Mortise Pal Manual - Popular Woodworking Magazine
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1. Mortise Pal Mortising Jig User s Manual Revision C COPYRIGHT 2007 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 Thank you for your purchase Mortise Pal allows you to make precision slot mortises with your plunge router If used properly the jig should provide years of trouble free operation 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 Mortising Templates e 1 Jig Body 4 Mortising Templates 1 3 32 Hex Key Jig Body Required Items To use the jig you will be required to supply e plunge router with a 6 base plate The jig is Kit Contents designed to be use with smaller sized plunge Fig 1 routers 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 heavier plunge routers Arouter bit Spiral up cut bits are recommended as they remove waste from the mortise while routing 5 8 outside diameter template guide Please note that the collar on the template guide must be no longer than 3 8 as shown i2. Depth your plunge router around the template As mentioned the template is sized 1 64 larger than the diameter of a 5 8 template guide allowing you to use this technique This technique is fast and produces a mortise with an excellent surface finish on the walls Just remember that your mortise will be 1 64 larger than the bit diameter Note waste chips will accumulate while routing the mortise You may need to periodically stop routing and remove this Overlapping plunge cuts Fig 13 waste A shop vacuum works well Front Reference Surface Tips and Techniques Practice first Practice using the jig on scrap pieces of material before using it on expensive stock Use A Marking gauge Using a marking gauge or similar precision marking tool when making layout lines will ensure consistency and create accuracy in Marking reference surfaces and making layout lines on leg assembly your joinery Fig 14 Mortise Pal Mortising Jig User s Manual Layout From Common Reference Surfaces Making layout lines from common reference surfaces on your stock will ensure that your mortises are accurately located Fig 14 shows two legs to be joined in a table assembly The legs share common reference surfaces that have been marked with the letters F and The front reference surface has been marked with the letter on each leg And the top reference surface has
3. been marked with the letter T on each leg Layout lines have been made on each leg referenced from those surfaces The resulting mortises made using the layout lines will be perfectly aligned with each other Fig 15 Layout Lines Front Reference Surface Marking reference surfaces and making layout lines on apron Fig 15 shows an apron with two sets of layout lines on the end grain The two sets of layout lines have common Surface Keep fence in contact with front reference surface for both mortises Fig 16 reference surfaces marked F and T The layout lines have been made referenced from those surfaces and the resulting mortises will be perfectly aligned with each other in Contact With a Common Reference Surface Keep the Fence Clamping the jig to your stock with the fence in contact with a common reference surface will ensure accuracy Fig 16 shows the jig clamped to the leg blanks previously discussed Notice that the fence is in contact with the front reference surface for both mortises Both mortises will be offset the exact same distance from that surface Note even if you have set up for mortises that are centered on your stock it is still good practice to use this technique Any error in laying out a centered mortise or error in aligning the jig to the layout lines will be negated Fig 17 shows Mortise Pal Mortising Jig User s Manual the jig cla
4. the top surfaces of your boards may not join flush or both A tip for compensating for this problem is to orient your router the same way with respect to the jig for each mortise you make For example always keep your left hand on the same side of the jig as the jig s clamping knob You might also make a mark or place a sticker on your router base plate as well as on the jig to help you in maintaining this orientation Note this will only correct problems with registration of the front surfaces as shown in Fig 41 and does not help with the top surfaces Making Loose Tenon Stock Making perfect fitting loose tenon stock is best accomplished by Top Surfaces Not Flush Front Surfaces Not Flush Template guide that is not concentric with router spindle can cause problems with joinery Fig 41 using a thickness planer and a set of calipers Using calipers and the lead screw that adjusts the cutter height on a thickness planer gives you great accuracy in making tenon stock that is exactly the right thickness First rip stock on a table saw so that it s width is just slightly smaller than the length of your mortise 1 32 is good Then measure the mortise width with the calipers and begin bringing the tenon stock to thickness on the planer Periodically check the thickness with the calipers Adjust the cutter height as necessary by calculating the number of turns that must be made to bring the tenon stock to final
5. thickness Then round over the edges of your stock using a router table Finally cross cut the tenon stock to length based on the depth of the mortise leaving a little space for glue 12 Mortise Pal Mortising Jig User s Manual 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 defective Excluded from Coverage Failure resulting from alteration modification misuse abuse or neglect or after repairs have been attempted or made by others 13
6. Mortise Pal Mortising Jig User s Manual Step 2 Make layout lines on your stock that mark the center of the mortise Fig 10 shows the completed layout lines on a leg blank before the mortise has been routed Step 3 Setting up the jig will require centering the template over the layout lines Referring to Fig 11 hold the jig s fence against the stock Note it is easiest to perform this step with the jig not clamped to the stock Align the engraved mark on the side of the jig with the first layout line as shown When the engraved mark and the layout line coincide turn the thumb screw to lock the template in place Referring to Fig 12 align the pointer in the center of the jig with the second layout line Then turn the clamping knob so that the jig is Make layout lines marking the center of the secured to the stock with the template centered over the mortise layout lines Fig 10 Step 4 Proceed to rout the mortise with your plunge router fitted with a 5 8 template guide Referring to Fig 13 Thumb Screw Align pointer with second layout line Align engraved mark with first layout line Fig 11 Fig 12 Mortise Pal Mortising Jig User s Manual the recommended technique for routing the mortise is to make a series of overlapping plunges to full depth along the Series of Overlapping length of the template Then make a finishing cut by moving Plunges to Full
7. area for a strong joint Fig 20 shows the same board with two mortises using the 1 2 template There is much more glue area and the joint will be less likely to twist Overlapping Mortises There may be instances when a mortise needs to be made an exact length that is not possible by the choice of templates included with the jig In these instances you can make overlapping mortises For example making a 1 5 8 mortise with a 1 4 bit is not possible by making a single mortise with one of the included templates But it can be made by using the 1 template and making two mortises with their centers are spaced 3 8 apart as illustrated in Fig 21 Notice that two sets of layout lines have been made marking the centers of the overlapping mortises The rule for calculating the overall length of this mortise is to add the template length the bit diameter and the distance between the layout lines In this example a 1 4 bit was used with a 1 template and there is 3 8 between layout lines 1 4 1 3 8 1 5 8 Note mortises longer than 2 should be avoided in thin stock The clamping nature of the jig may cause the thin walls of the mortise to be pressed into the bit The resulting mortise may taper in width towards its center Single mortise with 2 template Fig 19 Double mortise with 1 1 2 template Fig 20 1 5 8 3 8 Overlap mortises to create a m
8. e use of the jig The workpiece must be held securely with clamps in a woodworkers vise or by other suitable means A workpiece that is not properly secured could move while routing creating an unsafe situation or damaging the jig When using a woodworker s vise avoid clamping the jig to your stock as shown in Figures 3 and 4 The jig is shown clamped to the stock with too much distance between the jig and the vise jaws Forces generated from routing could leverage the stock and cause it to move Figures 5 and 6 illustrate a safer setup when clamping stock in a woodworkers vise 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 Too much distance between vise jaws Fig 3 much distance between vise jaws and jig Avoid This Set up Fig 4 Mortise Pal Mortising Jig User s Manual This Set up is O K Fig 5 Specifications Referring to Fig 7 Jig positioned close to vise This set up is O K Fig 6 e The minimum stock width is 1 Your stock needs to be at least 1 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 See the section on page 11 for details e The maximum stock thickness is 2 e The maximum mortise width is 1 2 as determined by
9. hickness of this board Additionally Fig 26 shows that the slot in the jig body is Stock less than 3 4 can not be clamped in jig 11 16 wide x 3 long Stock that is less than 11 16 thick without using shims and less than 3 long would not register properly with the Fig 25 bottom of the jig With these considerations in mind the recommended technique for mortising in stock thinner than 3 4 is to make a shim that is at least 1 2 thick 5 wide and long enough that the stock can be clamped to it Fig 40 shows the stock clamped to the shim with the top of the shim and the top of the stock flush Then the jig has been clamped so that the top of the shim is registered to the bottom of the jig Stock smaller than slot dimensions will not register properly to bottom of jig Stock clamped to shim first with top surfaces Fiz 26 flush Then jig clamped to stock Fig 27 Mortise Pal Mortising Jig User s Manual Compensating for a template guide that is not concentric with your router spindle If your template guide included a centering pin it is highly recommended that you use it to perfectly center your template guide with your router spindle A template guide that is not concentric with the router spindle can cause problems with your joinery Fig 28 shows that the front surfaces of your boards may not join flush assuming that you intended them to or
10. mped to the apron previously discussed Again notice that the fence is in contact with the front reference surface for both mortises One set of layout lines for first mortise Single layout line is all that is needed for subsequent mortises Fig 18 Front Reference Surface Keep fence in contact with front reference surface for both mortises Fig 17 Reduced Layout for Subsequent Mortises It is necessary that the first mortise made have two layout lines that mark it s center Subsequent mortises with the same offset from the front reference surface require only one layout line Fig 18 shows the two leg blanks previously discussed Notice that one leg blank has a set of layout lines and the other has just a single layout line The jig will be set up by centering the template over the set of layout lines and routing the first mortise Because the offset is the same on the second mortise only one layout line referenced from surface is required Align the jig s pointer to the single layout line and rout the second mortise Mortise Pal Mortising Jig User s Manual Making Multiple Mortises Making multiple mortises may be useful when the templates supplied with the jig are not of a length suitable for the width of your stock For example Fig 19 shows a mortise in a 5 wide board using the 2 template The resulting joint may be prone to twist and or may not provide enough glue
11. mplate width is 41 64 or 1 64 larger than a 5 8 template guide This small space between the template guide 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 The recommended technique for routing will be discussed in the section that follows Using the Jig Using the jig generally requires the following four steps 1 Selecting and installing a template 2 Making layout lines on your stock Template 3 Setting up the jig Brass Screw 4 Routing the mortise soles Template Jig Body Step 1 Referring to Fig 9 select a template and then Brass Screw 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 jig body so that the holes in the template mate with the corresponding dowel pins on the jig body Press down firmly to ensure that the holes in the template mate with the dowel pins The templates ystall template by removing brass screws and are designed to mate with the dowel pins with a friction placing template over dowel pins fit Carefully replace the brass screws To remove the Fig 9 template remove the brass screws insert your index finger into the slot on the template and pull it off of the jig body
12. n Fig 2 A quality template guide with a centering pin is highly recommended We offer a precision template guide manufactured by Whiteside Machine Company as an accessory Note for best results in your joinery it is important to install the template guide so that it is concentric with your router spindle A template guide that is not concentric with the spindle can produce unwanted problems with your joinery A quality template guide installed using a centering pin will avoid this problem If you choose not to use a 5 8 template guide with 3 8 maximum centering pin please see the section on page 12 collar length is required for a tip on minimizing this problem Fig 2 Mortise Pal Mortising Jig User s Manual 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 instructions and safety guidelines that were included with your plunge router Proper workpiece holding is essential for the saf
13. ortise of virtually any length Fig 21 Mortise Pal Mortising Jig User s Manual Angled Joinery Mortise Pal is extremely versatile and can be used to make Leg Rail Rail joined to leg at angle Fig 23 Jig clamped to rail at angle using angled shims Fig 24 Jig clamped to board at 45 for mitered Joinery Fig 22 angled joinery Fig 22 shows the jig clamped to a board at 45 to make a mortise for a mitered joint Fig 23 shows a rail joined to a leg at 85 such as might be found in a chair Note that mortises have been made in both parts so that they can be joined with a loose tenon Fig 24 shows the jig clamped to the rail to make an angled mortise Notice that angled shims have been inserted between the stock and the jig The angled shims have been made on the table saw by crosscutting a 1 thick 5 wide board with the blade at 5 10 Mortise Pal Mortising Jig User s Manual Mortising in Stock Thinner than 3 4 Fig 25 shows that stock thinner than 3 4 can not be Engraved Mark clamped in the jig without the use of shims Notice that the clamping jaw does not contact the stock when the clamping knob is fully turned Also notice that the engraved mark used to center the template over layout lines can not be centered on the thickness of this stock therefore it would not be possible to make a mortise centered on the t
14. the largest bit to fit through a 5 8 outside diameter template guide e The mortise length is determined by the template used and the diameter of the router bit used Referring to Fig 8 the template length is measured from center to center along the slot The templates Stock Width Stoc Thickness Mortise Length E Fig 7 Mortise Width Stock and mortise specifications Jemplate Length Width Template Specifications Fig 8 Mortise Pal Mortising Jig User s Manual supplied with the jig come in four lengths 1 2 Template Length in Mortise Length in 1 1 1 2 and 2 To determine the overall 1 2 3 4 13 16 7 8 1 1 1 1 4 1 5 16 1 3 8 1 1 2 mortise length add the template length to the bit 112 13 4 113 16 17 8 2 2 2 1 4 2 5 16 2 3 8 2 1 2 diameter For example the 1 template used 5 16 3 8 Mortise length equals template length plus bit with a 3 8 bit produces 1 3 8 mortise The diameter same template used with a 1 4 bit produces a 1 1 4 mortise Table 1 can be used to determine Table 1 the overall mortise length for common sized router bits Note by overlapping mortises it is possible to create mortises of virtually any length Please see the section on page 9 for details e Referring again to Fig 8 the te
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