Exploded Views and Hardware Lists Revised: 0 April, 0
Angle Cutting on the Router Boss The base plate normally mounts perpendicular to the machine face. In this position the variable guides allow angled cuts at +/- 0 in increments. For greater angles you can rotate the base plate 0, or and also use the variable guides to adjust the cut angle up to. Threaded holes on box beam shown in red A E F B C D G H Base plate mounting holes in red Revised: 0 April, 0
Angle Cutting on the Router Boss A B C D 0 degrees A B C B A D +0 degrees -0 degrees G F E H + degrees - degrees G H F E + degrees - degrees Revised: 0 April, 0
Base Plate with Variable Angle Guides For dovetails and joinery that requires router to be guided at an angle. Angle set by pins in green wings. 0 The variable guides binding post moves in an elongated slot when angle changes. Do not tighten screw. 9 9 Contents of Router Boss Guides and Base Plate Fastener Bag /-0 x -/" Flat Socket Head Screw Screws base plate to channel--front /-0 x " Socket Head Screw Screws base plate & alum guides to channel--rear /-0 x /" Low Head Socket Screw Screws guides to base plate (both variable & alum) /" L Size." OD Flat Washer Washers for no., & socket head screws - x /" Binding Post Barrel Center post for variable guides - x /" Button Head Screw Screw for above post (snug, not tight) 0 /" Angle Stop Pin ( extra provided) To set/hold angle of the variable guides -0 x /" Flat Head Socket Screw Screws variable guide rules to base plate 9 - x /" Flat Head Socket Screw Screws dust port metal strips under base plate 0 M x Flange Button Head Screw Screws router or transition plate to acrylic plate Router Boss Parts Also Shown Acrylic Router Plate Star Knob with /-0 /" stud Green Plastic Stop Aluminum Base Plate Variable Guide Green Wing Variable Guide Black Base Variable Guide Rules (for dovetails) Front Dust Chute with Magnets 9 Metal Strip (to which dust chute attaches) Revised: 0 April, 0
Base Plate with Aluminum Guide Rails For tenons and joinery that requires straight cuts or when the router is stationary and the wood is guided by the sliding bar. 0 9 The green stops can be used either on the base plate or in the guide rail T-tracks. Fasteners Included in Router Boss Guides and Base Plate Fastener Bag /-0 x " Socket Head Screw Screws base plate & alum guides to channel--rear /-0 x /" Low Head Socket Screw Screws guides to base plate (both variable & alum) /" L Size." OD Flat Washer Washers for no., & socket head screws Router Boss Parts Also Shown Acrylic Router Plate Star Knob with /-0 /" stud Green Plastic Stop Aluminum Base Plate Front Dust Chute with Magnets 9 Metal Strip (to which dust chute attaches) 0 Oval Nut, ¼ -0 Aluminum guide rail Revised: 0 April, 0
Box Beam Assembly Note: For most applications, mount fixed fence in third set of holes. Both the cam and the moveable fence operate within the track in the sliding bar 9 0 Note: Rules may be mounted in any of three optional locations Contents of Router Boss Box Beam Channel Fastener Bag -0 x /" Flat Head Socket Screw Attach rules to front channel /-0 x -/" Flat Socket Head Screw Attach fixed fence to sliding bar 0- x /" Nylon Thumb Screw Attach cursors to sliding bar T-tracks 0- Oval Nut Nut for thumb screw above /-0 Oval Nut Extras or for plastic stop when in aluminum rails mm Oval Nut Extras for user jigs using t-tracks Router Boss Parts Also Shown Assembled Channel with Sliding Bar Channel Dust Chute 9 Either Ruler or Story Board (left & right) 0 Gray cursor Aluminum Fixed Fence Moveable Fence (attaches to cam) Push Button Cam Assembly Digital Display & Mount (optional) Revised: 0 April, 0
Plunge Assist for DeWalt Router U-bar () inserts into plastic elbows () which replace router handles Screw from router handle 9 0 0 Screw from router handle Contents of DeWalt Plunge Assist Kit Fastener Bag 0- x /" Socket Head Set Screw Secure rods in standoffs and elbow /- x -/" Threaded Rod Joins `the top & bottom of rear standoff /- x " Flat Socket Head Screw Attach standoffs to acrylic router plate /" Sleeve Bearing /" OD, /" Length Insert into `plastic elbow on DeWalt /" Vinyl End Cap Cover for ends of straight steel rods Router Boss and Plunge Assist Parts Also Shown Acrylic Router Plate 0." Plunge U-Bar Plastic Elbow (replaces DeWalt handle) 9 " Rear Rod 0 Bottom-Half Rear Standoff Top-Half Rear Standoff " Front Hand-Grip Rod Front Standoff Revised: 0 April, 0
Universal Plunge Assist U-bar rides over router handles 9 Not for DeWalt or any router with switch in handle 0 0 0 Contents of Universal Plunge Assist Kit Fastener Bag No. Qty Decription Use 0- x /" Socket Head Set Screw Secure rods in standoffs and sleeve adapter /- x -/" Threaded Rod Joins the top & bottom of rear standoff /- Hex Jam Nut (optional usage) Spacer on threaded rod to extend rear standoffs /- x " Flat Socket Head Screw Attach standoffs to acrylic router plate /" Sleeve Bearing /" OD, /" Length Insert in plastic elbow /" Shaft Collar /" OD, /" Width Positions U-bar on rear rod Vinyl End Cap Cover for ends of straight steel rods Router Boss & Plunge Assist Parts Also Shown Acrylic Router Plate 9 Both " &." Plunge U-Bars 0 Plastic Elbow (mounts on rear rod) " Rear Rod Bottom-Half Rear Standoff Top-Half Rear Standoff " Front Hand-Grip Rod Front Standoff Revised: 0 April, 0
Twin Feather Board Optional feather board for support of work piece under base plate. Can be mounted on either the sliding bar or on vertically mounted T-track of mortise table. Twin Feather Board Parts Kit No. Qty Description /"-0 x -/" long hex bolt /"-0 x -/" long T-bolt /" x /" Nylon spacer /" x /" Nylon spacer /"-0 hex nut Knob Feather board Revised: 0 April, 0
Mortise Table -- Horizontal and Vertical Work Holder Back spine () T-track table () Knuckle clamp (optional) Optional User-made MDF fence secured with /-0 screws, not included. T-track table can also be mounted without the back spine by replacing bottom screw in the angle brackets with round knob and using alternative taps in t-track table 0 9 Contents of Mortise Table Fastener Bag /-0 x -/" Flat Socket Head Screw Screws vertical support to sliding bar and MDF fence to spine Spacer Plates /" & /" Thick Shim between vertical support and sliding bar /-0 T-track Bar (Double Tap Nut) Slides in the T-track of vertical supports /-0 x /" Flange Button Head Screw Screws the top of spine to T-track bar in vertical supports Four-Arm Knob with /-0 x /" Stud Attach bottom of spine to T-track bar in vertical supports Round Knob with /-0 x/" Stud Attach vise clamps to T-track table /-0 Oval Nut Nut for vise clamp knobs (slides in T-track) /" Inside Tooth Lock Washer Lock washer for vise clamp knobs 9 /-0 x /" Socket Head Screw Screws angle brackets to spine and T-track table (pre-installed) 0 Plastic Shims, ea. /", /", /" Fine tune parallelism of table to base plate /-0 x /" Flat Head Cap Screws Attach fixed fence to T-track table (see next page) Yellow Angle Locator Stop Pins Insert into holes in Table to establish miter angle (see next page) Mortise Table Parts Also Shown Vertical Support with T-track " x." T-track Table " x " Back Spine Angle Bracket Vise Clamp w/ adjustable pad Revised: 0 April, 0
Mortise Rail --Vertical Mounting Angle settings Insert yellow stop pins into holes as indicated for desired angles 0. 0. 0 Alternate installation of T-track portion of Mortise Rail By using a fence or inserted pins, a work piece can be clamped either vertical or at left/right miter angles then crank feed through cutter. Fixed fence installed Revised: 0 April, 0
Riser Plate with Fence - Inverted Router Table Rests between aluminum base plate and top of box beam channel and increases maximum depth of cut when cutter is in channel dust chute Edge profiling can be done using the feather boards to support a work piece under base plate. Close fences next to bit when edge profiling or use sacrificial fences to prevent breakout. Contents of Riser Plate Kit Fastener Bag /-0 x -/" Socket Head Screw Screws to attach base plate & riser plate to channel rear /-0 T-track, 9" Length, /" projection Attach T-track on front edge of riser plate # x " Zip-R ` Pan Head Screw Screws for T-track (pre-drill the MDF) /-0 x /" Flanged Socket Head Screw Screws for fence to T-track and riser plate to channel front /-0 Oval Nut Nut for flanged screw above (slides in T-track) Riser Plate Parts Also Shown /" x.9" x " MDF Riser Plate /" x " x " MDF Fence Plastic Feather Board (not shown) 9 Star Knob with /-0 /" Stud (not shown) 0 Hog Bristle Brush Feather Board (not shown) Revised: 0 April, 0
Multi-Angle Work Holder For angled tenons and other joinery that requires the work piece to be held at a single or compound angle 9 9 0 Contents of Router Boss Multi-Angle Work Holder Kit Fastener Bag Flanged Bearing for /" Shaft, /" OD Insert `in top edge of aluminum plate & MDF sides /" Dowel Pin, " Length Place inside above flanged bearings Angle Bracket (left & right) Attach bracket to aluminum plate sides #- x /" Flat Socket Head Screw Screws for bracket above /-0 x -/" Carriage Bolt Bolts angle bracket to MDF side with arm knob /" Neoprene Washer 0." OD, 0.0" thick Between angle bracket & side, Between arm knob & back Slotted Cam Stop Attach stop to inside bottom of each MDF side 0- x -/" Socket Head Screw Screws for stop above 9 0- Square Nut Nut for above screw 0 #0 Flat Washer 0.00" D, 0.0" OD ` Washer for above screw /" Yellow `Angle Locator Stop Pins Positions work holder on sliding bar & work piece on plate /-0 -/" T-bolt Bolts work holder to sliding bar (safety feature) /-0 Threaded Hole Arm Locking Knob Knob for T-bolt above (should be snug, but not tight) Multi-Angle Parts Also Shown MDF Back MDF Glue Blocks MDF Side (left & right) Aluminum Plate Arm Knob with /-0 threaded hole 9 Friction Clamp Revised: 0 April, 0