7902 Dado Jig. Owners Manual Please Read Carefully! Hardware List: 7902 Parts List:

Transcription

1 7902 Dado Jig Owners Manual Please Read Carefully! 7902 Dado Jig Hardware List: Identify and verify that you have all of the hardware shown below prior to assembly. Please read the instructions at least once, familiarizing yourself with the parts before beginning. You ll need to supply a #2 Phillips screwdriver for assembly. 5760B Oval Nut 42 BUSH002 1/4" Spacer 14 MB020 1/4-20 x 1/2 Screw 36 HB030 1 Bolt Parts List: Parts listed below are shown in photos in the instructions: Part Description Quantity Ultra Track Ultra Track Ultra Track T 36 Ultra Track with 2 holes A 1/4 MDF Fence B 3/4 Edge Fence C 2 pc. Bracket Set E Work Stop G Plate Guide P Router Plate Router Plate Hardware Knob 6 MF015 1 Screw 4 MF x 1/2 Screw /32 Allen Wrench /8 Ratchet Knob 2

2 1 Thru Hole MB020 x4 5760B x4 ATTACH MDF SUB-FENCES Identify the 36 Ultra Track (7900T) with a hole in the center slot near either end. This is the Adjustable Track and should be placed on the right hand side. Attach an MDF Sub-fence (7900A) to each 36 Ultra Track (4436 & 7900T). Insert a 1/2 screw (MB020) through the holes indicated on each Sub-fence and start an oval nut (5760B - flat side first) on each screw. Attach the Sub-fences to the Ultra Tracks as shown, with the oval nuts captured in a T-slot closest to the long edge of the tracks. Roughly center the Subfences on the length of the track and snug the screws using the Allen Wrench (5785). Set the Adjustable Track aside for now. 7900A x2 Thru Hole 7900T - Adjustable Track Stationary Track 2 90 ATTACH BRACKETS Attach the Brackets (7900C - 2 pc. set) to each end of the 36 Ultra Track ( Stationary Track) as shown. Insert a 1/2 screw (MB020) through the 6 holes indicated on each Bracket and start an oval nut (5760B - flat side first) on each screw. The end of each Bracket should be flush with the end of the track and square to the long edge of the track. Tighten the screws using the Allen Wrench (5785). Stationary Track 90 MB020 x6 5760B x6 Brackets x x2 BUSH002 x4 5760B x2 ATTACH ADJUSTABLE TRACK Lay the Adjustable Track on the Brackets and align the hole near each end of the Adjustable Track with the slot in each Bracket. The over hanging edges of the MDF Sub-fences should be facing each other between the Adjustable & Stationary Tracks. If the holes in the Adjustable Track don t line up with the slots in the Brackets, loosen and readjust one of the Brackets on the Stationary Track (keeping it square to the Stationary Track) until the holes & slots align. Install two 1/4 bushings (BUSH002) on each Ratchet Handle (5864). Insert the Ratchet Handle through the hole in the Adjustable Track and thru the slot in the Bracket. Secure it with an Oval Nut (5760B - flat side first) captured in the slot of the Bracket. Adjustable Track 1

3 4 12 Back Fence ATTACH BACK & FRONT FENCES Install 1/2 screws (MB020) through the 8 countersunk holes in each Track Bracket (reposition the Adjustable Fence as necessary) and start an oval nut (5760B - flat side first) on each end. Install the 12 Back Fence (4412) and 24 Front Fence (4424) Ultra Tracks to the Brackets as shown by capturing the oval nuts in the T-slots in the track faces and sliding them into place. Center the 12 Back Fence end-to end on the Bracket. Keep the inner long edge of the Ultra Track flush with the long edge of the Bracket and tighten the screws using the Allen Wrench (5785). Locate the end of the 24 Front Fence 6-1/2 from the end of the Bracket near the Stationary Fence. Align the inner long edge of the Front Fence flush with the long inner edge of the Bracket and tighten the screws using the Allen Wrench (5785). MB020 x B x Front Fence ATTACH ROUTER PLATE STOPS Attach the Router Plate Stops by sliding the head of two 1 hex bolts (HB030) into the innermost T-slot of each 36 Ultra Track. Place two 1/4 bushings (BUSH002) on each bolt, then start a Knob (5540) on each bolt and tighten. 5 HB030 x4 BUSH002 x x4 6 Work Stops x2 ATTACH WORK STOPS & EDGE FENCE The Work Stops attach to the edges of the 36 Ultra Tracks as shown. Slide the head of a 1 hex bolt (HB030) into the outside T-slot on the edge of each 36 Ultra Track. Place the Work Stop (7900E - raised side first & overhanging end facing down) on each bolt, a 1/4 bushing (BUSH002) and a Knob (5540), then tighten. Install the four 1 flat head screws (MF015) thru the four countersunk holes in Edge Fence (7900B) and start an oval nut (5760B - flat side first) on each screw end. MF015 x4 7900B x1 5760B x4 HB030 x2 7900E x2 BUSH002 x x2 Install the Edge Fence in the T-slot in the front edge of the 24 Front Fence as shown. Center end-to-end, then tighten the screws using a Phillips screwdriver (not provided). 2

4 P ATTACH PLATE GUIDE & ROUTER TO PLATE Attach the Plate Guide (7900G) to the Router Plate (7900P) using the 1/2 screws (MF035) and a Phillips screwdriver (not provided). Follow the directions in the 4973 Plate Hardware and attach your router to the Router Plate (7900P). Any type of router can be used but, to cut stopped dadoes (dadoes that don t exit the edge(s) of the workpiece), you ll need to use a plunge router. An optional drill style Router Plate (PN 7900PD) is available for semi-permanent mounting of your router, but it requires drilling mounting holes in the Router Plate. 7900G MF035 x2 8 SIZE 1/4 FENCES Loosen the 1/4 MDF Fences, re-position them so their front ends are slightly overlapping the front of the Edge Fence and tighten the screws. SELECT ROUTER BIT - IMPORTANT!!! For best results we recommend our /2 Downshear bit for use with this jig, however any bit up to 3/4 diameter will work. To cut the dado in two passes, the bit diameter can t be less then half the width of the dado. If your dado is wider than twice the bit diameter, you ll have to make extra passes. A 3/4 bit will cut dadoes up to 1-1/2 wide, a 1/2 bit up to 1, and so forth. Smaller diameter bits may limit the depth of the dado you re able to cut. Once you select a bit, the jig should never be used with another bit without A) Installing another set of 1/4 MDF Fences (7900A) and going through the sizing operation. Or B) Removing & rotating the 7900A s 180º and sizing the new edge. Install the bit in your router and set the depth of cut to just below the 1/4 Fences. SIZE 1/4 FENCES - CONT Rip a piece of 3/4 thick scrap roughly 1-1/2 wide x 24 long. Place it between the Stationary and Adjustable Tracks, resting on top of the 1/4 MDF Fences. Loosen the knobs on the Adjustable Track and slide it over towards the Stationary Track, with the 1-1/2 wide scrap between them. Tighten the knobs at each end of the Adjustable Track and remove the scrap. 1-1/2 Wide Scrap installed between tracks, on top of fences 3

5 SIZE 1/4 FENCES - CONT Temporailary remove the Edge Fence. Place the Router/Router Plate on the Tracks with the Plate Guide between the 36 Ultra Tracks. Adjust the front and back Stops so the router bit won t strike the Front or Back Fences. Clamp the Dado Jig to a workbench using clamps (not provided). Temporarily place some scraps of 3/4 thick material under the center portion of the Stationary & Adjustable Tracks/1/4 Fences to support them as you use the router to size the 1/4 Fences. Re-install the Edge Fence once completed. SIZE 1/4 FENCES - CONT 1. Place the Router/Router Plate on the Dado Jig against the back Router Plate Stops (make sure bit is not touching the 1/4 MDF Fence). 2. With the Plate Guide between the Stationary & Adjustable Ultra Tracks, turn the router on and, while holding the edge of the Plate Guide against the inside edge of the Adjustable Track, pull the router forward along the Adjustable Track. 3. When you contact the front Router Plate Stops, slide the router to the left so the Plate Guide is against the Stationary Track While holding the edge of the Plate Guide against the inside edge of the Stationary Track, push the router rearward along the Stationary Track to the back Router Plate Stops. The 1/4 MDF fences are now sized to your router bit and you are now ready to cut dadoes with the Dado Jig. Reattach the Edge Fence to the Front Fence

6 Workpiece sets dado width by indexing between 1/4 Fences SETUP FOR DADO WIDTH Clamp, or bolt, the Front & Back Fences of the Dado Jig to the workbench. Always check that the Front Fence is square to the Stationary Track before beginning. Select the setup workpiece you want to cut the dado for. Loosen the Adjustable Track and place the setup workpiece on edge vertically between the sized 1/4 MDF Fences. Position the Adjustable Track so the workpiece is sandwiched snugly between the sized 1/4 MDF Fences, tighten the two knobs on the Adjustable Fence and remove the setup workpiece. Butt the two Work Stops against the back edge of the workpiece to be dadoed and tighten the knobs. These hold the workpiece against the Edge Fence. Clamp the workpiece to the workbench, or clamp stops to the workbench on either side of the workpiece, to hold it s position while dadoing. 5

7 DADO JIG OPERATION 1. Place the Router/Router Plate on the Dado Jig against the back Router Plate Stops (make sure the bit doesn t touch the workpiece), with the Plate Guide between the Stationary & Adjustable Ultra Tracks. 2. Turn the router on and, hold the edge of the Plate Guide against the edge of the Adjustable Track as you pull the router forward. 3. When you contact the front Router Plate Stop, slide the router to the left so the Plate Guide is now held against the Stationary Track. 4. Push the router rearward to the back Router Plate Stop

8 DADO JIG STOP ACCESSORIES The Front Track of the Dado Jig can be extended on one or both ends. The Extension can be ordered as a 24 inch Extension (7924 shown) or a 48 Extension (7948). Both Extensions include a Track Connector (4536). The Extension allows you to attach Work Stops to the extra length of track to make cutting multiple dadoes on same size workpieces easier. The Extension (7924 or 7948) does not include any Flip Stops, (789S) which can be ordered separately. An accessory to the Flip Stop is the Micro Adjuster (4523). It attaches directly to the Flip Stop and allows up to 5/8" of fine adjustment. Copyright WOODHAVEN INC. 5/21/15 (800) or Fence Extension 789S Flip Stop 789S Flip Stop with 4523 Micro Adjuster 789S Flip Stop 4536 Track Connector 7