Instructions for Tenonmaker

INSTRUCTIONS FOR TENONMAKER

Router Woodworking

Assembly

Your jig has been calibrated to better than 90.0 degrees, sample from your unit enclosed. The fence is set to 90.00 degrees. To recalibrate, rest assembled unit upsidedown on flat, preferably granite, surface. Loosen fence nut plate and swing fence as needed to 90 degree machinist's square resting in window. Clamp the fence to the panel, then retighten nut plate.
Insert vertical panel in its dado.
Insert 4 1/4-20 x 1-3/4 cap screws into barrel nuts to fasten both members.
Locate corner brace and screw the brace in place, twin-fast screws supplied. Be gentle, no need to drive the heads deep into the MDF.
Screw jig to your workbench for the cleanest setup. Clamp if desired but use 2 clamps, jig is ready for service.

Select cutter and bearing, fasten to arbor. Insert at least 1-3/8" of shank into collet and tighten.
Start router at slow speeds checking for vibration. If none, then slowly accelerate to max RPM, ~18-24,000. If you feel any vibration run the router below that speed.
Set the toggle plunger to thickness of work. Toggle should require about 5 pounds of force to lock. Too much force and you bend the jig. The toggle is NOT your primary clamp.
Prepare a 6-1/2 x 17-1/2 x 1/2 (or larger) ski or install purchased ski on the plunger.
Rest router on the platform above the fence. Rest/nest work against fence and gently against bottom of subbase. Lock toggle.
IMPORTANT: Use secondary C-clamp (through clamp window if desired) to hold the work. Without the secondary clamp the work may pivot or squirm.
Rest the cutter on end of stock and zero the router. Set the plunge stroke for target depth.
Rout in a climb cut ~3/8"/pass. The bearing must roll on the stock to complete every cut.
Work longer than bench is high? Then clamp work in a vice and the jig to the work. Use step ladder if necessary to get at the work. Test the security, your stability, visibility etc. without power before routing. A long stick has a tendency to pivot in a vice so block it in the vice if you have to. Take no foolish chances.

5/15/05