White Oak Tools, LLC
Contents
1. Table of Contents Section Page Route a Pocket Plug Cutter Components i Table of Contents amp Introduction iv Specifications amp Safety 1 Joint Anatomy amp Preparing the Pocket 2 Preparing the Plug Stock 4 Router Table Set up 6 Machining the Plug Overview 8 Machining the Plug Step 1 10 Machining the Plug Step 2 12 Machining the Plug Step 3 14 Machining the Plug Step 4 16 Installing the Plug 1g Maintenance 19 Customer Support 20 Introduction Route a Pocket plugs can be made from virtually any natural or manmade wood product They can also have nearly any grain direction This flexibility gives you the freedom to make your Route a Pocket joinery invisible by matching the color and figure of the plug with the pocket workpiece or celebrated by purposefully making and installing plugs with contrasting color and or figure The show surface of the plug stock is not altered during the plug making process This makes it easy to pre select stock that will give the desired effect after plugging It also makes it possible to retain the stock s show surface on the plug s show surface when laminated or pre finished stock And because the plug size is easily and precisely adjustable flush fitting plugs are a reality Route a Pocket is changing the way woodworkers use pocket screw joinery Starting with clean cut pockets screws can now be concealed w2. This page intentionally left blank Route a Pocket Plug Cutter Components Patent Pending Rout a Pockeet Route a Pocket Plug Cutter Component Par Route a Pocket Plug Cutter assembl 101010 Double rounding wedge assembl 101041 Flush trim router bit with upper bearing 104040 User Manual 108005 www routeapocket com Route a Pocket Plug Cutter Components White Oak Tools LLC Route a Pocket Plug Cutter Components Exploded View of Plug Cutter Part Name Part Body 106040 Upright station 106041 Upright station 106042 Clamping bar set of Z 106043 Clamping plate 106001 Adjustment 106045 Finger guard set of 106046 Finger pad right 106017 Finger pad left 106018 Clamping 106049 Thumb screw 102040 Thumb screw set 917 102041 Thumb screw 102047 Thumb screw 102043 Machine screw set oF 2 102001 Machine screw set oF 2 102045 Lock nut 102016 Washer 104041 Spacer set o7 104047 Roll pin set of 2 104043 Roll pin 104047 Compression spring 104045 Compression spring set of2 104046 Washer 104047 Double rounding wedge 106050 Jam nut 102047 Machine screw 102048 www routeapocket ii Table of Contents amp Introduction
3. 35B 44 45 218 212 112 dam gam 358 5 1 5 Workpieces less than 5 8 thick can not be plugged due to insufficient head clearance see Figure 2 ie Cl www whiteoaktools com
4. m Position 1 Router Bit L Position 2 Figure 6 Step 1 10 White Oak Tools LLC Machining the Plug Step 1 Use a pencil to draw an X on the surface of the blank that is to become the plug surface Load the plug workpiece blank into Sta overhanging the Nose of the plug cutter with X down and the end slightly Tighten thumb screw When making cross grain plugs tighten thumb screw K in addition to thumb screw e Note Thumb screw is used to provide additional plug workpiece support near the nose of the plug cutter The additional suppor is typically needed only when making cross grain plugs Turn the router on Hold the plug cutter as shown in Figure 1 Using several light passes guide the plug cutter from router bit position 1 to router bit sition 2 On the final pass keep the bearing of the router bit in contact with surface Step 1 is complete when the end of the workpiece is fully rounded Turn the router off Loosen thumb screw s J and if used Remove the plug workpiece from Station www routeapocket com Machining the Plug Step 2 Figure 7 Step 2 White Oak Tools LLC Machining the Plug Step 2 If making a single rounded plug measure pocket length d1 see Figure 2 If making a double rounded plug measure d1 on the scrap material previous
5. rounded pockets are machined 12C the Route a Pocket s upper stop positioned at If machining a double rounded pocket determine d1 by relocating the upper stop to 12C and cut a single rounded pocket in scrap material d1 is needed later in Machining the Plug Step 2 The suggested single and double rounded settings are listed on the back cover of this User Manual www routeapocket com 3 Preparing the Plug Stock and 2 are c defined in Figure 2 EZ MT WE Figure 3 Single amp Double Rounded Blank Dimensions 4 White Oak Tools LLC Preparing the Plug Stock Route a Pocket plugs begin as simple rectangular blocks called blanks The blanks are made using common woodworking techniques and equipment Route a Pocket plugs may be single or double rounded Layout and machine the blanks from stock that will give the desired effect The width of the blank is sized to provide a slip fit or light press fit when inserted into its pocket The blank width is typically slightly less than 3 8 0 3757 The blank height is not critical but must be greater than the pocket depth The blank height is typically equal to the thickness of the pocket workpiece When making a single rounded plug the blank length should be approximately 1 4 longer than pocket length d1 see Figure 2 When making a double rou
6. e To keep the Route a Pocket Plug Cutter sliding smoothly across the surface of the router table periodically apply coat of good quality silicone free paste wax to the bottom surface of the plug cutter Prior to each use confirm that the flush trim router bit is clean and sharp Also confirm that the router bit bearing is clean and spins smoothly and freely If the bearing does not spin smoothly and freely the bearing should be replaced or lubricated using one of the many available router bit bearing lubricants www routeapocket com 19 Customer Support Feel free to contact us at White Oak To 4840 Adams Rd Rochester 48306 Email support whiteoaktools com Website www routeapocket com Telephone 248 891 7198 Additional Route a Pocket components and accessories can be ordered from our website or by telephone Thank you for choosing the Route a Pocket System 20 White Oak Tools LLC This page intentionally left blank Suggested Single and Double Rounded Plug Settings m Single Double E E Rounded Rounded m 5 9 ga gz s E 8 2 a PB B E 3 S ss 1 4 3 4 35 234 12 3 sop 1 12 1 34 X4 112 34 385A 234 I2C 3 sep 1 12 1 DC 358 sec 134 2 14 1 1 2 LI4 35B 414 12C 4 2 45 22 8 2 2 1 12 dam daa
7. gure 1 Using 1 or more passes guide the plug cutter from router bit position 5 to router bit position 6 On the final pass keep the bearing of the router bit in contact with surface Z Step 3 is complete when the plug workpiece is fully notched Turn the router off Loosen thumb screw N Remove the plug workpiece from Station If making a single rounded plug skip to Installing the Plug If making a double rounded plug continue to Machining the Plug Step 4 www routeapocket com 15 Machining the Plug Step 4 Router 1 7 Position Router Bit_ Position 8 Figure 9 Step 4 16 White Oak Tools LLC Machining the Plug Step 4 The double rounding wedge is used to properly position the plug workpiece in Station A during Step 4 Rest the plug workpiece on the double rounding wedge with X up and the rounded end in contact with surface w Load the double rounding wedge and plug workpiece into Station A with the end of the adjustment screw touching surface Loosen the jam nut and turn the adjustment screw to achieve plug length d2 see Figure 2 Tighten the jam nut Re confirm that the end of the adjustment screw is in contact with surface and that the rounded end of the plug workpiece is in contact with surface w Tighten thumb screw J Tum the router on Hold the plug cutter as sho
8. ith precision ending the backside banishment of pocket screw joinery iv White Oak Tools LLC Specifications amp Safety Table 1 Route a Pocket Plug Cutter Specifications Plug Width 38 Plug Length ingle Rounded 1 5 to 5 0 Double Rounded 1 5 to 2 5 Flush Trim Router Bit with Upper Bearing 1 2 cutting dia 1 cutting length 1 4 dia shank 1 2 dia bearing Read and understand this user manual in its entirety before using the Route a Pocket Plug Cutter It is also imperative that you follow all safety and operating instructions that came with your router and router table Figure 1 illustrates the proper hand placement when using the Route a Pocket Plug Cutter Always keep the finger guards between your fingers and the router bit Figure 1 Proper Hand Placement www routeapocket com 1 Joint Anatomy amp Preparing the Pocket Mating Workpiece Single Rounded Plus 9 single Rounded Pocket Pocket Workpiece 7 Screw Matting Workpiece Double Rounded Plug Double Rounded Pocket Pocket Workpiece Figure 2 Single and Double Rounded Joint Anatomy 2 White Oak Tools LLC Joint Anatomy amp Preparing the Pocket Prepare the pocket and pilot hole by following the instruction in the Route a Pocket User Manual The pocket may be single or double rounded Single
9. ly prepared and discussed in Joint Anatomy amp Preparing the Pocket Loosen thumb screw L Slide the adjustment bar until the pointer is aligned with length d1 Note The plug can be made to fit above flush when installed into its pocket by setting the scale to a Slightly longer dimension Tighten thumb screw L Load the plug workpiece into Station B with X in contact with surface q and the rounded end in contact with the end of the adjustment bar Tighten thumb screw M Note Thumb screw M and its washer may be relocated to hole H Hole H may offer improved clamping under some circumstances Turn the router on Hold the plug cutter as shown in Figure 1 Using several light passes guide the plug cutter from router bit position 3 to router bit position 4 On the final pass keep the bearing of the router bit in contact with surface Z Step 2 is complete when the plug workpiece is fully tapered Turn the router off Loosen thumb screw M Remove the plug workpiece from Station www routeapocket com 13 Machining the Plug Step 3 Router Bit Position 6 Figure 8 Step 3 14 White Oak Tools LLC Machining the Plug Step 3 Load the plug workpiece into Station with surface t with X up and the rounded end in contact Tighten thumb screw Turn the router on Hold the plug cutter as shown in Fi
10. nded plug the blank length should be approximately 1 4 longer than pocket length d2 see Figure 2 www routeapocket com 5 Router Table Setup 1 3 8 Router Table Surface Figure 4a Setting the Router Bit Height 6 White Oak Tools LLC Router Table Setup Set the height of the supplied flush trim router bit 1 3 8 above the surface of the router table Confirm Station C clears the tip of the router bit by approximately 0 030 the thickness of a credit card Figure 4b Confirming Station C Clearance www routeapocket com 7 Machining the Plug Overview Figure 5a Single Rounded Plugs Steps 1 3 8 White Oak Tools LLC Machining the Plug Overview Route a Pocket plugs are made using either a 3 or 4 step process Single rounded plugs are made in 3 steps whereas double rounded plugs require one additional step Step 1 is accomplished in Station A Steps 2 and 3 are accomplished in Stations and C respectively and Step 4 is accomplished in Station A using the double rounding wedge Double ge Rounding Wedge Figure 5b Double Rounded Plugs Steps 1 4 www routeapocket com 9 Machining the Plug Step 1 Note Plug show surface X is hidden from view router
11. wn in Figure 1 Using several light passes guide the plug cutter from router bit position 7 to router bit sition 8 On the final pass keep the bearing of the router bit in contact with surface Step 4 is complete when the end of the workpiece is fully rounded Turn the router off Loosen thumb screw J Remove the plug workpiece and the double rounding wedge from Station A www routeapocket com 17 Installing the Plug When test fitting the plug into its pocket use one of the following techniques to facilitate plug removal If test fitting prior to assembling the pocket workpiece to Remove the plug by inserting a slender object such as pilot hole and work the plug from its pocket If test fitting after assembling the pocket workpiece to its mating workpiece Lay strong fishing line across the pocket prior to inserting the plug Remove the plug by simultaneously pulling on both ends of the fishing line s mating workpiece rewdriver through the If the plug is too wide its width may be reduced using a sanding block or file Other alterations may be accomplished by re machining the plug in Station A B or C If desired the plug may be permanently installed using glue and then sanded flush ines may be further concealed using one of the many available designed to repair scratches Small gaps or witne woodworking products 18 White Oak Tools LLC Maintenanc
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