User`s Manual - The Woodshop
Contents
1. Mortise Pal PRECISION MORTISING JIG User s Manual Revision D COPYRIGHT 2007 2008 BY R G Jig Co WARNING NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF R G Jig Co Mortise Pal Mortising Jig User s Manual Mortise Pal allows you to make precision slot mortises with your plunge router Please take the time to thoroughly read this manual and familiarize yourself with how the jig is used as well as the jig s safety precautions Kit Contents As shown in Fig 1 the jig is supplied with e 1 Jig Body e 4 Mortising Templates e 1 Doweling Template e 1 5 8 Template Guide Bushing with Nut and Centering Pin e 1 3 382 Hex Key Note The supplied f Doweling template guide bushing Template Mortising fits Porter Cable style Templaies base plates Check your users manual Others will require a universal Template ee Guide base plate adapter not Bushing included Fig 1 Kit Contents Mortise Pal Mortising Jig User s Manual Required Items To use the jig you will be required to supply e A light duty plunge router with a 6 base plate These routers are generally 2 1 4 horsepower or less and weigh less than 12 pounds The jig is not designed for and should not be used with heavy duty plunge routers Various factors such as their overall size weight and center of gravity make heavy duty plung2. The mortising templates supplied with the jig come in four lengths 1 2 1 1 1 2 and 2 e To determine the overall Template mortise length Length add the Template Width template j z length to the bit diameter Fig 10 Template Specifications For example Mortise Pal Mortising Jig User s Manual the 1 template used with a 3 8 bit produces a 1 3 8 mortise The same template used with a 1 4 bit produces a 1 1 4 mortise Table 1 can be used to determine the overall mortise length for common sized router bits Note by Template Length in Mortise Length in 1 2 3 4 13 16 718 1 overlapping 1 11 4 1 5 16 1 3 8 11 2 11 2 13 4 1 13 16 17 8 2 ran 2 21 4 2 5 16 23 8 2 1 2 mortises it Is Bit Diameter in 1 4 5 16 3 8 1 2 possible to Table 1 Mortise length equals template length plus create bit diameter mortises of virtually any length Referring again to Fig 8 the template width is 41 64 or 1 64 larger than the 5 8 template guide bushing This small space between the bushing and the template allows you to rout the mortise by moving your router around the template thereby producing a mortise with an excellent surface finish on the walls Just remember that your finished mortise will be 1 64 larger than the bit diameter Using the Jig Using the jig generally requires the following five steps O
3. bracket with the template positioned anywhere along the guide rods If your base plate is not supported by the jigs fence and the jigs clamping bracket do not use the jig as this can create problems with your joinery damage the jig or create an unsafe situation Non Circular Referring to Fig 3 some Buse Blais base plates are not completely circular or have an offset clearance hole or both Care must be taken when using these plunge routers to ensure that the widest Fig 3 Some base plates are non circular or have offset clearance holes Mortise Pal Mortising Jig User s Manual portion of the plate is at least 6 and maintains contact with Base Plate the jigs fence and clamping Fence bracket at all times as shown in Fig 4 Proper stock holding is essential for the safe use of Widest Portinon of Plate the jig Your stock must be held securely with clamps in a Bracke woodworkers vise or by other pre suitable means Stock that is Fig 4 Use widest portion of plate when it is not properly secured could not circular or has an offset clearance hole move while routing creating an unsafe situation or damaging the jig Mortise Pal Mortising Jig User s Manual When using a woodworker s vise avoid clamping the jig to your Too much distance between jig and stock as shown in ies BS Figures 5 and 6 The jig is shown clamped to
4. defective Excluded from Coverage Failure resulting from alteration modification misuse abuse or neglect or after repairs have been attempted or made by others
5. on the template block Press down firmly to ensure that the holes in the template mate with the dowel pins Carefully replace the brass screws To remove the template remove the brass screws insert your index finger into the slot Template Brass Screw x Holes in Template Template Block Fig 12 Install template by removing brass screws and placing template over dowel pins on the template and pull it off of the template block Step 3 Make layout lines on your stock that mark the center of the mortise Fig 13 shows the completed layout lines on a leg blank before the mortise has been routed Mortise Pal Mortising Jig User s Manual Step 4 Setting up the jig will require centering the template over the layout lines Referring to Fig 14 hold the jig s fence against your stock Align the centerline mark on the side of the jig with the first layout line as shown When the centerline mark and the layout line coincide turn the thumb screw to lock the template in place Fig 13 Make layout lines marking the center Fence of the mortise Centerline Mark Layout Line Fig 14 Align centerline mark with first layout line Mortise Pal Mortising Jig User s Manual Referring to Fig 15 align the centerline pointer with the second layout line Then turn the clamping knob so that the jig is secured to the stock with the template centered
6. e Ee O O Install the template guide bushing Select and install a template Make layout lines on your stock Set up the jig Rout the mortise Mortise Pal Mortising Jig User s Manual Step 1 The template guide bushing includes a centering pin that allows you to install it perfectly concentric with your plunge routers collet Template Guide Bushing Referring to Fig 11 Nut insert the appropriate end of the centering pin Centering Pin into your plunge routers 1 4 or 1 2 collet Tighten the collet Then ee ane Install the template 1 2 Side guide bushing by placing it into the counter Fig 11 Template Guide Bushing Nut and bore of your plunge centering Pin router s base plate Thread the nut onto the template guide bushing but do not completely tighten the nut Plunge the centering pin through the bushing so that the center portion of the pin mates with the inside diameter of the bushing Lock your plunge router at this depth and tighten the nut Then retract the centering pin and remove it The template guide bushing is now installed perfectly concentric with your plunge routers collet Mortise Pal Mortising Jig User s Manual Step 2 Referring to Fig 12 select a template and then install it by first removing the brass screws Use the 3 32 hex key that was included with the jig Place the template onto the template block so that the holes in the template mate with the corresponding dowel pins
7. e routers unsuitable for use with this jig e A router bit Spiral up cut bits are recommended as they remove waste from the mortise while routing Safety To operate this or any tool safely and efficiently it is essential to become as familiar as possible with its characteristics Take as much time as necessary to become familiar with the jig Also read and follow all of the safety procedures noted in this manual If you do not understand any of the operations or safety guidelines discussed in this manual please get answers to all your questions before attempting to use the jig by emailing support mortisepal com or calling 619 459 7951 Read understand and follow all of the safety instructions that were included with your plunge router This jig should only be use with a plunge router Never use the jig with a fixed base router The jig is designed to be used with plunge routers that have base plates that Mortise Pal Mortising Jig User s Manual are at least 6 in diameter Referring to _ Base Plate Fig 2 your plunge 4 Fence router s base plate Template must be supported by by the jig s fence and the jigs clamping bracket at all times P CERROS during use Before using the jig check to Serene see that your plunge routers base plate is Fig 2 Your plunge router base plate is supported by supported by the the jig s fence and clamping bracket fence and clamping
8. over the layout lines Fig 15 Align centerline pointer with second layout line Step 5 Proceed to rout the mortise Referring to Fig 16 one technique for routing the mortise is to make a series of overlapping plunges to full depth along the length of the template Then make a finishing cut by moving your plunge router around the Series of template This technique is overlapping plunge cuts fast and produces a mortise with an excellent surface Mortise Pal Mortising Jig User s Manual finish on the walls Note waste chips will accumulate while routing the mortise You may need to periodically stop routing and remove this waste A shop vacuum works well Maintenance The jig requires very little maintenance To remove dust and debris from the jig use compressed air a soft bristle brush or a dry rag Periodically place a drop of lubricant or tool oil on the four stainless steel guide rods Warranty R G Jig Co stands behind its products with a one year limited warranty If you have any questions regarding the warranty you can contact Customer Service by email at support mortisepal com or by calling 619 459 7951 Coverage R G Jig Co warrants that this product is free of defects in factory workmanship and materials during normal use If this product fails during normal use because of such a defect R G Jig Co will at its option repair or replace free of charge any part or parts shown to be so
9. the stock with too much distance between the jig and the vise jaws Forces generated from routing could leverage the stock Fig 5 Unsafe Vise Setup and cause it to move Too much distance between jig and vise jaws Fig 6 Unsafe Vise Setup Mortise Pal Mortising Jig User s Manual Figures 7 and 8 illustrate a safer setup when clamping stock in a woodworkers vise gt Jig positioned close to vise jaws The stock has been repositioned so that the jig is closer to the vise jaws Forces generated from routing are less likely to leverage the stock Fig 7 Safe Vise Setup Jig positioned close too vise jaws Fig 8 Safe Vise Setup Mortise Pal Mortising Jig User s Manual Specifications Referring to Fig 9 Stock i e The minimum Stock stock width Thickness Mortise Width is 1 Your l Morlise Length stock needs to be at least 1 Fig 9 Stock and mortise specifications wide to be securely clamped in the jig e The minimum stock thickness is 3 4 Note mortises may be made in thiner stock by using shims The maximum stock thickness is 3 The maximum mortise width is 1 2 as determined by the largest bit to fit through the 5 8 outside diameter template guide bushing e The mortise length is determined by the template used and the diameter of the router bit used Referring to Fig 10 the template length is measured from center to center along the slot
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