the Route-a-Pocket User Manual
Contents
1. White Oak Tools LLC User Manual 108000 06 Route a Pocket Components Route a Pocket Hardware Optional Hardware Patent Pending Optional A Quantity Part Route a Pocket assembly 101000 Route a Pocket router bit 106008 104001 2 ball tip square drive driver 106010 106012 5 7 I pocketscrew 106060 7 x 1 1 2 pocket screw White Oak Tools LLC Route a Pocket Components Gandi F s Usar anual White Oak Tool LLC User Maroal 10800 06 1 1 1 4 I 1 2 O 2 5 8 Route a Pocke Transparent Screw Overlay White Oak Tools LLC Route a Pocket Set up amp Screw Selection Template White Oak Tools LLC www routeapocket com Patent Pending Made in USA Route a Pocket Component User Manual Overlay amp Template www routeapocket com ll Route a Pocket Components Exploded View of Main Assembly 2 Drillguideassembly 101003 3 Lowerstop block assembly 101004 5 Retainingpin 106002 9 _Edgepad 106003 iii White Oak Tools LLC Route a Pocket Components Exploded View of Optional Sa ti www routeapocket com Iv Table of Contents amp Introduction Table of Contents Section Route a Pocket Components Table of Contents amp Introduction Route a Pocket Specifications amp Required Tools Using the Template amp Adjusting the Stops Setting the Drill Bushing Height Plunge Router amp2. www routeapocket com 9 Plunge Router amp Power Drill Set up Figure 3c Adjust the plunge stroke such that the router bit fully retracts into the guide bushing Confirm that the router collet and bit do not contact the guide bushing or base plate at any point through the entire plunge stroke Figure 3d Install the supplied 9 64 diameter drill bit following the safety and operating instructions provided with your power drill 10 White Oak Tools LLC Figure 4a Secure the workpiece to your workbench Position the Route a Pocket near the workpiece Figure 4c Slide the Route a Pocket over against the edge of the workpiece www routeapocket com Machining Procedure Figure 4b Rest the Route a Pocket on the workpiece Figure 4d Securely tighten the thumb screw 11 Machining Procedure Figure 4e Figure 4f Position the plunge router over the Route Rest the router base plate on the incline of a Pocket the Route a Pocket Make sure the guide bushing is between the upper and lower Note Follow the safety and operating instructions stops that came with your plunge router 12 White Oak Tools LLC Machining Procedure Figure 4g Figure 4h Slide the router up the incline until the Turn the router on Plunge the router to the guide bushing is against the upper stop bottom of its plunge stroke www routeapocket com 13 Machining Procedure Figure 4i Figure 4j Slide
3. Power Drill Set up Machining Procedure Aligning the Pilot Hole with the Pocket Assembling the Joint Using the Optional Mounting Plate Joining 2 or More Route a Pockets amp Maintenance 2q Customer Support Introduction Thank you for choosing Route a Pocket The Route a Pocket has been designed to produce professional quality pocket screw joinery with your plunge router and power drill Please take the time to read and understand this user manual in its entirety By doing so you ll be introduced to all the jig s features We also suggest you practice using the Route a Pocket on test pieces prior to using it on your next project This step will build your confidence with the jig and ensure you have configured the Route a Pocket to produce the anticipated results Finally don t forget to visit the Route a Pocket website www routeapocket com The site includes an interactive Set up amp Screw Selection Template along with other useful resources e vV White Oak Tools LLC Route a Pocket Specifications amp Required Tools Route a Pocket Specifications Allowable Workpiece Thickness Minimum 1 2 Maximum 1 1 2 Pocket Width Pocket Length Minimum 1 2 Maximum 4 1 8 Pilot Hole Diameter 9 64 Pocket amp Pilot Hole Angle Screw Grip Length Minimum 7 16 Maximum 1 1 8 Required Tools Plunge Router For your safety it is important that you select a good qual
4. index small slits on each side plate is aligned with the mark corresponding to the workpiece thickness In this example the index is aligned with 3 4 Tighten the 2 wing nuts We N ATAN SZ a y LN www routeapocket com 7 Plunge Router amp Power drill Set up Figure 3a Install a 3 4 outside diameter guide bushing not included and the supplied router bit following the safety and operating instructions provided with your plunge router and guide bushing Note Confirm that the guide bushing is concentric centered to the router bit If adjustment is necessary consult the operating user manual that came with your router Additional information on this topic can be found in the section entitled Aligning the Pilot Hole with the Pocket 8 White Oak Tools LLC Plunge Router amp Power drill Set up Note Scale not included on older models aoeyins doy araidyjom Huney u1 yapim adom f i aay N Plunge Depth based on workpiece thickness in Guide Bushing Notch 8 e 3 Ve ww a 0a 5z w 3 5 ce AD gr om 3 amp Figure 3b Using the Set up amp Screw Selection Template set the plunge depth by aligning the tip of the router bit with the line corresponding to the workpiece thickness On newer model Route a Pockets the plunge depth may be set using the scale located near the thumb screw In this example the plunge depth has been set for a 3 4 workpiece
5. the router bit If they are not concentric to each other consult the operating user manual that came with your plunge router and make the necessary adjustments 18 White Oak Tools LLC Aligning the Pilot Hole with the Pocket Figure 5b Often it is difficult to make the guide bushing concentric with the router bit For this reason your Route a Pocket has been designed with shims on the sides of the drill guide These shims can be used to correct for misalignment between the pilot hole and pocket Your Route a Pocket was shipped with 1 thin and 1 thick shim on each side of the drill guide By moving the shims from one side to the other the pilot hole can be shifted relative to the centerline of the pocket Reposition the shims as needed to center the pilot hole in the pocket For reference the thin shims are 0 02 thick and the thick shims are 0 04 thick Note To maintain proper side plate spacing all 4 shims must be used at all times www routeapocket com 19 Assembling the Joint Figure 6a Install the supplied driver bit and adjust the clutch setting following the safety and operating instructions provided with your power drill Figure 6b Figure 6c Or select the optional screw driver The driver bit and screwdriver are designed with a 2 square drive ball tip end This feature allows the driver to be used off angle up to 25 20 White Oak Tools LLC Assembling the Joint Figure 6d Rest the poc
6. the router down the incline until the Slide the router back up the incline until guide bushing is against the lower stop the guide bushing is against the upper stop This step clears the chips from the pocket 14 White Oak Tools LLC Figure 4k Return the router to the top of its plunge stroke www routeapocket com Machining Procedure E O TO O OG Figure 41 Turn the router off Lift the router off the Route a Pocket 15 Machining Procedure 16 Figure 4m Position the power drill near the front of the Route a Pocket Note Follow the safety and operating instructions that came with your power drill Figure 4n Start the power drill Guide the drill bit through the drill bushing Continue until the drill bit enters the pocket Note It may be necessary to partially retract the drill bit to clear the chips prior to the bit entering the pocket White Oak Tools LLC Figure 4p Loosen the thumb screw www routeapocket com Machining Procedure Figure 40 Back the drill bit out of the drill bushing Stop the power drill Figure 4q Remove the Route a Pocket from the workpiece 17 Aligning the Pilot Hole with the Pocket Figure 5a When looking into the pocket the pilot hole should be centered in the pocket as shown at A If the pilot hole is off center as shown at B adjustment is required Start by confirming that the guide bushing is concentric centered to
7. erface Top Surface w a u 3 e o E a amp rT gt Cad D m 4 2 5 E U e b v w a knes n m 1 Route a Pocket wn ee 1 1 4 Set up amp Screw Selection Template te oad 1 1 2 White Oak Tools LLC www routeapocket com Patent Pending See User Manual for Made in USA Mating Workpiece Width in template instructions Figure la Caution template shown above is not full scale Place the centerline of the desired screw on the sloped line corresponding to the workpiece thickness In this example a 7 x 1 1 2 long screw is to be used with a 3 4 thick workpiece 2 White Oak Tools LLC Using the Template amp Adjusting the Stops Bottom side of screw head is positioned at 24B Pocket Workpiece Mating Workpiece Uf SS UNDIUD Idom uo paseg udag abunig Top Surface Guide Bushing Notch Rest on router base plate QO Route a Pocket Set up amp Screw Selection Template White Oak Tools LLC www routeapocket com Patent Pending See User Manual Eare Made in USA g Workpiece Eare instructions Screw will not break through mating workpiece having a thickness of 3 4 Grip Length Penetration Screw will not break through mating workpiece having a width of 1 Figure 1b Caution template shown above is not full scale Choose the lower stop position by sliding the screw along the sloped line and align the bottom side of the screw head with the lower stop position that pr
8. g the 1 2 screws provided The 2 front screws should be positioned 1 2 from the edge of the plywood Note The head of the rear screw must fit into the notch of the small plate This will prevent the plate from rotating during use 24 White Oak Tools LLC Using the Optional Mounting Plate Wi lt yp Figure 7b With the mounting plate facing down and hanging over the edge of your workbench secure the plywood to your workbench Remove the clamp pad 1 it may be stored in the storage tube and slide the Route a Pocket s swivel pad between the spring loaded plates 2 The Route a Pocket will snap securely into position when the swivel pad finds the large hole in the mounting plate assembly Note The tab on the mounting plate assembly will fit between the Route a Pocket side plates when properly engaged www routeapocket com 25 Using the Optional Mounting Plate Figure 7c Route a Pocket shown properly engaged with the mounting plate 26 White Oak Tools LLC Joining Two or More Route a Pockets amp Maintenance a o Figure 8a Your Route a Pocket has been designed with two spare through holes These through holes may be used to join multiple Route a Pockets at fixed distances from each other This is often useful when multiple pockets are needed on multiple workpieces To join two or more Route a Pockets slide a 1 4 diameter threaded rod not included through each spare hole Pos
9. ition the Route a Pockets along the rods using nuts not included on both sides of each Route a Pocket Maintenance To keep the plunge router sliding smoothly over the incline surface of the Route a Pocket periodically apply a coat of good quality silicone free paste wax to the surface of the incline www routeapocket com 27 Customer Support Feel free to contact us at White Oak Tools 4840 Adams Rd Rochester MI 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 28 This page intentionally left blank Suggested Route a Pocket Settings Workpiece Thickness in 7 Screw Plunge Depth amp Drill Guide Height Lower Stop Position Upper Stop Position Note 1 Can not be plugged N Note 2 If plugging set plunge depth amp drill guide height to 3 4 Note 3 If plugging set plunge depth amp drill guide height to 1 1 4 Note 4 If plugging set Upper Stop to 45D White Oak o s www whiteoaktools com
10. ity and well maintained plunge router for use with the Route a Pocket Selecting the proper plunge router will also make it easy to achieve the quality results you expect The plunge router must accept a router bit with a 1 2 shank and should have a plunge stroke of at least 2 3 8 The maximum suggested plunge router horsepower rating is 2 1 4 Guide Bushing The guide bushing must be compatible with your plunge router and have an outside diameter of 3 4 The collar length should be 1 2 or longer Power drill The power drill used to drive the pocket screws should be equipped with an adjustable clutch www routeapocket com 1 Using the Template amp Adjusting the Stops Included with your Route a Pocket is the Set up amp Screw Selection Template This template makes it easy to select the appropriate screw and Route a Pocket settings for your joining application The template may be used by placing an actual screw on the card or by overlaying the transparent screw overlay also included on the card This section describes the process Notes e For most applications the suggested Route a Pocket settings are listed on the back cover of this User Manual e An interactive Set up amp Screw Selection Template is available on line at www routeapocket com Centerline of 7 x 1 5 screw is placed on the 3 4 line Pocket Workplece Mating WorKpiece IN Ul SS UxDIYI d AOM uo paseg yidag abunid Butt Joint Int
11. ket workpiece and its mating workpiece on a flat work surface Figure 6e Nua If desired add glue to the joint interface Align the workpieces and push them tightly together Figure 6f Clamp both pieces to the flat work surface www routeapocket com 21 Assembling the Joint WWIII on D WS SEIZE a ZA Figure 6g Position the tip of the screw in the pilot hole Begin to drive the screw with the driver off angle if required Figure 6h Drive the screw home Note The driver can become less off angle as the screw approaches home 22 White Oak Tools LLC Assembling the Joint Figure 6i Remove the clamp Val a Figure 6j The joint is now complete www routeapocket com 23 Using the Optional Mounting Plate The optional Route a Pocket mounting plate saves time when working with smaller workpieces Once the Route a Pocket is snapped into its mounting plate tightening the Route a Pocket s thumb screw not only secures the Route a Pocket to the workpiece it also secures the workpiece to the workbench This section describes how to use the mounting plate Figure 7a The mounting plate is typically secured to a piece of 1 2 plywood not included As the plywood will be used as a work surface it should be flat and smooth The suggested minimum plywood dimensions are 12 wide x 24 long Fasten the mounting plate to the bad side of the plywood usin
12. ovides the desired grip length and penetration In this example the screw is aligned with 24B Confirm that the screw penetration does not exceed the width or thickness of the mating workpiece and adjust if necessary In this example the screw will not break through a mating workpiece that is at least 1 wide and 3 4 thick Record the selected lower stop position In this example 24B is recorded www routeapocket com 3 Using the Template amp Adjusting the Stops Tip of screw is positioned 2 lines to the right of Lower Stop position Driver shown 25 deg off angle Pocket Workpiece Mating Werkpiece _ i A _ Ut SS9URDIYI BdaIdyIOM uo peseg yidag unid Butt Joint Interface Top Surface Guide Bushing Notch Rest on router base plate Route a Pocket Set up amp Screw Selection Template Lower Stop White Oak Tools LLC www routeapocket com Patent Pending See User Manual for Made in USA Mating Workpiece Width in template instructions 1 1 2 Driver clears top surface when Upper Stop is positioned at 56C Figure 1c Caution template shown above is not full scale Choose the upper stop position by repositioning the screw along the sloped line until the tip of the screw is aligned with the second line to the right of the previously recorded lower stop position Positioning the tip at this location represents the tip of the screw entering the pilot hole 1 4 In this example the tip of
13. the screw is aligned with 35B Observe the upper stop position corresponding with the first line to the left of the screw head Confirm that there is adequate driver access and adjust if necessary In this example the driver has adequate access when used at 25 off angle and the upper stop is positioned at 56C Record the selected upper stop position In this example 56C is recorded 4 White Oak Tools LLC Using the Template amp Adjusting the Stops 4 PA ARN EA LAY WR Figure 1d Remove the pins and orient the stop blocks with the recorded stop block letters visible from above In this example the lower stop block is oriented to the B position 24B The upper stop block is oriented to the C position 560 Note The stop block letters must be oriented right side up when read from the drill guide end of the Route a Pocket In this example stop block letters A and D are hidden from view on the reverse side of the stop blocks www routeapocket com 5 Using the Template amp Adjusting the Stops Figure le Insert the pins through the recorded hole numbers making sure both legs pass through its respective stop block In this example the lower pin is inserted through holes 2 amp 4 24B while the upper pin is inserted through holes 5 amp 6 56C 6 White Oak Tools LLC Setting the Drill Bushing Height Figure 2a Loosen the 2 wing nuts Slide the drill guide and scale until the
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