'Olt' ...... Ier.

He re" good flt of Ine rod and "111 In Ilie column


ply.
,oei 1111 eloHlv In It, g'~, n don IlIt (OU
phl'l9 "ul. When bolII column plles If' glued up. llot

n..

nul wUl IN If~Pped .nd un.bl, 10 ro!.llit In III uvlty,


tve" withoUI INlrI(I epCI ~l ed .
I 80

Roule, M.iOIC

4. ROll! the 1l1"OO>''''' fo r thc rod. Ilo !.hb OII 'br


...,.lIe' .. bit. U.... )lrai!lht OI'" ~. bOt tiut iJ tlle .......
lItt"""er .. Ihe rod. OI" :a do:,.., ' o tlIC -.net ... you C2Il
cumt:. Se.-! thc dcl"h <li rut 10 hal( Ilie rod '~ lIttmnet. h '~
bat 10 etttp up OII ,II<: ~ dq>th ci CUI. Grou>'<: both
pIa:n. tII .. " Ilokl tiI<:'" 10jIct1ler and _ II Uw: rod fi",""o
Ilie dunnet. If ItlC dunl\("l i ~ tOO om:olI. nu~ ... oond JWf
OII n..1l pk """ cllCd: lh .. fi, :apu>. II lhc: mannd b tOO
I>i& soon ovcr.
In nuJr.ing .Itt........

~"U1S. ~

tlw: """er lObk: """'" ~

t'"

f:IOO'~

AnII

,..., .. dooo: ta Ihc ('O>la ~ lhe )lOCk '" pOS<;ibk


ona: .... ,
Il.., b"", in II.., ..."", ~ lOr aU ou/).

k:I."

JOqunKCU~

Thc:sc: inilW gn:x ....,. C2n bo<

rout~

IIlrouIlh. OI" tht'y

<:an "" >loppnl.

5. ROllI 1"" groo'u for Ihe n"l. ThI5 Uw"I...!S


""""'itlf! thc fi"" I '" 1". Incht
IIJ'OO''C ,,'i<!rn :tnd
dttpm 1,
:occ:ornrtlO<1o,,' II ... co""llnll n" l. R~""",, ""'".
!Ion'1 choI<>gc Ihc li:ncr p<>Si1~'" rrom Ihc pn:Yiou5 cut:

of.""

,n

""",,~. d"'ngc tii,,". ;\1.,-........, .ht "'''

,n

(ron' /l:It

tO f1n. ond .....


I >tr.dght bit who!c di:un<1r. n"Irnc..1'11<' "'fll h '" CUt

........ kl hc I\:I.lf Ihc bit d!:un"'''''. ROI" boIh plcr~'


To rlnj~h 0(( Ihc gn~,,'C, fur thC nu. . . . I S<rutU
dian ...", V1If"'l'1nB hll. Rotit a V-grt>O'"" . '" "''''''.. In tltr
d,.. wlnB C<>I",,,,, 1(",,/1"1/ :wq"e"ce
0 >1< ho ... ItIC nul ~u. " ou ouy nccd tu CUt Ihc
btt dfII'1'.or "'..,., .wllCh b:oct. tu tltr ... r>iIdu bit
10 cu' , liule dpcr 'n... pJ" t" get tII<' nut tW>!lf"nnJ

""W'>"'""

to thc <'<>iwnn

6, Gh>e up ,hot: oo' umn. u... up tII<' J!:fOO'"CS" rou

dam"You.11<'don',
'..-o CtJIumn

gI","

h;lI>U. An<l

ono( !oQ~t.o

doo',

O>~

Ihc

bloci< ,II<' chan""b,

Replacing the Threaded Rod


R~pla(;ng

tM

,.ve,.1 ~""fjts .

Htt~ht

NllV, hcH}hHtOP rod "'tlh. Jj;tnt:tI-d,,,,,.te. rod "'tth 16 ,tlruds

~r

Inctl (tpl) ylckls

The moSI obvJous, pttrNPS , i5 IMI MI)USITtW!nIS can be iNttSed In Incrtmenu Ih ..1 are f.. mUia. to ","ulc.. n
"'oodWOfkttS- 16Ihs, 12nd~ , tven 64Ih~ . Slxlun tpl b.uh down 10 \II . lneh per I"U revolutlon. FOUI lums Ihus
1. )01. ""h, ",h.l. I QUMtenu.n 15 \oLo In<:h.
llulllle "-Ineh rod Is ..150 heavie. lhin Itle H,I.chl"s Jlock 6-mllllm01" 'od, whteh m.1t~es It 16' IpllO fin. Arod
1I'r'011 f"f~e tM rod, you ,.n use. 1on9t' ptec~, whleh helps .I!gn 'r'OII' rOUlt< Cflnk.nd kftpltfromwobbl,ng
Can yo<I ",pllC~ Iht rods On Olhe, ,oule,,? Som~ vou un, yu , bul nOI .U. VOI' h.ve 10 _.1 .....1. lhe rod m.1~
0t'I vo,,, .0111.. and decide whtlhe' 11 'lin tit rtplllced ltnd ",hethe. It should tie .eplued
On Ihe Hllachl, ,epllteemen\ ls .. m.uer of drllhr>g oul .nd .tt.. pp,n" the I>o~ for the.od In Ilie roule' bueo
The dellll, /lf Ihls prorus lrfe Ilid 0111 In Ihe futuf"f "Culltn; Th",'d~" in Ihe ltppend.x. Se(N'llt Ille motor
f.om Ihe base 10 do Ihls . Then Ihe yoke on Iht motor hous,n!! mull ~ opentd up 11I1<:(omll>Od.olt lhe 14t'9l!"
d meter rod. Vou Citn do \hl. u~,ly w,\h. ,.u.. ,1 file. TM yoke j~ formed of .. ~oft. USlIy 1,led miTe.lallhal"s
oflen ealled POl melal."
Tu.n li couplt of joIm nUiS on!O lhe new rod, lhen turn 1\ '''''' lhe hoit tn tht boItse. Tu.n Ihe nulS down Ilie rod .
Iim Ilie fim ~insllhe Ns.!.nd 1'" lKOtICI ~n'llhe fitiL RtlASI.U the molOt on tM NIt. Turn \'Ou. new roult.
efOnk on tht rod, JAd you "'" ",aoty 10 h.ong tM m.1tch_ '" \/'OU. mut ... lob!..

,.
O

."

~
aii'

.
T.... dlffenonce II ob .. loul. The Hllaehl 'O UI"~
SIOC' 6'm\lllmeter rod 15 clta.lv ,malle. Ihan il li
ineh 'od. Tht I.n., rod m . ~u il eUle. 10 adJu\t bli
ultnsion In p,edlClablt incremenll.

Inll.mn" Ihe ..... rod II 1 mlntr of dtlUIr>g 0111


ind rellpplr>g Ihe moun, l"9 hoIe In Ihe , ouler's
b.I~t . Som. model. h.ove. mounl'''9''' Ih'l
Ultnds lIUltle "'IV Ihrou!!h Ilie Nit , 10 VOU Clln
WOfk lrom the boltom, " _"""'n . Tht "POI
used fDt" mOll b.lses is very .olt; ~ l/f:nl ~ . I brol<e
out plece of It !!elting the lip ~W1ed ,

met.,.

ROIIler

C, .n ~

18 1

'''''!It

9. Altaeh II.., " ......,k 10 th<: <'Ulumn. O>cct<


of .hc: roIumn In 'bc """'- tr n.,a"",,), ",nd <Jow,'n
~""umn ~ .'10 It ,,'111 61 In Ihc: .,.. Appty stuc 10 'hc:
Moppc(l hoIc in 'hc pb'c . .moJ IUCr1I11e coIumn.

t""

10. Epol<}' the nm In p lace. !.n''C thc nut , .... 'ht


rod AppIy a wn:dI """""" 01 c-poIf 10 .hc nut, then oIitk tht
rod :uId nut hom<:. (1ltc tQd Itdpt; kap thc nul :dJgrto:d ..1Uk
thc qJUxy >Ctlo.) I ld'I. thc nut pro''''d,,'8 ju.>t a "'...... '" ....
nut :uId IlO! ......""""" cot""", .."OUld rub .... thc )""e.
(./t.<"IU1IIy, l2lhcr tiut> ~-.: mcul conl3<1ng mcul. I UKd
n)'1on ,,'a>IIn"
thc cohImn.. OUl anii thc ) .... e.)
Ik <lbc""'" In .ppl)''''1'1 Ilie cpoX). If)"OU ..,., .00
m""h OI put It ill ,"" " .1'Ofll! placa, Ilie aCC,", can oou
In'o .hc ""an",,1 lOr .hc rud . ,,'hich ... ilJ ,nn.!lorm ,""
pk In,o """'p
AIIer thc c-poxy drico.. """"'... Ihor rod rrom Ihc n .. :uId
n:ill>t>JI ~ on Ilie mutCT. 1hcn ilUlall ,"" <T.Ulk on thc routeT.

"""""cnI

Super--Tuning Ihe Roucer


EpOl" Ilo .. ....1 1"'0 Ilo .. (01"", .. , MI~" Vtry 1",,,11
"",ounl of houlehold tPO~v ilc(o.dlnIlIO Ihe dire( '
Imn> OII Ilo, pl.(~il9Inll. O;,b il on nlultd fI"l of ,lot
nUl, II Ihown, ind Ih,uSI ,Ilt nul InlO Ihe (Olu"'II, le
dIS(~tI, If yOll ilpply 100 "'uch tpo.y, It wlll well lnlO
iI"'U wlot'" ro .. don \ wanllt, bOlch,ng Ihe job.

7, Chamfer Or lurn tll" oolumn, On ITIO>I roul~""


Ihe helgh ..... op rod 1 ...,.,Ied q llll~ elaM- 10 lM roul~r
mOlor. Obviously. ~ 1 Y.inclqw.", C'OImn" ..;u IlO! ..,.... "
In such dosc qmne,.,;,'" II mUSl hc lrim~ down.
R1p 1"" eolum!> do"",, 10 .bOI.1I 1 'nd> oqw...,. or sm..Ik:r
iril Is possibk. )led"ce 'Ile K<.'!Kln funhcr br dumkting or
rouroling<n'C,. .lIe ~ .
f lnally,crmocut .hecolumn 'O'M final length . , .... rmy
"';"'110 iqw"" Ilie ""d o(lhc coIllmn 'lu.llhc "" fil$ no.
bul toc sur.: )'JU do,,', In...n'C ..",,<Iy cur. o.hc ""'Do< for
,"" nUl '1'>1)"'-' _ed"" diUgm ., 10 crnl~ .

OI

8. Mal! the cr .."k. u.e: ~ pKcc of ltoc cuIumrt Mock.

.-...
OI

\.ar ",,' '11<: .lupe, as .......n In R"",w C,..mll La)VU"- 50 ...


:o ,1",
cr. nk .0 " .. pe on ti", band A"', ond Iand Ihor edtI:n-lf

..:

)'OU _nl ,)'OU ,-""n chaml'ct-or rot ...........f f 'hc: edacf..


I>riU'II" 0010, a '10"""" hok for.hor cr.nk Iundk, a
Sl<>ppctl h<,lc fur Ihc: ~oIun'" o".nmlM ,"" dLlmnn- 01
''''' holc ror ,1", coIWJln by 1IIC'.asw1nJI Ihc: coI"",n.
1 u><"ll reti pb."11c knob ..... lu.ndk. Tht: pankubr
knol> 1 ""k<:ted Iu.o il "1o-lnch-<kcp irbcn. " l ' Hnc:h-IoolII
moun,lnll bol' ,"", prm"llks ~ 01 cnoHo-ftOd pI3y, conlributl~ 'o Ihc: lu.ndl~ . r..,.,..,." nf "",...,mcrll

182

lOUltr Magoc:

1b """ IM bnf OUl 01 ,"" m"'er CT.Ink.)'OU ncro I routeT


'hal pI .....,." """,,"hl)' tiut 11Ia>'CI'I', usnI '00 1"IUrI)' pI'-"'#
routCTll ,hal worted tipi,
OUt o( ,"" box, l"ou ......
nttd 10 buIf 'cm I bule u ,mlIt
Rnno>'C 1"" motor from ,"" baS<'. Thlf ... n.. tt~r 01
"""'-"'inIt 'hc nUlS r""" thc: hcll!h'<itop ...... and pulllnil 'ht
motDt
Ihor ph.,. pooo, .)CI Ihc JIlrt/l)l> :akk
_
poli'" ,,,,- pO.b. If tbc """ef'o plullJl" actlon
ha. bcftI .'CI')" .lId,y, )'OU m;I)' ...
10 ute finc--wit cmCT)'
papcr Oftlmcs. )'OU an Imprm-.: lhc aaKln <lmply h)' polishin:g thc poM> ..; , h tomClhinI liI<c Scotchl:>ri,( p.d. I

It""""',

al.,.

-an.

"..." up t"" 1"""'" until 1""," IItcr.l11y sI.l"" (" Il1U tIIb
buffIn. ;ofka .hc Iltl' )'011 uk."Un I unknowlllJd)' ro:mo>...
thousandth or 1'01'0 of mcul rtont ' Ile posu:lnd nu~c . 1Iem
100 Ioooc In thc bu.hln(l:l''-' fuoetlon pruJlCTlY1" 1l1cy "'"
<JIIC"I.IOm I a4:ed, 1C'I "'" .ctl )'OU Thc .......""1 apcn 5 I 11'1.
sukcd -.m:I "'" It .."OUlIJ I>~C bo"TS o( bum~ ">'l'h
cmcry ""per,,, """"'" I ,,,,,,,,,,,,,",h orr <hc rud>. PuIl.hb1K
Ihcm ..1II1u..'C only a POS;tn'C dTect on tl>clr pcrfonn,,,,,,,.)
ll"or1c on Ihc bwhrIJIS tru" thc: pll1/If!IC poostS fii Imo. RoD
'hc cmcry p.apcr in.o a ' .. bc. :uId buff .hc buY1lngs ... ith ~.
Il"ipe thc poM> and bu>hinjs c .... " . ,I>cn ,... x ,he poM>
mll)' " .....
Whcn 1"" rnsscmblc ,"" '....ncr. )"0'-' mar w:ln, 'o
'hh !rid<: louuII <>nty ,1Ie .pnng ,,,,,.-. on 'hc ,;klt hy 'ht
1>ciWM-MOp tQd. llcre. thc r:tIlloo",tc.n ", """er b Iksll/,llCd
'o plullJlC' smoothly"'hen fon:c is appUcd '0 11C1T1l 1u.ndlCI.
Whcn )'OU """ ' hc: ( .. nk ("r an)" ""I.... men ' knob). l"'" "'"
In dkct 'ppI)in8 ,"" ron:r '" ""1)' onr han"I<:, "'hich
III ....... Ihc .}... "", out or b:L1."", YOLL ..... n ~'on: tI'<' baJ.
ana by lc:n1ng "ut ,1", unc -'Pf!Ojj,

tI,

Table Saw Extension


Router Table
Goli"

il

rouler lol.blC whhout sa( rlfldng

precious "hop

s~(e'

Inltgn.le

il

router

"'Il<:<' moon:d 'o Lh lnch<ll:lmc'cr r.l11s. ,(

5Iand>n1 tip
)"" h:....: l><Ch"

,1\(

rwry ",.. oonary


addt'd ~" I
~ lilll<opKt' from all.hc OIIK,.,..
H~ . I 5OIU1ion . lmcw;o", tM ro" U:r into Ilie ubk .. ,.,
~. J'U Ix" thc" !\ni 10 admi, w, 1 ..,.."cd ,hls
:If'PI'I.l'K'h !lui ""'i ns finalI)' hulit an o,............."IIjt mu,er
uIW. , an ..,.:ommmd 1\ lOr smalt 5hop$-:as an n<y-<obuiI,J lInt ro..I<:' Iibk: Of U """""''''''' _dar)' ro",,,..
_

(wtIid> . ,...

"* in my """"" ..oopl.

n.c ;od\':I"'''8''> 01 dois arn".-mmt """ 5c'O.:nJ


~ Ilie li". ......,.. in'..".",,,,,, of _
nny
..-....1r.".. ,., fOII ...., ... """ In ,.,..... >hop (o. )'OU ""'
. I><>uI 10 Ft ond),
Thc !>.bIe ...... Os good .nd hc~. :and Ils n_ ...w hdp
d:lmpcn ,ibfttlon ond odoI,o ,"'" ""',,,.,. tabk ~ >t:obllily
n.c bro;><l ap:on... 01 ,Ix .."" tabk: """'~ lVU"-': ... a
hqI muIe. t.bIe:
Tl><: abi<: """".,. rlp renc., an dotIbk a, Ilie bul. for

/1. W:>k _

ruole. l3Ne
Thi~

~.

proieCt i::I bascd ..... 'he ruule, ,.bI., IOP I ,n.:I<k fur

lIIf Rock .... dl (nu", Oei ) ronnxtor" ""W, <'q.ripp<"<l ..'ltlt

comra<t""'. SI .... Ihc

~if...,.

pra<:m....t

here .hollld ,.m!ti for )oor SI...... lr 1"OY tu\~ I diffclTnl


"'"' nod.)"0\1 fIU}'
10 m.kc ......., ".l IrBllon> And ar,.Inly a dlfli:n:n. rlp-fi:ncc " lUUIlllnll ........ 1<1 abu prvbab1r
:alIC,,"'1otu 'o ,IIC' ""',.". 'abk 1Of> or II>
moun, lnjt .ppro;och
,\ Ir _ I l ~, k>ncd In ni)' >hop ... ,Il... I <100', h:o,~ 'o
~ thc ""',.". "'bie: rrom 1110: f ..... , 01 ,Ilo: P'N. 1 SI~p
:around thc ,..... 'o """ np., and """" .. ,Ilo: mii 01 tM

n.."

'"c
O

...,.,uiR: ........

;;

""'<'fi""
ubk
I...:tu.kd ..'it" '"ls

...-.~

Os. 1>oJ;1iI:~ t:octns lOr ,"" rip


le,,". ,\Ir
"",,~r . - 01 1.... .". oon
nno ... '" from mr for 01 1~""'rn'ly """i. . tM UM
I'cnc<! . C".,a rbld,,dppnl ","'IOn "' ~I "'" ..ruminum bul not
Sle<:I, s.. ..'h~n 1 ~ thc: """'" Ilodn.J.. I .....s.: ~ j' , indic:>
wllk, JO 1 ............
burl horIwnUl ~
" 'lhou, rncru:.ocN.. on ,"" fma'. >ted.
1\. piua
lCn doill'l b Ih:o' i , kn"c:l >li a ~"
lOr d~ and dtipe. 1 Jwt piUI! thc """" ''KUIlm '. """'" inm
'he lIok: a' 'he ~nd
fma, Ind muci!
rout ......
""....... ,o:U 1k1Jri. b pulkd '1"....lIh 'he I"o:t>cr Oprning ...."r
r..... ' , Jy boi'. AdmlucdIy, 'hen:'. I lot
cnds up "" my
pan,und .no." .IRI on ,1.., fIoor. III1! ""-nr Unle bi' 01 duSI
~

"bM"'" "bou'
"bou,

oi,,,,,

oi,,,,,

oi,,,,,

'ho'

~'Olk.:,1oo

1..,1"".

'"

'"

TAUE SAW EXTEHSION ROIJ'TER TAUE EXPlOOEO \/IEW

,"

"

Threaded Inseru -"-________


)

.-...
OI

.,.

(!

)"01'

""Ing cunillll ....orlc . ",,,I""lt your ,al'k <:IW

"'In"

on:l\1ll)' ,"ou an: at>ou, 'o nukt an "Icl\SIon


for
U Wh .. ,1I"uk! 'M dlmen,l"n, 01 1, be' (It )'OU Iu. .. t "
Mock,,dJ/lkll . comranor". !::LW, ItIr dln ... uon. 'l"'Oflrd
t>c.., wl1l ""O'" pcrfe"II)',) ClLn II t>c nlOUnlcd 10 ttlr,.....
.h""m in 'he d"'w"l!"l l{n.... h" ... an Y'>U . uaeh Ihc new
extc",;!oo wlnlL 'o LI ... -",w'

1. Makc Ihe tablelo ..,. CU, IW" plCCCli o( ' ~i""h


pl)'",,,od to the din,,,n';!on, .pttllicd hy thc CLll tin8 U ...
Glur-I:lmln"c Utcm (:Le<" 10 (~ . ~""re haRlWQO<l .,......
Indinll "'hlle thc "'L1e <'u"'~ ''hen , he d.m p ~.re o/J thc
plywuud '~hlelOp con:, Lrlm II to ><lu. re .hc e"n: .nd
dc." up IlIc cd~ . TI ... n aplll)" the cdlt<'b.ndIn8. Fluj./t.
, rim Ihe cdllC'"l>aodln8.
IIppl)" thc pl;l).lc I.mln.te next . TIle .op . urfacc
.llOUkl ~t pko o( ."' OQIIL, 1;lIh...,-"oI u~ . un.ltcmcd
I.mlna,e . ln mI' opinl"" ( 1 u,;cd a plece of Illk"hl~
!>mln.o.e I ("und In the Ruwl le ~""i' 1>.,.ll/n SII"p . n'" It
mOlch",," 'lle color of .he
" Iecl)" .nd "'''''co "'cII
mh.nlc:olly HUl II ', '00 d..... for lOc 'o n .lIl' ..,C tllc
""'LlP li""" I ."mc, ln'e~ (>Cndl ''" Ihc ,.hlelop) Appll'
hackcr .o thc bo""m .ul'fi Trim tlLe "miNie w l. 1I a 'ISo
~ clu.mfcriltJl bit . ("r mltlJl tlIC hc,'eI .",und thc
tahle.o p at the """",. Ilmc
I( ,h;, b your firM ,'cn.u", ,,1 .hl. ,." n urn l<l Ihe
dup'cr "Cu.lom 1I0UL~r ""bl~ Top" on p:l.Jl:t 1)6 (or mo",
lkullcd Inform:.. lon O" m.kl"M I t.blctop.

OI

O
OI:

""w

Subslrl,e

-----fi

Making and Installing


the Tabletop
""'(o..,

.'

cun.,. u

"n

Qty.

,
,
,

Subu",,,
E~wnds

unas

Dlmensions
)6')(

1")(

16')( 2S"
1 ~"X

Il"

Milleriill

"'"

1")( 1\\.')( 2r

00>
00>

Hardware
I'InhC: Ilm,n'.I. 19" X 28"
BJ,cker, 19" x 28"
] brtss Ih ..udtd Insens. loI&"18
1 he~-Mld boIu .. ,.11 n.u "Uhfrl. loI&"18 )( 1"

2 brlsi ,h",icltd Insens. 4'0"16


2 CIP bolu. )\"16

x 1 y,o

A(ryllc pllstk mOUnllng p!.alf. ,"" X 10)4"

2. !.ay Ou, t h e m<luml"g holu. I anachcd ,tit


,Ou',,, table"'P .he "".....'lth bol" drL-n. thl'OUJlh tI><

'Q

",,)Olron P ..... bIe . ...... ,"" rip fcncc nilf.Th do '/li . I loot:
..1,;on'>tIC of ",,1.. lntI h"l.", In the _
.. bk.nd 'he nUs.
On Ihc Mo<.,,'elVOelta "" .... lhe Mand:lRl Mlm~
.. cel
In", 'R" mounlcd
.h= "'indt
boII> ron throlll(h UIC " 'Inllln,,, 'hrndcd I>QIcJ In 'M P'W
tallie 11)" usln~ ',.. ineh bolb. l eould In..,n them Ihrough
tht ""W ,abi,, ', hok . dri"inll ,hem Inlo ,hR"a<kd Insc"" In
rlLe fQtller t.hle ' <>1'. Utln~ ,Il" ' RlJllet batu cvcn provi<lnl

",,,,,,Ion ...

""'fljI.

TUUTOI' I"\.AN VIEWS

"".'"

TOP YlEW (Substrate wllh tdOt tIoonds applied)

,.

~ JrIQ

poInt
10 lip fmct raii

R,p le net
bar

...

gUde

+-, ,,. _~

".
h")( h"
'Ibbtl fo,
mounllng plate

Rip fenee

~~~~~U""".
ENO VIW.

expo~d

edgt

""ls of 10uler

1...../

1~ :J:=

".

\11

.,'

Il l'>" _ _

= 10...n
~j' \ : ' 1o'\' ""8th'Udtdin

6'c

.
-....
~

....u """"u"" oI.<lIUMabilily. ..., I <:QI.I/d C'tISUn:: IN' thc


IIbk tOJl ",ould Ix flush ,,'i.h thc sn-' ':oble:
In addillon . he o<. en!-lon " 'ntt i> a.txkd . 0 och
ncc: r;dl ..'i,h ingle bol . To ruG",," .bc ......." r t.bk
qt.1 ~ ""1' bolt. In..,ntd tII""""" tht r.ol ....... and
twntd inlo IIIn:.ded nscru.
To 10)' nu. 'h" II""'" for ,bc fi..., th"".dtd insorn ... I
dwaptd """,e .... ppot"t>l.o . bc ,.bl~""w ( .flc, """,",,'illl!
.. a~""lon " lnJ!.. of COUNC:). n.cn I "'" .bc tablctop in
,.. ... d ohlnu"ed 1':lS nco;,CSSi>1')' '" li"", k 1I":lnd lK"IrIjI
I flIIIh wlth ,he """" ,ahi" U.... OI~lJlhtnlR<' 10 dtc<:k
. . flt pmcU tltroll~h ,h .. appropriale
an<! .... rIt
fOI&<I'

hol"".

.tb<~ .ndlnl! .

l ',"taU the th....,"d.:<1 Inscm. o'Ioc .11 thrcodc:d


""""..., .like, oo chk '" dMe,mi"", tbc "",ulm.! sI ror
.. piIoI hoIc:. 1Iorc tlle r>ik .. bolal . ..,b'll driIl or pI"'W

driv" ,he In"" I>. II.., boiI (of tbc appropri;ole


* ) 1I11h ''''0 mtlS IOl1lmtd 100001h on l' as 001.
li)

ThI""l;2d 'hc illSC1't on,n 'hc hol . 'Igh' "I' .0 .lte n",~. Gel
.hc ill>Cn ",.ncd In,o Ih" woocl ncJ IlIm tlte bolt with.

...n::nch. Th~ hanl ~n ls k.,.,.,inll tbc hoIl [l('rpendic"l.r


", .bc ..Ufkpico;,e. Wlw;:n .bc I"""n b ful1f In.u lk<J . "..,
."'" ... ...".,.,110; tu un~ 'Il" n .. " , .nd IUm ,h" boII oll! of
.bc In..,n
II
4. Moun. ti", Ulblttop o n the ,,"w. Se. ,lte tobk:top
UJIfIOf't . 11bC1't tII.. bol .. IUMJ IljIh'''''
1hnn. I>bU .......... hc t:lhlctop ;' flu>h " 'Ith tlle!Q'" ,~t>lc
Ndt: an thc

''''''.-.rY

s.

Cut o u, li.. n '''<lntlol/. ,,1:..... " f"' n Jn lf,- W],h III<'


I:I"'OP In pIIer. ,t"o In ras}" man"" to ~"'UI 'ht: openl.... for
tbc """ont~ pbl~. from "'hk:h .bc ...... ' .. r honll'. R;t'h
. hln n::pc:u _hRl' o ~ . 5pd1ed OUl
hy 'k:uJled
.... p on paIIf 168. I .........,,""'''''' )'QIJ o"m 10 tha. d ."p... r,
UnI\'ct'>oOI ~ .. r Mounll''8 1'1:.01.. n.c .... )'QIJ1J ""'m bow
10 11LOkc.ht: plai" md It"" oht: .......
h. A",t "",iU tt
"""" j"OU CIO LIS(: k o" /(Ui<k 'ht: nI"iatt nI.1Ie """er pun

"'' 1'

"".0

i n 'hc 12I:tIdop.

.... ltln" a small bolt throtlgh a la .g e hole pro


vldes .. musu,e of ~Ju.u.bihlV. II is p,euy dimCul!
~t tha th.udld
9O.lllo"ed
th~ tabletop
edg, wlTh absolute precl.lo". So the adjuSlablhry
f"cto' .1I0w. )'Ou 10 mo"e Ih, tablttop .lIghtly 10
.lIg" It pe.flctly wlth tlle ."w t.blt,

1",1",

1"

,..,..,,1"\ ......

10

11'5 noI p lly, bUl II il o.derly. Tht


dl!. w!ra in Ihe wllY. Th,y'd jllm IIglll",1 Ihe bollom
of Ihe Ilbltlop. IImlllng II>! dtplll of <ul ""d_
Vi!nung ma f,om j ..., hfung Ihe roule' and piile OUl fii
1.... !.IhttlOp. So I ... mOVl!d Ihem. The power tOfd cIw>gle<! OII the floo. Ind mlde k hlro 10 'WHP up. Sa I
rolled II 1"'0 il coli iIIId tied It. To lift 'I>! I'0<Il" OUl 01
Ihe !.Ible, I unpluv 11. TI>! Slrlp m~nel holll! Iht c...
wrel\Ch oUl of ,he wilY bUl close III hind.

Making and Installing


the Rip Fence Facing
Though ,his rip """"" bdng 10 hillcd "" C>fl'ional.l ..."OUIdo1
do "ithout I. As;1 IIM lumnI ..... 1 """ Ihb ruutcT
101. And m., WIk "' .... rlp ,."",., 10 a mi pI ... I """ ~ ..
poMtion qulcIdy ......, ....I!h """ t...nd
Uf<l lip . .
tIM: kDtt ",ouleln', 1><" qulc "" ..... toI ..ilhaut , .... Iwa

'"'*.

.-...
~

.
~

."
w

CI

oc"""'.....

>iCction """'"

C.UI. _
. su"lng 10 s uppOr'! the uobl.nop
wt" le \'OU ml,k tht Instrt 10Ullon A plec' of p/y.
,"'ood ellmped 10 IIM! unde"ido! of IIM! 'IW\ fenn
'l'" .upt)Oflld my ubietOl' just aboul nu.h wlth tht
SlW Ilbl . A tOUP'- pal .. of bulldm shim. W~ "II 1
nHdflI lo .. lst IIM! Ilbletop Inlo parleel po.ltlon .

6. ~r\u; )'o ur routu Ulbl<o, l.InIiko: m.,.,.,.,...


~ I\00I,,,, 'ru*: "" I"'W" 212. thb """ lu:5 no.,.,....
J'lIl"_ ut dro,"~
bila :ond QI\lI:'r ~ g.uIf. AIIer
~ IN ul*a ..".......,.I~ IN ....... _
conoumlnJI p:ort 01 >dUP ..."" Ilndi"ll IIM: . .ns .... ~h. Sa
I sc,....'n! ohon "rip ""'lI"C' 10 11\1: bOIIO"" oidc: 01 'IM:
Wlk, ..... lOr ,IM: """'ndI.
I .ba """'d my>clf NMIn,: "" ",,'cn>lon con! "'~
Iim<: I .....",nI 'u "'"" ,IM: ...... 'e. "'hoit: , So I 5prm, fu< 'IM:
~ dtttri<'al supJ1'l"" 10 011111, 11\1: uhk .... lth a
....~Ichnl out ..... '"" """"n In IIM: ""cllmpan)'I"lI ~IU"',
' I'rno'c. ", 'IM: 1l<1I.1Ier n,hoIt:' 00 po"" 190. I lIIOWl,nI ,1\1:
" " " ori ,IM: untkni<k of ,1\1: u"'" "'..... and 1 bundkd ,hc
cabIc ..ilh ,IM: l~bIc !IO .....~
c"nI "" ,IM: nun,1>c:r o(
ohk:i on;a.kln,:w.:fUOO Ihc ~""(",,e sh" " t100r b m l"In>I~.

ro.

p<'''''''

1 86

ROUla' Mlgk

fadng.

1 . Cui thc partii. lbc: ""k il .simp!c """"'" lhII ""


aii .1\1: pati> ~I oIf tIM: NI. Jol'" .nIl tllitUno
thI: lumbct, Ihrn Tip aud croMCUI IIM: paru 10 IIM: _
.sioN ....(ir>td by ,II<" Cuttiflg Ust
1 llSnI popIat for thI: """'" patul y.... eould .,., ""
""nho.'OOd. bu< In n:troo.pccl. 1 1II1nk p/y'JI-'OOd " .....Id Il\'.
...,.,. ~ ehoicr. Whi!c III<" Icndcncy miJ!.h1 IM: lu 111<.
(2JS ......

",U,,}' material, )'OU <Iu lItt\I

'o "'" ""'bie, .. r.lgllI"*,""",

..od:.., ih>, thI:,."",.,.uy.; " ... jdlI aud 1"'"


2. Cui thc Jolncry. Y"" roukl eu, ,hc tongunOIII
1""1 join il.., fn>eo:: bo~ an ti.., rouler l.bIt. b,"f
COUI"X you don 'l
onc.'bu m .. <Iu Ihc joi} wilh . ~
IM:Iel touter. bu< (..... Idt. I,.s C'aSil::r 10 do it an tII<" .. bk ...
Cui thI: gro<l"'" fll'>1. Sel II.., I~:uk Iw.ijchl , . nd pooii:II
Iitc frnce ~.'nd! rrom Ihc hbdc . .\.I.kc. fi ... p..sort exil
of tI><: (our grooo....". Itcp<ltlon 'he rip
ontl mal:< ,
" . 0.><1 pa..", un och gro<l'''', If nn."t':S>Otry, nlltl<c > Ihinl pol
10 COIIlplc1C IIM: gtUO'"C!i
car> bc lUnned in mueh thc """'" fa<lIiol
Dun 'l eh"""" "'C !>I.d<: hci{dll scnlnJ!. Ilt'pooilloo
hown In Ihc d"''''nl/.. 10 "..~c Ihe >huoMIr
cad> I'ittc. Then m......... 'hc fcntt doIct.
thc bbtk. """ . tim t>ff ,tic ttroaining :;Il,.... of wa"c.
gtUO'''''

Ilo,..,

k,...,....

"'e '''''li''''"

"'ne<'....
(..,,-/ou. ""

tht.

1I ~

FEHCE FACING EXPLODED V I[W

RIP FENCE FACINe

Cutting lis.
p. n

Thrud~d InS~rl )

...
.
_

~,

Qty.

,
,
,

From/lla,k

...

/~

Oim ensio n s

Mate ri al

Ito"X4"X27"

Ha,dwood

M" X2M" X 21"

liardwood

Ito" x lY.."

Hardwood

X~"

Hardware

le

Plaslic Iamin_te. S" x 28'


8 ovalhead wood screws. /116 x M' Ilor .nd cap,)
4 thruded In,en,.

....

'

heM head bolt .

~ 20

~ 20

X 2Y.."

_ _ From

Bonom
5AWlNG ff:NCl JO IN ERY

CUITlNC THE CROOVES


Rlp '.nce 'adng

L..
Front/back

."

""

."
,

1. Sl'tth.

blad~ height. Pa,1tlon


the Itnet. n shown. Makt ~
fim pu. On ueh !jroove.

I
2. MoV<! the lenee the thickne 01
Ihe blade 10 Ihe right. Make_
.eeond pas. un eaeh g'oove. II
the groove li not 1"'1 w1<l ""ogh.
move the lenee il ,eeond tlme and
make addiUonal paue,.

~
iD

3. The complete<!, proptrly


dlmensloned groove .

...D1

CUTTINC THE TONCUES


Rlp lenee
fadng

'''' '1-.
bon'e-

."

"'1

th~ same bl~de h~lght. Sut


reposUion the lenee lor Iht
,houlde, eUl. a hown. Makt
1W0 p~ .... on ch . dg" 'o
dtfint ai i 100' tongues_

1. Kup

tD

Rlp lence
faclng
Topi
bonom

- f-- 'I

."

\.10":-

2. Move the lene. clo.e, 10 Ihe


blade 10 Irlm olf the ~m.lnlng
waSlt .

3. The eompleled, pmpedy


dlmensioned longoe.

Table Saw EMtenslon Route' Table

187

lUP FENCE fAC ING

,,- - - - - ---1

fRONTVlEW ~

ENO VlEW

r---- Il'h"

,.

~
3'h"

' L..!
I'h"

I !iti" di .

L..

,.-

$EcnON VIEW

1>-1

BonOM VlEW

ll1t",ad.;)

lY

",~ ~nd caps "'" ... bbc.ed 0<1 . 11 !'our nlgQ. Whik 1I, i)
"'"Ould >lI"in tic RfJOd '''tJl~f .able "petallon. il C<ln fo, Ilib
prtlj1 bc .... bl~ SI'" proccdu.." s", .he bI.dc: hcigl" 10 j.l.

ind,. ond po;;.ion .II~ fcnc~ Y. ind! (ro'" .Ile bbdc:. s .. nt1
III~ cap On end. U.~k 1. up wi. h a go<>tkI~ """'p. n<!
p",,11 i, .h""'&h II'" bbdc: wlLli .k """'p. Rcpca he
proo....".,; to cu 1", ~ olaU.1le ... bbcts 0<1 botll ca[>$<
'fu .... ke .Ile IDouIde:. n",. I(no,'cr.he bWk: ..... "'po;st.
,ion .hc fcncc.~bkc II", ~.... '" with
col' ilaI O<I.hc
"'w, f'-"<:<ling 'hc WOfkpiccc wi.h push Slkk. To ..'Oi<!
1I:"ing .1Ie "" t, kkk back the tl;o,dikc "':lS'c ~,tiPi. po,;i.ion
.he (cnce !iO .ru" .Il(: .......<Stc wil! rau .0 dt~ kfl of tM hbdc:.
Thl. "'''"''''' )\MI M'''' ,11.0 e:<lrA M~p of "'J'OS.ioning ,he
fmcc ofter
CUts 0<1 boIh col"'.

,t..,

.-...

,.bIt

"'.kin.tl.\\!"

3. Cu.the bit opcnffi.ll. Thls il! fonncd by cuning an


arc In dte bonom boan!. and > ,,,,,,e:ued uimgk: in dte
OI f""" . tll ,h., ."'" pom .ugcthcr.o "'y Ou, dte cu . U"" a
saOC' !law,u nulte 'hc n u"".

~
~

."
CI

27~

80",. I >lHnch-dWnCl"" hoIc In ,he c ... ntcr of one ""1'


TItIs is Ihe """,ning fOO" 'he $hop , .. c ho. !':Is,... n
Cip
ov.:r noe cnd 01.1>c "'nec. Cho<N: dtc cnd dt .. ,uilO )'011.
F",.en .hc ooIld cop "'.." Ihe OIhcr cnd. 1t Is bcs. nOI '0]1) ...
thc cot>' in place. In ...,..,. 1hc con! 01 tM honcc <an W'
impaCtCd \\;dt chit>'.
,,'hen a """" va<: !s 1iI"'''in3
dtrough ~.~ ""',.., )'IlUt"'Clf II.;" ckan-<JtI. "",Ion . U.., S<'f<"\\'
'U.>CCtlR-' tl", ca",.

,Iu,

el"'"

7 . !'repare .he roUler tence tor OlO""'ing. o..


ruf I:IbIc -"'w. dte rip kncc """ four r.inciHJi.mcter ~
In It. OOIcnslblr for Ins<alUng foclng. It !s. si"'ple """,,'r
' 0 inst:lll 'hl'C:3dcd irlS<'rtS in thc baek of thc rou,~r~.
. hen In",," hoIts dtroush 1"" rip f~ne,,'. hol"" and inlo Ihr
ro'" CI" knce.
JIul
TItc f:bunc. hNtb ... ill protrudc: 00
.h~ ~ oppo;;,e 'he roul~r knc.... TItus,lo hol,., Ilie ""',..
fenec """""ncn,1y a"xtted 10 Ilie tip fcncc's r!ghl skle.)'OU
nttd .00 10 Iu,.., bcing u ched '0 ,he ldi ,"de:. "T"I'II,

'he"'" Iti."",

W:OY.)\MI con ruun,,,,,,,lnlt Of ~'OUn .... rbo", .I>c fosten". hc-a<b

4.

Aso;cmbk tii<: fcnce box. TItis i p"'''y ~imple


m.ner. j\.pply ghl(: '" ,ho: ,ong""" a,..1 gro",..,., and fit thc
pons '''S<''her.
up an)' ld"" "<IlIzcout promp1ly.
Cheek .hc """"",bl)' wi.h 51, ....'" 0$ 1"" 'pply dtc ctamps.
'0 ""5U", ,10... hc 00 .. ;" sq"","". ( Don't In".11 Ihe cnd caps
untll ofte he pl2>lk;" .pplk<J.)

Wi""

"I"".e. ,,'"

S. Apply ,h" pla.o;llc 1.:..


pUI'J'OS"
of 'he plastic tamilUlc b 'o m:tl;c thc fi>tt >l1dt. dt .... ntaking it
c:lSiC1" to ftt<l ,,'Of1t along 'OC kncc. It onty nc:Ws 10 bc
..
_
..
.
pplled.o.1le (ace. [fu ,"mplc job.
1
Cut 'Ile lami ... ,,, abou< 1 Indllong.oo , ineh widc:r.han
Il'" r... ncc I'x". Apply contact ccmcn' .0 bnth . he bmilU,c
..... tM ren.:., r..cc. MIow.1le <;C1IICfI' .u tlry. Afler It is dricd.
~pply 'Ile Wttin;,o,~
!he ~ ..... bumi>l' It dot>'fl ""'II .}
roIkr. Widt nu;h--tr\mn,inp. bit In > <OUlc:r.lrim thc r:dlItC$ 01
tlll." 1:unln>1~ . Ik """' .., nm ,1Ie ,rimmc:r in", tM bil openlng.

'u

6. (optional) InstaU tI>t:: end caps. trutolJ .hcsc if)"oo


I'Lln 10 """ tM fl"lK'C core 0$ d,annd lOr (1,-", roIk<tIon.

188

ROUI." M ~g lc

Into dtc f.tcing.

So whcn 1 m.de: .1Ie r'O,UCI" kncc. [ aJso nude: tip


(acin!!, For ,..M, it"s "'l>nh. 'l> tttake tM faclng, 1 gI ....
"'",i .... ,cd lWO pice"", of I-l-!nch blrch plytt."OOd. lhen
.pplled plostic "'",in"e ' 0 Of>(: $kIe. (Sincc 'Ile pl}""'ood iii
\, In~h scan, of 1-> Inch 'hld: . 'he pla.>lk: bmln'lc l>rinto
tM facIng .ltl<:l:mss 'o cxactJy 1 lrtdL A!; Iong a.! I remcmoo
10 """''''' ..... IC b)' IMt 1 ineh.l <an usc 'he rule e.ehed int~
.1Ie tip (ence .... b.o SCI thc fcncc.)
'fu ",.",fe, .k hole Ioat. io", from tl", tip fcncc .0 .hr
foclng.OO."., rouler fena:,c"'mp.1le pom-noe "'"
of COUI"SC-'O 'Ile rip fi:ncc. '!l>cn in;o:" a hol' .h""'&h thc
hIl.[c ..... "'1' i, ... i,h , ham""' .., dcnllng .1Ie W\>otl. "1 Ihr
de:nt.<, dtil! tM appropriatcly ";led hok. O,;" C thc . h .... dcd
ln ....ru. Coumc.oo", Ilie ril' facIn.!!.
fcn~c

"m(.

8. l""lal1 thc rouler fentt. TIti... ,all!Cly" .... ,""


of dnvlng dte bolt> ,M. h<>1d 'Ile pom ,000000~t. Hu' thc
f.tt:e of .he rou'''r fi:ncc . ht>o.Jld hc "'1"""" .0 .hc rou.er I:IN<
'op, AfIc. OOhlng thc fencc in pbce,dtcck wi,h. sq .... '"

II ,IIe: kncc b

0UI""'~....,.., . 1ooKn

,IIe: kntt Ind In.cn

..... bct...ttQ "'" tip Ii:tltt ond tho::......,. ~ ~


...... how far OUI,IIe: Ii:tltt b,~""'" bycDol~ tip"
.arni'" ,IIe: mlsalignmmt. RCligII,C1\ ,"" bolt> and nrlIrdr;

.......

1, " I ~ PfO""""IM "',,:., ""'''''' 1<> ,"" tlbktop.

~~,

il .... <iI J'OU Iu."

'"'" rrna io lwxIy bcaux 1... ri8h'

10 I>ddk w\tII. An<! " """,,', ohlft .... <il posirioll. cithc:r

Thc ~ 01 uoInJ! u.. "",w'f rmc., crop< lip


" 'hen )'OU ....., ....itching baei< and mh hcI-..'tt!I u.. """el"
tabk and u.. oabI< _ ,

Makinf!:

lJsIAA ,hhi nllUr, uoblr IMn a wholr 101 diffc",m Ihan IIMnS
"yOlhc',

Ikn~ <il ,"" 1oc:I.k>n of "'" """eI" and .1.. oricn",


tlon <il "'" "'...... rena, J'OU mosi freqll.,mly Ipproad11M
lOW:f l<Ibk: from ... ho, is Ihe "",,'s rigIIl reu romcr 1lIe
_ 'irqt FH.IlJirrd ..... o....co 'hb ckat. v""........ 'o ~ttp
.... :un.round ,1Ie ....,'. fiPl. md ckat MI J'OU an """'"
uound and manc:u>..". I ...'Od;piotte.

il good aampk. To nuIIc 1Ut1'O-..'

W3.D' 10 mut ,IIe: profIic Olt

"ido hoard. ,hcn


rtp 1"" sdck rrom tho:: b<>lrd.
rolll ,1Ie proflk an ,1Ie ,..'"
"""'. tlICn np i. from "'" bo<ud, To do 'hls. }'O\llu." '0 kccp
.hll'll"8 llIc rn.cc back ~nd t<lnh . LcI o .. leU)'OO fron, O"perknce.I' Udm-c J'OU 011111.
In th<:>Ic ~ 11'10 btIlff 10 ~ SC"V"t.."
""'--c for the mutel" labIc. 00 )'OU ~....,
mu.er
WJk ....cup "1Uk u5in/I IIM: rip Ii:nct" ro.. IIM: ..... OJICI"'ltlooS.
In odltt ~ wd1 .. ~ biu. IIeIlirqt bit
~ and ronuoIIing Ihr ......... P>'<'. do wilh ..., n)UleI"
WJk .. )'OU ...'OUId "ith :ati)' othcr !OUIeI" uIX
mokJi"ll".)'OU

Using the Router Table

,,,,-,,,, "" .IIe: .....

' 'ou DO oIidc" it U>Io .,.,...ion quickly and....c il. 1'010 dam ...

t"""

1"">'<' ' ' .""

FUO Oi llECTION
ROl/it. toble fff<! dlre<:lion

When u~ln'il Ihe t~ble nw's nI>


lenee 10 'illlide a 'Olll!' cut,
!M Iff<! direction Is uatllv oppo.ite
.hol fo r a nw CUI. So Ihe OPt,mal
Post 10< a <OUle' woodworh, is
f.cing Ilie righ. eM of Ilie w w.

,.
1;)

Tlble

$lIw

C
fi

.,"

fHd direction

-....
fi

Wnh IIM splil 'enet P<>1t1iont<l


0lIl1>0;0,01 of the blt. !M Iff<!
dlreellotl mlm"i lho\ of a uw

(ul, SUnd In f,onl 01 Ihe Siw


and push Ilie wo,k, jU.I., In
m.lkln'il ~ s~w t\ll .

Whe<t IIslng bit'. piIoIlo \llIlCIe


a Cllt. you' wo<klng post 1. mo,,"
flulble . Tht feed d,reetlotl
"rotltes" clc<kwlse .round
Ihe bll.

A Iong IIr.1lghltdge can be


aCn;lU IIM SlW table 10

d.m~

'ilUldt a CUI In VI uptd.'"" Ion\l


O< wldt wo<kpl~e . Thl.
.pp,o.oth p'oYldu Ihe bel!
suppat! 10' the Wil,kpl~e,
Posltion the len" "behlnd"" Ihe
blt . nd Id lrom Ihe saw',
,i'ilhl 10 Its leit,
T.blt

s..w [xttnilon Raul" Table

189

Power to the Router Table


II you a'e le,loUI .I>out mUI~' tabl. "'o"', you
nud. UIUP tllatlncorporale> a S"'rlcheel rtptacl .
TII. adVllntagei are several. PosluOll Ilie oUllel
nt~1 to Ilie mutt" mal"ng il conven'tnt to unplug
",lItn cllang,ng b'tI. me ma,n reUon woodworktls
fa,l lo lal<t 1111$ simple ~fety Slto 's Illai ,t's IMO"Vt
"lent.) You Ciln poslllon.n on'Off ~wolell ",,,",re 11'1
U~Y 10 flnd mls .. tsptC'ally appullng "'Mn you
nHd 10 ~1I111Ie ,Oule, fim_) Vou un .dd an OUIIet for
sometl!l"g IIM a dUSI colleccor OI a shop vacuum.
maltlng Il S",llcll..;on\rolltd: Whtn Ilie , OUler IJOH OII.
.0 does Ihe dU~1 collector_
",orks "you. raul...
hu Ilie soft-start- fUlule, or II bolh roul..-.nd duSI
COIlIOI ar. rdluvely lo"'ampe~ . IlIrIIW1l 111911.
.mpt!f1ot mOlor.-ny,' 14.mp roul.... nd. 12-.mo
duSI co!leclor--klcltlng OII .tlhe ~.lnSlallt CilII
O'IIttload a 20-~mp t l.tU'I, Iflpping 1"" ~ak"-.I
To sl,n, otl som. elect'''''1 suool,.s, W'II! Ilie
wlung d,,,g m, 111.... '1 I 1111 of 1"" sluff I us-td_
E>tery1h,ng skould bt .v"lIble at you' loca' bu,ld'ng
supplo.. empOnum-... 'lh Ilie U<tOIOOll of 1"" Ihrough
box, wltoch \'OU un get II .n elecu",,1 suppiy hou5t_
llegl" tov lltacll'''11 the receptaele box 10 the
'ou le. "bl., In.I,lIlh. oIug OII OII. entl of Ilie .pp!i-

rn".

.""te"

ance cab"'. and ,,, n !he OI"". Ind ;"10 1""


box, w"e Ilie s.... "e/\ follcno,ngille w!t]"9 d~"m,
.nd illstall tIM! sW"eh ol~ ... UhWlIe. Wtfe ~ receptoti! a"d Inslall!he 'tptiK'" plale.
Plug ..... rycll'''9 III. Ind you .... 'udy 10 IlO

Hardware
th'ougll rec,ptael. box
I conntC'or
I slngle-pole SWltell
1 "ulil)- s"'itell pLate
I duplt .. rec'ptiKle
I

ul~ity

receptael, plate

l' Romu

tab~.

12n ""th grouncl

I g'ouncl,"9 clip or Krew


I etimo 'ing (for ground

cond\ICt~)

IIr 10 20' eO<"d, 1612 IVpe SJ

,".,

WIRIHG DlAGRAM
(onnKl b,J,e (ground)

conduclor 10 1iI,.. n
(groundlngl KreW,

Black (hoO conductor f.om


swlltll 10 .t<~ptade

' ...--1, 81aek (1101)


COndUClO'
f,om Ineom,ng
power table.

COIInecl blKk (hot)


Con!lU(l .... from s",ilcll 10
b,~ss..;oIorHi ' .. m' .... ls.

I 90

louler MagIC

I"comlng paw" (Un cable)

Horizontal
Router Tab
Turn the traditlon .. 1 rOUle r table on
its ur. Un II 10 CUI le"OnS, rilise
panels , and edge'1lroo'tl" bouds.

lltU~ i. li" 1"'~roIloljI _ _ ~'inf.


turn on tII<' 0101 horbofllal """CI' uble lda.
MoumllQl ......ner,;o Ihc bol'~ oxio i> ~I , ... "
o.wI: ,;urf;oo:c b II'" ~ &nul' ,...,. n"y op<'t3llon ,""
~ ..... "" un./i,W'l' IUIIla I:oIbk. ..."OUkl rcquirc JOII
10 bob...,.. 1/1(' """""pIctt OII ~ ,

hh

_ CUIlIng ' '''''''''


. CunI!A wi<k nlll>cu
. ~1"", Ilie cdi!:tc> oI .. ~ , fb, lIo:.lclNf
p;llIds wtth ''allal bll
RoulilIII oudlilNr,I. ~ ,,'1\11 tlll fa..
moIIInA bit<
- Cul'DA <IovnaiI 1'1....
doYnalb

.Ibisi""

for..u.nn.

11K "",riuont.I.......,nolO\Jl k1c. Isn ', p."k .. l.tly new,


01 reuD<: ROIII'" "'apelan.
I><'cn Olbbllnlllhcn, up
lor ro"". II ... wh.cn Phil Gchrc. and Roh YDlkt, IW" of

Iu,-.,

. , ..-ood ..l>t1I.inl collclalln, flDl nlOlImN " roU1~ r On


dIr ornd of" table ....... Ihc ~ .. c",l ,"el iot) w,,-, C",HJJI
Irbal Q ~_ . , Id_
I'\g:)~" ~t:I.I 1'OUtC'l'

""'''1' OII .he labk""w

"""'"fl<K'I' In Ihc ""'P.T1It roule. b ....... "100 II Ihc Iert


<ftd o( tM WIk _ lliuaIlr. )'OU koxp Ihc: ,,"'" ."",mI tlul
cad dnr 50 )'OU c= CtO!iSCUt .. boo.n.1 ,h .. ~ ~ r .11,,,, 2
Ion. Kcq)ing th:I.l am cint ....,.,.. !t ', lkad sp;>cc. l h l'

"

,Iw _

" au. It
""
it> _ 'n noo..!pXC; It". wri"llllK I..bk oaw'.

n.- ~'C. 11K

,wjllll an" pi"'lU UI' whc:n )'QU w;>nt ,o


r.llK p.tnd OI" CUI
but tlro"" "',,"'L'rlkn tlr ou. of
'he wzy ... hen Il Lv", In ll>C U. """"""'" ~'I Im[>ing<'
.,.,.,.00 woodwori<l"fI opcntiON.
Tbc $Ctup ukes jIOOd od\':lJ1t2.jlt: of tlle s:t w '~ nw;.,;. and
Il mak!Ii ""alkn, ...., of ,t.." ...... .~
tahk,OfI ,o..
<Ion ', """,d a " llIhpowCK<J muter for 1. ; It ', on<: >c1up ,n

a,,,n.,.,

i>ro;od."".

:o
O
c

.,.

...-~

any mu.t. ",m won: (w hid. 1. ~mp lu'icall)' NOT


"'8ul~. ,,,,,,,, , hk~). As doIgne<J. trus horil.Ollw I'D
rou'~r moun,l"fI ",'cn.".",,,,. a fun<bmen':oJ short(()rTtn$ of Ion

....I<:h

."'" of

"""" 1\ori1.<""al mo"miltJi': fine adlu:;une",.


TIte doollin 1. clca"",,ut A plf"'uod .uppon 1"'",,1 1.
au..,h <'Il .0 ,t.." rin. of ,lte ..",'1 a,en""", winll. and it"lI
~rKhOt'C d
. ltc ,",'" ho,.,;inll ~ It 1, pnfn."tly pcrpcndicul. , to ,he .. .., I~bl~ lloht:>tl '" ,he """""" I"'nd 1." ,hlck
..... Inll ~rm . whkh hokb 'he ""u' er. As 1.. ... me Implic>
Ihl, un' , ... In!!, "n " bolt. ral~"SI and krto'Crinll thc: toUtc'
a"" hit , l'Inc . dlu,'n,,,n'3 tu Ihe eul""g <kpt h .'" madc
tltroltllh ~ I~"bcn."w. whkh can """'C tiu. owl"Sl .rm
. Imus' Inllnl ,,,.l n.. l 'moun.s. You .djutt 'he hot lK:ight
cmro<ly. hy """SUfinll 'he hl1 poMllon ...' )'OU """.., ,he
am, wlth )'ti'" h.nd l ""'n )'OU """.., tIM: " ck~' lIIidc
" lPln .. . lte
Turnlnll thc jock~' m<I\..,. 'hc a ..... In

.<,

.I'n\.

'"

HORllOHTAl ROUTEIt TABU EXl"LODED V1EW

$wing ;r"m b.ise ply

000
000

o o o

o o

Pbsllc knobs

.......q ..
Swln!iJ i,m lop

Slidt bonom

pI~

Slicle lop

~,

--Cunlng Ust
Pout

..- r

Qty. Dlmenslons

~~_g a,m ba,~

OI

-."

Y,," x 18Y,," x 2r B",h ptywooel

ply

2 plfKtS plUIi(: Jimlnalt. ueh 20' x 28"


t jacksc.tw. *"16; IAj55oo from Rtld TooI
Sl/ppIy Co. (8OQ.2Sl0421J

1 V, x 18y"" x 27'

SypPQrI

1 V," x zr X ny,'

SPiCe'

IWx2Wx27'

Hi'dwood

Shdt lop

I~'X 1~'X4W

HUd~

y,"X IWX IV,"

H",rdw~

3 fiI/Ied pI",stlc knobs ... ilh h'16 X 1Y,," slui


Sluds; '01(-6 from Reld Toot Supply Co.

{! r
OI

Muerl .. 1

Swlng i,m 10p ply

. ti
~

Ha rdware

Sildt bonom
Shlf

BI~h

plvwood

BI~h plywood

1 ...r~ x11"x2 ' Y.

such Ilnr V.<hlk>ns II.., )'<'U h. ,.., 10


pncd~c

n,,!~tC

Ihe eul 'o

8 Tnul$, JoIo"16
ht~hud

bolu wlth wuht.s. *"16 X Z"

1 flultd plulle knob wilh y."ZO Ihrudtd


Inun: ,01(59 from Rtld Tool Supply Co.
1 c",rrlagt boII. Yo" X 2'
2 caHlagt bo115. h" X 111'

IM diffcl'On .

Eq...1Iy ""poft.m.l"" rig an "" ronMructru .00 boIl~


10 al"","" .nr ""'-""din, l2bIc _ In malle. u( bou...
T11c o<<:Mk 1tanJW2n: I,,'.n, ...., ,.. do6/: as )'UUr 'ck phonc

6 drywi ll

scr~W$.

2" long

2 ht~ nUIS, h"

arid "",1110"

Thluctup li "'" ..,h&lilule tOr,.. muIe. l.bIe ItalhcT II',


,.. romplcmc:r.. '0 1"" mute,. uble. In Ilact, 1',.., IlOl ,.. mula

ntth,-

h""fl unda ,""


e,,,mMon winj] u( my ubl<: ""w
(,."., 1"" photo on f"lIII' 18}). I """ ,"" !"OUl'" ,able ..,IIm...a,- lkM '..-.:wf<~ 1I\.>OCU'-a:abitiIY" \1 key M In nry
<kd$ioft ,~ li 1 hzvI: 10 ~
on cdfIi': 10
nuchw II OII 1"" mula 'able. 111 _bch ' Ol ,"" hotizonlal
.nup ... 1can by II rbt.

WQI\o:.,.,.,.,

192

ROUlt.!Qg1C

Building the Horizontal


Router Table
Wi, h a bI' u( catt:fu1 b)'<'UI won:, thi:; ris wiU <"OnI<
l<J8I"1hcT n>lly. Ikbte )"Ou Slan. nl>ke sun: )'OI' h.:...., .lI 01
Ihe malcriab spccificd by Ihc Culling U51. cspccially Ihc

IIO'UlONTAL ROUTER TABLE PLAN VIEWS

""~

ENDVIEW

fRONTVIEW

Suppon shelf

'---t-:~

Suppon .,anei

--1-7

Suppon
shelf

Suppon .,anei

'--bolt

"NG ARMLAYOUT

Pivot hole
pli ~ s. and apply
the pl~Sl lc I~mlnate. Then
lay out three key elements
on the ~wl n9 arm blank:
I BV," , . The pivot hole Iocation
2. The angled bonom ~ge
3. The end line for the
curved ~Iot

g, Glue up the

A. With route, and


Irlmmtl baseplate,
make an opening tlle
sin of your route'"
base In Ihe thkker ply
of th swlng a,m.
Posltlon fi a. shown.
19W

1W rad. -

""""

-..! End of curved slot

r--:::------:,:;:------;:---<

l W rad./

I g" rad , ~_ _

C. With router and


trammel, roul the
curved slot and Ilie
arm's curvO!'(! fronl
edge . Cut Ilie afm's
angled bonom edge.

Horlzon lal Rouler Table

193

h;mj".. rc.AI I~I O<>e of Ihe h~rd".. ,-c,

;ICms, Ilie ~bc""".


unllkely 10 flnd In yuur 1<.><:11 h.rd ..... n: ~Oft ()nkr
Ihc oddl>;oll 1"" fronl Ih" =oru"",n<lc<l "",,,,,, nd " 'I",n
)"01,11;0,,, "'"CI"},hlng In h:lnd. ~ 10 won..

)"QU ~n:

Building the Swing Arm


Sean by bulldin", II>c swlng Uni Doing Il nI">! IIJ.1ko II "':d~
bIe for U5C in b)ing oul and building II>c JUpport >.!KmbIy

1. Culllle 1"'0 layen 10 slu. 1"0 m:lkc lloc:wm a.'


.ciff:as ""","bie. yuu lOnn II from 1_ bycn of bOn:h pirwood. On<: is '1 Ind!.. .1\0; OIhcr \, indI. CUI.hc nO'\> ~
1<.> .hc dl""""""",, .pa.irocd by .hc Cultinl! u...

I""'e o .. e. Ihc: ''''inll .m. You 11"1 001)" onc c ...""" ., ,!ID_
llIc."",, wrf:oC'f$ Sllck IIghI OCK."C".1Ie)'
confllC1 'IfbnI
\1.., Ioml"".c is oJown . hu,nisll 'hc: ...rbtt .iJlDRlU>lT orid!
a J-tOIIc.
Rcpn. Ihr procrM 00 lhc ~.. 5Idc
Trim 'hc lamllUlc Ouoh ... ilh Ihc eti!P o( Ihc bbIIiI
...."". n>lMe' and n...tHrlnlmlnjj hI. Th opcn up lhc ..,.,.,.

..,.1:"

fOr II", r"O\ltef. dtW a hoIc 'hn>llIIh lhc bmInal" omn......


In 'hc mWlc o( Ihr ..,...".. ~ Ihc """............. Ihc 1K>Ic. .......
Ihc

",,",ndi,. 'hruugh It. s...leh

OII lhc rouon - ' kt-d


lhc pr:rim<1a of lhc m:uo-, IIrIIH """ hc.:orin& C2ICftro
lhc ~.lbcn "'"' fOUl:uuund Ihr Inncr niF oI"!hc "'"""
hII

t~

5. Jtou, Ilie adJU'!iID>ClI1 slot. lllis b :.n<.>Ihcf """(ro

2. R(KlI Iloc opc:ning rOf" tht I"QUlcr. 10 II.., wmplctcd ami. thc routn SCl:i inw ~ ......tncIMIttp trCO& and ..
bo!lcd 10 Ibr rnnaining nwcrW oflbr arm. 1lx C21lIoI"'"3)"
"",".t .. II>c ""'OI> > 10 cut oomplclcl}" ~ Ihc llUekn
pty.ono<l lzy<:T """'" """
si_ 'Q8Clhcf
Si""" I _
" I'onn-C>bIc 690 rouIn. " 'hlch ~ "
round t.oooc.. CUlliojI lloc opm~ "'""" " simple .... lIn 0