Bosch RA1181 User Manual
Operating/Safety Instructions
Consignes de fonctionnement/sécurité
Instrucciones de funcionamiento y seguridad
RA1181
IMPORTANT:
Read Before Using
IMPORTANT :
Lire avant usage
IMPORTANTE:
Leer antes de usar
For English
See page 2
Parlez-vous français?
Voir page 32
¿Habla español?
Ver página 64
Consumer Information
Renseignement des consommateurs
Información para el consumidor
Toll Free Number: Appel gratuit : Número de teléfono gratuito:
1-877-BOSCH99 (1-877-267-2499) http://www.boschtools.com
2 610 927 748 09/05
2
Power Tool Safety Rules
Table of Contents
Work Area
Keep your work area clean and well lit. Cluttered benches
and dark areas invite accidents.
Do not operate power tools in explosive atmospheres,
such as in the presence of flammable liquids, gases, or
dust. Power tools create sparks which may ignite the dust
or fumes.
Keep bystanders, children, and visitors away while
operating a power tool. Distractions can cause you to
lose control.
Electrical Safety
Grounded tools must be plugged into an outlet properly
installed and grounded in accordance with all codes
and ordinances. Never remove the grounding prong or
modify the plug in any way. Do not use any adaptor
plugs. Check with a qualified electrician if you are in
doubt as to whether the outlet is properly grounded.
If the tools should electrically malfunction or break down,
grounding provides a low resistance path to carry electricity
away from the user. Improper grounding can shock, burn,
or electrocute. Grounded tools are equipped with threeconductor cord and three-prong type plugs. Before plugging
in the tool, be certain the outlet voltage supplied is within the
voltage marked on the nameplate. Do not use "AC only"
rated tools with a DC power supply.
Double-insulated tools are equipped with a polarized
plug (one blade is wider than the other.) This plug will fit
in a polarized outlet only one way. If the plug does not
fit fully in the outlet, reverse the plug. If it still does not
fit, contact a qualified electrician to install a polarized
outlet. Do not change the plug in any way. Double
Insulation eliminates the need for the three-wire
grounded power cord and grounded power supply system.
Before plugging in the tool, be certain the outlet voltage
supplied is within the voltage marked on the nameplate.
Do not use “AC only” rated tools with a DC power supply.
Avoid body contact with grounded surfaces such as
pipes, radiators, ranges and refrigerators. There is an
increased risk of electric shock if your body is grounded. If
operating the power tool in damp locations is unavoidable, a
Ground Fault Circuit Interrupter must be used to supply the
power to your tool. Electrician’s rubber gloves and footwear
will further enhance your personal safety.
Don’t expose power tools to rain or wet conditions.
Water entering a power tool will increase the risk of
electric shock.
Do not abuse the cord. Never use the cord to carry the
tools or pull the plug from an outlet. Keep cord away
from heat, oil, sharp edges, or moving parts. Replace
damaged cords immediately. Damaged cords increase
the risk of electric shock.
When operating a power tool outside, use an outdoor
extension cord marked “W-A” or “W.” These cords are
rated for outdoor use and reduce the risk of electric shock.
Refer to “Important Information About Extension Cords” in
your router table manual.
Personal Safety
Stay alert, watch what you are doing and use common
sense when operating a power tool. Do not use tool
while tired or under the influence of drugs, alcohol, or
medication. A moment of inattention while operating power
tools may result in serious personal injury.
Keep guards in place. Maintain the guards in working order
and in proper adjustment and alignment.
Avoid accidental starting. Be sure switch is “OFF”
before plugging in. Carrying tools with your finger on
the switch or plugging in tools that have the switch “ON”
invites accidents.
Remove adjusting keys or wrenches before turning
the tool “ON.” A wrench or a key that is left attached to
a rotating part of the tool may result in personal injury.
Do not overreach. Keep proper footing and balance
at all times. Proper footing and balance enable better
control of the tool in unexpected situations.
Use safety goggles (head protection). Wear safety
goggles (must comply with ANSI Standard Z87.1) at all
times. Wear non-slip footwear and a hard hat, if appropriate.
Also, use face or dust mask if cutting operation is dusty
and ear protectors (plugs or muffs) during extended periods
of operation.
Tool Use and Care
Use clamps or other practical way to secure and
support the workpiece to a stable platform. Holding the
work by hand or against your body is unstable and may lead
to loss of control.
IMPORTANT SAFETY INFORMATION . . .2–5
Parts List . . . . . . . . . . . . . . . . . . . . . . . . .6–9
Router Table Assembly . . . . . . . . . . . .10–20
Router Table Operation . . . . . . . . . . . .21–31
Read and understand the tool manual and these instructions for the
use of this table with your router. Failure to follow all instructions listed below may
result in serious personal injury.
SAVE THESE INSTRUCTIONS
3
Do not force tool. Use the correct tool for your
application. The correct tool will do the job better and
safer at the rate for which it is designed.
Do not use tool if switch does not turn it “ON” or
“OFF.” Any tool that cannot be controlled with the switch
is dangerous and must be repaired.
Disconnect the plug from the power source before
making any adjustments, changing accessories, or
storing the tool. Such preventive safety measures reduce
the risk of starting the tool accidentally.
Keep guards in place. Maintain the guards in working order
and in proper adjustment and alignment.
Store idle tools out of reach of children and other
untrained persons. Tools are dangerous in the hands of
untrained users.
Never leave tools running unattended. Turn the power
OFF. DO NOT leave tool until it comes to a complete stop.
Maintain tools with care. Keep cutting tools sharp and
clean. Properly maintained tools, with sharp cutting edges
are less likely to bind and are easier to control. Any
alteration or modification is a misuse and may result in
a dangerous condition.
Check for damaged guards or parts, misalignment or
binding of moving parts, breakage of parts, and any
other condition that may affect the tool’s operation.
If damaged, have the tool properly repaired or replaced
before using. Many accidents are caused by poorly
maintained tools. Develop a periodic maintenance
schedule for your tool.
Use only accessories that are recommended by the
manufacturer for your model. Accessories that may be
suitable for one tool may become hazardous when used
on another tool.
Service
Tool service must be performed only by qualified
repair personnel. Service or maintenance performed by
unqualified personnel could result in a risk of injury. For
example: internal wires may be misplaced or pinched;
safety guard return springs may be improperly mounted.
When servicing a tool, use only identical replacement
parts. Use of unauthorized parts or failure to follow
maintenance instructions may create a risk of electric shock
or injury. Certain cleaning agents such as gasoline, carbon
tetrachloride, and ammonia may damage plastic parts.
Additional Safety Warnings for Router Tables
Read and understand table and router manual and
accessory warnings. Failure to follow all instructions
and warnings may result in serious personal injury.
Fully assemble and tighten all fasteners required for
this table and for mounting the router to the plate.
Do not use the router table until all assembly and
installation steps have been completed. Check the
table and the router to make sure fasteners are still
tight before each use. A loose table is unstable and
may shift in use.
Make certain the router is not plugged into a power outlet when installing into the table, removing from table,
making adjustments or changing accessories. Router
could accidentally start.
Do not plug router motor power cord into standard wall
outlet. It must be plugged into the router table switch.
Power tool switches and controls need to be within your
reach in emergency situations.
Before operating, make sure the entire unit (table with
router installed) is placed on and secured to a solid, flat,
level surface and will not tip. Use of auxiliary in-feed
and out-feed supports is necessary for long or wide
workpieces. Long workpieces without adequate support
can flip off the table or cause the table to tip over.
Be certain router motor is fully and securely clamped in
the router base. Periodically check the base fastener
clamping tightness. Router motor can vibrate loose from
the base during use and fall from table.
Do not use the router table without the overhead guard
or auxiliary bit guard. Remove all dust, chips, and any
other foreign particles that can affect its function.
Adjust the guard height so that it clears the router bit
and the workpiece. The guard will aid in keeping hands
from unintended contact with rotating bit.
Never place your fingers near a spinning bit or under
the guard when router is plugged in. Never hold the
workpiece on the out-feed side of bit. Pressing the
workpiece against the out-feed side of the fence may
cause material binding and possible kickback pulling
hand back into bit.
Guide workpiece by the fence to maintain control of
workpiece. Do not place material between router bit and
fence while routing the edge. This placement will cause
the material to become wedged, making kickback possible.
Routers are intended for working with wood, woodlike
products and plastic or laminates, not for cutting or
shaping metals. Be sure workpiece does not contain
nails, etc. Cutting nails may cause loss of control.
Do not use bits that have a cutting diameter that
exceeds the clearance hole in the tabletop insert.
Bit could contact insert ring, throwing fragments.
Install bit in accordance with instructions in router
manual and securely clamp the router bit in the collet
chuck before making any cuts to avoid bit becoming loose
during operation.
Never use dull or damaged bits. Sharp bits must be
handled with care. Damaged bits can snap during use.
Dull bits require more force to push the workpiece, possibly
causing the bit to break or the material to kick back.
The router table is designed to cut flat, straight and
squared materials. Do not cut material that is warped,
wobbly, or otherwise unstable. If the material is slightly
curved but otherwise stable, cut the material with the
concave side against the table or fence. Cutting the
material with the concave side up or away from table may
cause the warped or wobbly material to roll and kick backm
causing user to lose control.
Never start the tool when the bit is engaged in the
material. The bit cutting edge may grab the material,
causing loss of control of the workpiece.
Feed the workpiece against the rotation of the bit. The
bit rotates counterclockwise as viewed from the top of
table. Feeding the work in the wrong direction will cause the
workpiece to “climb” up on the bit, pulling the workpiece and
possibly your hands into the rotating bit.
Use push sticks, vertical and horizontally mounted
featherboards (spring sticks), and other jigs to hold
down the workpiece. Push sticks, featherboards, and
jigs eliminate the need to hold the workpiece near the
spinning bit.
4
Piloted bits along with the starter pin are used when
routing internal and external contours on the workpiece.
Use the auxiliary bit guard when shaping material with
the starter pin and piloted bits. The starter pin and
bearing of the piloted bit assist in maintaining control
of the workpiece.
Do not use the table as a workbench or work surface.
Using it for purposes other than routing may cause damage
and make it unsafe to use in routing.
Never stand on the table or use as a ladder or
scaffolding. Table could tip or the cutting tool could
be accidentally contacted.
Use only Bosch replacement parts. Any others may
create a hazard.
I
Additional Safety Warnings for Router Tables
If an extension cord is necessary, a
cord with adequate size conductors that is capable of
carrying the current necessary for your tool must be
used. This will prevent excessive voltage drop, loss of
power, or overheating. Grounded tools must use 3-wire
extension cords that have 3-prong plugs and receptacles.
NOTE: The smaller the gauge number, the heavier
the cord.
RECOMMENDED SIZES OF EXTENSION CORDS
120 VOLT ALTERNATING CURRENT TOOLS
Tool’s
Ampere
Rating
Cord Size in A.W.G.
Wire Sizes in mm
2
3-6
6-8
8-10
10-12
12-16
18 16 16 14 .75 .75 1.5 2.5
18 16 14 12 .75 1.0 2.5 4.0
18 16 14 12 .75 1.0 2.5 4.0
16 16 14 12 1.0 2.5 4.0 —
14 12 — — — — — —
25 50 100 150 15 30 60 120
Cord Length in Feet Cord Length in Meters
Important Information About Extension Cords
Improper Fence Location and Workpiece Feed
The fence and/or workpiece are
improperly located anytime it would result in:
• The front of the bit being exposed during the actual cutting (Fig. A).
• “Climb-cutting” – The bit must not enter the workpiece in
the same direction as the feed direction, which is likely
to cause the workpiece to “climb” and may lead to loss
of control during operation (Fig. B).
“Fence Traps”: One type of improper fence location
warrants special attention. “Fence traps” happen when
the fence is positioned so far back that the front side
(power switch side) of the workpiece would be behind
the router bit.
Fence traps are dangerous for two
reasons:
• Exposure of the bit on the front side (power switch side)
of the workpiece.
• Likelihood of climb-cut, which can cause loss of control.
Fig. A shows a fence trap.
Do not feed the workpiece from left to right: (Fig. B)
• It would cause climb-cutting.
• It would be difficult to keep the workpiece against the
fence faces because the bit rotation would push the
workpiece away from the fence.
FIG. A
FIG. B
WORKPIECE
EXPOSED BIT
WORKPIECE
CLIMB-CUTTING
DIRECTION
OF FEED
CORRECT
DIRECTION
OF FEED
INCORRECT
DIRECTION
5
IMPORTANT: Some of the following symbols may be used on your tool. Please study them and learn their
meaning. Proper interpretation of these symbols will allow you to operate the tool better and safer.
Symbol Name Designation/Explanation
V Volts Voltage (potential)
A Amperes Current
Hz Hertz Frequency (cycles per second)
W Watt Power
kg Kilograms Weight
min Minutes Time
s Seconds Time
Ø Diameter Size of drill bits, grinding wheels, etc.
n0 No load speed Rotational speed, at no load
.../min Revolutions or reciprocation Revolutions, strokes, surface speed, orbits
per minute etc. per minute
0 Off position Zero speed, zero torque...
1, 2, 3, ... Selector settings Speed, torque, or position settings
I, II, III, Higher number means greater speed
Infinitely variable selector Speed is increasing from 0 setting
with off
Arrow Action in the direction of arrow
Alternating current Type or a characteristic of current
Direct current Type or a characteristic of current
Alternating or direct current Type or a characteristic of current
Class II construction Designates double-insulated construction tools
Earthing terminal Grounding terminal
Warning symbol Alerts user to warning messages
Ni-Cad RBRC seal Designates Ni-Cad battery recycling program
Symbols
0
This symbol designates
that this tool is listed by
Underwriters Laboratories.
This symbol designates
that this tool is listed
by the Canadian
Standards Association.
This symbol designates that
this tool is listed to Canadian
Standards by Underwriters
Laboratories.
This symbol designates that
this tool complies to NOM
Mexican Standards.
This symbol designates that this
tool is listed by Underwriters
Laboratories and listed to
Canadian Standards by
Underwriters Laboratories.
This symbol designates that
components of this tool are
listed by Underwriters
Laboratories and listed to
Canadian Standards by
Underwriters Laboratories.
6
Parts List
Refer to Parts List below and on pages 7–9.
• If ANY of the parts are missing,
DO NOT attempt to assemble, install, or use your
router table until the missing parts have been found
or replaced and your router table has been properly
and correctly assembled per this manual.
• For missing parts or technical assistance,
call 1-877-BOSCH99 (877-267-2499).
• In order to simplify handling and to minimize any
damage that may occur during shipping, your
router table comes unassembled.
• Separate all parts from the packaging materials
and check each part against the illustrations and
the parts lists on pages 6–9, to make sure that all
parts have been included. Do this before discarding
any of the packaging material.
Key No. Description Quantity
ROUTER TABLE ASSEMBLY
1 Router Tabletop 1
2 Router Mounting Plate 1
3 Tabletop Insert w/ 1″ Dia. Hole 1
4 Tabletop Insert w/ 2″ Dia. Hole 1
5 Tabletop Insert w/ 23⁄4″ Dia. Hole 1
6 Table Leg 2
7 Leg Storage Panel 1
8 Leg Cord Wrap Assembly 1
9 Front Fascia Panel 1
10 Switch Assembly With Lockout Key 1
Fence Assembly
11 Aluminum Fence 1
12 Fence Facing 2
13 Vacuum Port 1
14 Large Clamping Knob (in hardware bag) 6
15 Overhead Guard 1
16 Spacer (in hardware bag) 6
17 Small Clamping Knob (in hardware bag) 6
18 1/16″ Jointing Shim 2
19 Featherboard 2
Starter Pin Assembly
20 Starter Pin 1
21 Starter Pin Guard 1
22 #10-32 x 3/8″ Truss-Head Screw 1
Items Not Illustrated
23 Operating/Safety Instructions 1
7
Parts List
1
2
6
8
7
20
22
Starter Pin Assembly
21
Featherboard
19
16
17
Fence Assembly
13
14
14
12
18
11
15
17
16
Tabletop Inserts
5
4
3
6
10
9
Router Table Assembly
8
Parts List
Key No. Description Quantity
FASTENERS (FOR TABLE ASSEMBLY)
24 #10-32 KEPS Nut 8
25 #10-32 ESNA Stop Nut 13
26 1/4-20 KEPS Nut 9
27 9/32″ ID x 5/8″ OD x 1/16″ Thick Washer 8
28 #10-32 x 1″ Pan-Head Phillips Machine Screw 4
29 #10-32 x 3/4″ Countersunk Socket-Head Screw 9
30 #10-32 x 3/4″ Truss-Head Phillips Machine Screw 8
31 1/4-20 x 11⁄2″ Carriage Bolt 8
32 1/8″ Hex Key (Allen Wrench) 1
FASTENERS (FOR FENCE ASSEMBLY)
24 #10-32 KEPS Nut 2
27 9/32″ ID x 5/8″ OD x 1/16″ Thick Washer 2
33 #10-32 x 5/8″ Countersunk Phillips Machine Screw 2
31 1/4-20 x 11⁄2″ Carriage Bolt 6
34 1/4-20 x 1″ Carriage Bolt 6
FASTENERS (FOR MOUNTING ROUTERS)
26 1/4-20 KEPS Nut 4
27 9/32″ ID x 5/8″ OD x 1/16″ Thick Washer 4
35 #10-32 x 3/4″ Pan-Head Phillips Machine Screw 3
36 1/4-20 x 11⁄2″ Pan-Head Phillips Machine Screw 4
37 #10-24 x 3/4″ Pan-Head Phillips Machine Screw 3
38 #8-32 x 3/4″ Pan-Head Phillips Machine Screw 3
39 5/16-18 x 3/4″ Pan-Head Phillips Machine Screw 3
(26) 1/4-20
KEPS Nut
(25) #10-32 ESNA
Stop Nut
(24) #10-32
KEPS Nut
(27) 9/32″ ID x 5/8″ OD x 1/16″
Thick Washer
(30) #10-32 x 3/4″ Truss-Head
Phillips Machine Screw
(29) #10-32 x 3/4″ Countersunk
Socket-Head Screw
(28) #10-32 x 1″ Pan-Head
Phillips Machine Screw
NOTE: The hardware bag contains fasteners for several models. Some fasteners may not be used in the
assembly of this model. Refer to the parts list above for the correct sizes and quantities used with this table.
9
Parts List
(32) 1/8″ Hex Key (Allen Wrench)
(34) 1/4-20 x 1″
Carriage Bolt
(31) 1/4-20 x 11⁄2″ Carriage Bolt
(36) 1/4-20 x 1
1
⁄2″ Pan-Head
Phillips Machine Screw
(37) #10-24 x 3/4″ Pan-Head
Phillips Machine Screw
(35) #
10-32 x
3/4
″ Pan-Head
Phillips
Machine Screw
(33) #10-32 x 5/8″
Countersunk Phillips
Machine Screw
(38) #
8-32 x
3/4
″ Pan-Head
Phillips
Machine Screw
(39) 5/16-18x 3/4
″ Pan-Head
Phillips
Machine Screw
10
Router Table Assembly
TOOLS REQUIRED (not included)
• Phillips screwdriver
• Small sized adjustable wrench
• Tape with adhesive backing (optional)
ROUTER TABLE LEGS (FIG. 2)
1. Insert eight 1/4-20 x 11⁄2″ long carriage bolts (31)
through the router tabletop (1) as shown in Fig. 2.
2.Assemble the legs (6) to the router table as shown
in the figure.
3.Assemble a 9/32″ ID x 5/8 OD″ x 1/16″ thick
washer (27) and a 1/4-20 KEPS nut (26) onto
each of the bolts.
4.Securely tighten the fasteners.
NOTE: It may be easier to assemble the legs by
laying the router table on its front or back, or by using
adhesive tape over the carriage bolt heads to hold
them in place and turning the router table upside down.
FIG. 2
ASSEMBLING THE ROUTER TABLE
TABLE LEG INSERTS (FIG. 1)
The router table includes two table leg inserts:
• Leg storage panel (7) for convenient storage of acces-
sories
• Leg cord wrap panel (8)
The table leg inserts must be installed before attaching
the tabletop.
1.Place the table leg insert (7 or 8) into the opening in
the table leg (6) so that it is positioned at the very top
of the opening.
2.Press the insert in so that it is completely flush with
the leg.
3.Push the insert down as far as it will go to lock it
in place.
NOTE: The cord wrap panel has two tabs at the top
of the panel that lock under the table top. These tabs
help prevent the panel from coming unhooked when
wrapping or unwrapping the cord.
FIG. 1
8
31
6
6
7
27
26
6
1
Router Table Assembly
ATTACH THE SWITCH/FASCIA ASSEMBLY
TO THE ROUTER TABLE (FIG. 4)
NOTE: The fascia assembles to the inside of both
the table legs and the router tabletop.
1.Line up the holes on the fascia panel with the holes
in the table legs and the two slots on the front of the
router tabletop.
2. Attach the fascia panel to the router table top using
two #10-32 x 3/4″ truss-head machine screws (30)
and two #10-32 KEPS nuts (24), as shown in Fig. 4.
3.Attach the fascia to the legs using four #10-32 x 3/4″
truss-head machine screws (30) and four #10-32
KEPS nuts (24), as shown in Fig. 4.
4.TIGHTEN all screws SECURELY.
FIG. 4
11
ATTACH THE SWITCH TO THE FASCIA
(FIG. 3)
1.Align the two outermost holes on the top of the switch
assembly (10) with the holes in the front fascia panel
(9), as shown in Fig. 3.
2.Insert two #10-32 KEPS nuts (24) into the
hex-shaped recesses in the back of the switch
assembly (10), toothed side out, and secure the
switch to the fascia panel with two #10-32 x 3/4″
truss-head machine screws (30) while holding the
KEPS nuts in place in the recess with your finger.
FIG. 3
24
30
10
9
24
30
30
12
Router Table Assembly
ASSEMBLING THE FENCE
ASSEMBLING THE FENCE (Figs. 5 and 6)
1.Insert the pins molded into the top of the vacuum
port (13) into the holes on the rear of the aluminum
fence (11), as shown in Fig. 5.
2.From the underside of the fence, insert two #10-32 x
5/8″ countersunk machine screws (33) up through
the holes in the bottom of the fence and vacuum
port. Secure in place with two #10-32 KEPS nuts (24)
(Fig. 5).
3.Place the fence right-side-up on a flat surface and
align the counterbored holes in the fence facings (12)
with the slotted holes in the fence. The counterbored
side of the facings should face OUT (Fig. 6).
4. Attach both fence facings (12) to the front of the fence,
using two 1/4-20 x 1″ carriage bolts (34) and two large
clamping knobs (14) for each fence facing (Fig. 6).
5. From the front of the overhead guard (15), insert two
1/4-20 x 1
1
⁄2″ carriage bolts (31) through the holes in the
guard. Slide a spacer (16) on each bolt so that the tabs
on the spacers fit into the slots on the guard.
6. From the front of the fence, insert the carriage bolts
through the holes in the top center of the fence. The
tabs on the spacers will fit into the top channel on the
fence. Secure in place with a small clamping knob (17)
on each bolt (Fig. 6).
NOTE: To simplify installation of the router adapter plate
and router, do not install the fence onto the router table
at this time.
33
24
13
11
14
16
12
NOTE: Two plastic jointing shims (18) are included to
provide the proper fence offset when jointing. For
more about jointing operations and shim placement,
see page 27.
FIG. 5
FIG. 6
17
34
31
15
13
TOOLS REQUIRED
• 1/8″ Allen wrench (32) (included)
• Phillips screwdriver (not included)
• Straight edge (not included)
• Small-sized adjustable wrench (not included)
NOTE: The fences must NOT be installed on the router
table for the following procedures.
PRELIMINARY INSTALLATION OF THE
ROUTER MOUNTING PLATE
(Figs. 7A –7C)
1.Completely thread a #10-32 ESNA stop nut (25)
onto each of the eight #10-32 x 3/4″ countersunk
socket-head screws (29) as shown in Fig. 7A. The
orientation of the stop nut on the screw must be as
shown in Fig. 7A.
NOTE: It will be helpful to use the included Allen
wrench and an adjustable wrench because the nut
has tight-fitting threads.
2. Place the eight assembled screws and nuts into
the eight hex-shaped pockets in the recess on the
tabletop as shown in Fig. 7B.
The screw threads are to be inserted into the
holes at the bottom of the pockets.
3.Place the router mounting plate into the opening in
the tabletop so that it rests on the heads of the
screws as shown in Fig. 7B.
4.Position a straight edge or level across the mounting
plate as shown in Fig. 7C. The straight edge must be
long enough to extend completely over the opening
in the router tabletop.
5.Insert the Allen wrench (32) through the eight
round holes in the mounting plate, engaging the
hex socket in the screw heads (Fig. 7C).
6.Raise and lower the mounting plate by turning the
screws until the mounting plate is level and flush with
the top of the router table.
7.Remove the mounting plate from the tabletop.
NOTE: It may be necessary to make slight
adjustments after final installation of the router
adapter plate.
FIG. 7A
INSTALLING THE ROUTER MOUNTING PLATE
STRAIGHT EDGE
1/8″ ALLEN
WRENCH (32)
FIG. 7B
FIG. 7C
Router Table Assembly
29
25
14
Router Table Assembly
DETERMINE THE MOUNTING METHOD TO
BE USED (see chart on page 15)
If your router model is listed in the chart on page
15, proceed to step 1 below. If it is NOT listed, you
must purchase a BOSCH RA1186 Router Adapter
Plate, available separately.
If your router model IS listed:
1.Determine the hole pattern that matches the
mounting hole pattern for your router.
2.Determine which fasteners you will need to attach the
router to the router adapter plate.
3.Determine which mount type (1 or 2) is used for your
router model.
SELECTING THE ROUTER HOLE PATTERN
FIG. 8
MOUNTING PLATE GUIDE FOR COMPATIBLE ROUTERS (Fig. 8)
A
C
D
B
1/4-28 THREADED
HOLE FOR
STARTER PIN
A
A
B
B
D
D
D
C
C
C
10-32 THREADED
HOLE FOR STARTER
PIN GUARD
OVER-TABLE
ADJUSTMENT HOLE
MOUNT TYPE 1
MOUNT TYPE 2
MOUNTING PLATE
ROUTER BASE
MOUNTING PLATE
ROUTER BASE
BEFORE USING THE ROUTER TABLE, REFER TO THE ROUTER
OWNER’S MANUAL FOR OPERATION INFORMATION.
E
E
E
TOP FRONT OF PLATE
15
Router Table Assembly
Router Router Hole Fasteners Mount
Brand Model Pattern Required Type
Bosch 1613 series A 1/4-20 x 11⁄2″ Pan-head Phillips machine screws (36), 2
washers (27), and 1/4-20 nuts (26)
Bosch 1617 series (fixed B #10-24 x 3/4″ Pan-head Phillips machine screws (37) 1
base models only)
Bosch 1619EVS C 1/4-20 x 1
1
⁄2″ Pan-head Phillips machine screws (36), 2
washers (27), and 1/4-20 nuts (26)
Craftsman Most Craftsman E 5/16-18 x 3/4″ Pan-head Phillips machine screws (39) 1
1/2″ collet routers
DeWalt DW616, DW618 B #8-32 x 3/4″ Pan-head Phillips machine screws (38) 1
(fixed base only)
Hitachi M12VC B #10-32 x 3/4″ Pan-head Phillips machine screws (35) 1
Makita RF1100, RF1101 B #10-24 x 3/4″ Pan-head Phillips machine screws (37) 1
Milwaukee 5615, 5616 B #10-24 x 3/4″ Pan-head Phillips machine screws (37) 1
Porter Cable 690 series, B #10-24 x 3/4″ Pan-head Phillips machine screws (37) 1
7529 plunge router,
and 892–895 series
(fixed base only)
Ryobi R161, R162 E 5/16-18 x 3/4″ Pan-head Phillips machine screws (39) 1
ATTACH ROUTER TO MOUNTING PLATE
(Figs. 9 and 10)
1.Remove the plastic subbase from your router
(Fig. 9).
2.If your router has its own dust extraction hood that
mounts to the top of the metal router base and you
want to use it under the router table, this is a
convenient time to install it.
3.Using Chart 1, determine the hardware and mount
type for your router.
• For most router models, the screws are driven into
threaded holes in the router’s base (mount type 1).
• For some router models, the screws go all the way
through the base and are fastened with washers
and nuts (mount type 2).
The top and front of the mounting plate is determined
by the location of the guide pin holes. These holes
are to the right of the bit opening.
4.Refer to the mounting plate guide (Fig. 8) on page 14
and align the appropriate mounting plate holes for
your router to the router base holes. Make sure that
the depth adjustment controls on the router face the
front of the mounting plate.
5.Mount your router to the mounting plate (Fig. 10).
FIG. 9
REMOVE
SUBBASE
FIG. 10
CHART 1
16
Router Table Assembly
FINAL INSTALLATION OF THE ROUTER
MOUNTING PLATE (Fig. 11)
1.Place the router mounting plate, with router attached,
on the leveling screws in the tabletop.
NOTE: Be careful not to trap the cord between the
router mounting plate and the router tabletop.
2.Recheck the router mounting plate to be sure it is
level. If necessary, loosen the locking nuts and adjust
the leveling screws with the allen wrench as needed.
Once the router mounting plate is level, retighten the
locking screws.
3.Secure the router mounting plate (3) to the table with
four #10-32 x 1″ pan-head Phillips machine screws
(28) and #10-32 ESNA stop nuts (25) (Fig. 11)
through the inner corner holes in the plate. Tighten
the screws snugly, but do not overtighten.
TO REMOVE THE ROUTER AND/OR
ROUTER MOUNTING PLATE
To remove the router from the mounting plate, you
must first remove the router mounting plate from the
router table.
THE FENCE MUST BE REMOVED FROM THE
ROUTER TABLE WHEN REMOVING OR
REINSTALLING THE ROUTER MOUNTING PLATE.
Make sure that the router is NOT
plugged into a power outlet when installing into the
table, removing from table, making adjustments or
changing accessories. Router could accidentally start.
1.Loosen the four #10-32 x 1″ pan-head Phillips
machine screws (28) holding the router mounting
plate to the tabletop.
2.Lift the router mounting plate and router upwards
from the tabletop.
3.Remove the countersunk machine screws securing
the router to the mounting plate.
4.When reinstalling the router mounting plate, be sure
that the plate is level with the tabletop. If needed,
readjust as described above.
3
28
FIG. 11
OVER-TABLE HEIGHT ADJUSTMENT
The router adapter plate features an access hole to
allow use with the over-table height adjustment feature
on the Bosch 1617 series routers. Refer to your router
manual for additional information on using this feature.
For the Porter Cable 892 and 895 and the Milwaukee
5615 and 5616 model routers, it is necessary to drill an
access hole to accommodate the over-table height
adjustment:
1.Remove the subbase from the router and align
the mounting holes in the subbase with the
corresponding mounting holes in the adapter plate.
Be sure to orient the subbase so that the router
switch will be toward the front of the table.
2.Using a pencil or centerpunch, mark the location of
the over-table height adjustment hole on the router
adapter plate.
3.Remove the subbase from the adapter plate and
carefully drill the over-table height adjustment hole.
4.Make sure that the hole will accommodate the height
adjustment tool for your router. Remove any burrs or
rough edges with sandpaper.
25
Router Table Assembly
ATTACHING THE FENCE TO THE TABLE
(Fig. 12)
1.From underneath the table, slide two 1/4-20 x 11⁄2″
carriage bolts (31) up through the slots in the tabletop
and the holes in the bottom of the fence. Slide a
washer (27) onto each bolt and loosely attach a
large clamping knob (14) onto each bolt.
2.Make sure that the fence assembly slides smoothly
from front to back.
NOTE: Use the scale on the tabletop as a guide
when aligning the fence for routing operations. Once
the fence is positioned and aligned correctly, tighten
the clamping knobs SECURELY.
INSTALLING THE FENCE
14
FIG. 12
27
31
17
18
Router Table Assembly
METHOD 1 (Fig. 13)
1.Set the router table on a workbench or other stable
and sturdy surface, with the FRONT (switch side) of
the router table facing toward you.
2.While holding the router table in the desired position,
mark the location of the four mounting holes (one in
each corner).
3.Remove the router table from the workbench and set
it aside.
4.Drill a 1/8″ pilot hole (for wood screws) or an
appropriately sized hole (for machine screws)
at the marked locations.
5.Place the router table on the workbench and align the
mounting holes in the router table legs with the holes
drilled in the workbench.
6.Secure the router table in place using wood screws
and washers (not provided) or machine screws,
washers, and nuts (not provided). If using wood
screws, applying a little bar soap or bees wax to the
screw threads will make it easier to thread the screws
into the pilot holes.
7.TIGHTEN all screws SECURELY.
FIG. 13
MOUNTING THE ROUTER TABLE TO A WORK SURFACE OR WORKBENCH
Before operating, make sure the
entire unit (table with router installed) is placed on
and secured to a solid, flat, level surface and will
not tip. Use of auxiliary in-feed and out-feed supports is necessary for long or wide workpieces.
Long workpieces without adequate support can cause
the router table to tip over.
TOOLS REQUIRED (not included)
• Phillips screwdriver
• Small-sized adjustable wrench
• Electric or hand drill with drill bits (depending on
mounting method used)
• Fasteners (not included):
• Four #14, #16, or #18 x 2″ pan-head wood
screws (for solid wood work surfaces or
workbenches), or
• Four 5/16″ pan head machine screws, washers,
and hex nuts, or
• Clamps
You may also use the optional Bosch RA1190 Router
Table Floor Stand, available separately through your
Bosch retailer.
The RA1190 Router Table Floor Stand features:
• Places the router table at the optimum
working height.
• Has adjustable nonslip foot pads for leveling the
table on uneven floor surfaces.
• Has two heavy-duty steel shelves for storage.
19
Router Table Assembly
ALTERNATE METHOD (Fig. 15)
1.Cut a board 181⁄4″ wide by 29″ long from a piece of
3/4″ thick plywood or other flat stock.
2.Set the router table on the board, with the FRONT
(switch side) of the router table facing toward you, so
that the spacing between the router table legs and
the edges of the board is equal on all sides.
3.While holding the router table in the desired
position, mark the location of the four mounting holes
(one in each corner).
4.Remove the router table from the board and set
it aside.
5.Drill a 1/8″ pilot hole (for wood screws) at the marked
locations.
6.Place the router table on the board and align the
mounting holes in the router table legs with the holes
drilled in the board.
7.Secure the router table in place using wood screws
(not provided). Applying a little soap to the screw
threads will make it easier to thread the screws into
the pilot holes.
8.TIGHTEN all screws SECURELY.
9.Place the router table on a workbench or other
stable and sturdy surface. Firmly secure the board to
the workbench with screws and washers, clamps, or
other suitable means.
FIG. 15
FIG. 14
METHOD 2 (Fig. 14)
1.Set the router table on a workbench or other
stable and sturdy surface, with the FRONT (switch
side) of the router table facing toward you.
2.Secure the router table legs to the workbench with
clamps, making sure to tighten them SECURELY.
IMPORTANT: Be sure the placement of the clamps
will not interfere with operation of the router table.
3/4″ THICK BOARD
20
Router Table Assembly
ALWAYS MAKE SURE THAT
THE ROUTER IS TURNED OFF AND THE POWER
CORD IS UNPLUGGED BEFORE MAKING
ANY ADJUSTMENTS.
TABLETOP INSERTS (Fig. 16)
This router table includes three tabletop inserts with the
following hole sizes:
• 1″ in diameter (3), for use with bits with diameters
up to 7/8″
• 2″ in diameter (4), for use with bits with diameters
up to 1
7
⁄8″
• 2
3
⁄4″ in diameter (5), for use with bits with diameters
up to 2
5
⁄8″
No insert is used for bits with diameters over 2
5
⁄8″ and
up to 3
1
⁄2″.
Do NOT use the router table with
bits over 3
1
⁄2″ in diameter!
TO INSTALL TABLETOP INSERTS (Fig. 16):
1.Select the tabletop insert that best accommodates
the router bit to be used.
2.Press the insert into the large hole in the router
mounting plate (Fig. 16). If the fence is in the way,
loosen the clamping knobs on the fence support
brackets and slide the fence back out of the way.
3.Press down evenly over the tabs until the insert locks
into place.
4.To remove, pull up gently until the tabs disengage.
When not in use, store tabletop inserts behind the
storage panel in the table leg or in another
convenient place.
DO NOT attempt to remove
tabletop inserts from the tabletop unless the
router is unplugged.
1″ HOLE (3)
2″ HOLE (4)
2
3
⁄4″ HOLE (5)
3
5
⁄8″ HOLE
IN ROUTER
MOUNTING
PLATE
FIG. 16
21
Router Table Operation
SWITCH INSTRUCTIONS
ELECTRICAL REQUIREMENTS
A 14 gauge (or heavier) three-wire extension cord with
a three-hole grounding receptacle and three-hole
grounding plug is to be used for connecting the
switch to an electrical outlet.
DAMAGED OR WORN EXTENSION CORDS
ARE NOT TO BE USED AND ARE TO BE
REPLACED IMMEDIATELY.
The electrical cord at the back of the switch will accept
three-hole extension cords.
The electrical receptacles at the back of the switch will
accept either three-prong or two-prong plugs from a
router or accessory.
In the event of a malfunction or breakdown, grounding
provides the path of least resistance for electrical
current in order to reduce the risk of electrical shock.
This switch box is equipped with an electrical cord
that has an equipment-grounding connector and a
grounding plug.
The extension cord must be plugged into a matching
outlet that has been installed by a licensed
electrician and grounded in accordance with
all local codes and ordinances.
DO NOT modify the plug from the switch if it does not
plug into the extension cord. Obtain an extension cord
with the proper outlet.
Improper connection of the equipment-grounding
conductor can result in risk of an electrical shock.
The conductor with insulation that has a green outer
surface, with or without yellow stripes, is the equipmentgrounding conductor.
DO NOT CONNECT THE EQUIPMENT-GROUNDING
CONDUCTOR TO A LIVE TERMINAL.
Check with a licensed electrician if the grounding
instructions are not completely understood, or if there
is doubt as to whether the electrical outlet or extension
cord is properly grounded.
DO NOT PERMIT FINGERS
TO TOUCH TERMINALS OF THE PLUG WHEN
PLUGGING IT INTO OR REMOVING IT FROM
THE OUTLET.
IF NOT PROPERLY GROUNDED,
A POWER TOOL CAN PRESENT POTENTIAL
HAZARDS OF ELECTRICAL SHOCK, WHICH CAN
POSSIBLY RESULT IN SERIOUS BODILY INJURY
OR DEATH, particularly when used in a damp
location, in proximity to plumbing or out-of-doors.
If an electrical shock occurs, there is always the
potential of a secondary hazard, such as your
hands contacting the router bit, or falling down
or against an object.
USE THE SWITCH BOX ONLY
WHEN PROPERLY ASSEMBLED TO THE ROUTER
TABLE. USE ONLY WITH A ROUTER THAT HAS
ALSO BEEN PROPERLY INSTALLED ON A
PROPERLY ASSEMBLED ROUTER TABLE.
THE SWITCH HAS A RATING OF
15 AMPS. DO NOT EXCEED A TOTAL COMBINED
RATING OF 15 AMPS WHEN CONNECTING THE
ROUTER AND ANY ACCESSORIES SUCH AS A
LIGHT OR WET/DRY VACUUM.
GENERAL INFORMATION
The power switch is designed for use with most
BOSCH Router Tables. It provides the convenience of
an ON (RESET)-OFF switch at the front of the table,
thus eliminating the need to reach underneath the table
to turn the router ON and OFF.
The power switch also provides an optional
simultaneous ON-OFF control of an additional
accessory, such as a light or wet/dry vac.
The switch has an internal, resettable circuit
breaker to provide overload protection.
LOCKOUT
KEY
SWITCH BOX
Switch receptacle orientation
(as viewed from front of switch)
FIG. 17
Router Table Operation
CONNECTING THE ROUTER POWER CORD
TO THE SWITCH
• MAKE SURE THAT THE SWITCH POWER
CORD IS NOT PLUGGED INTO ANY ELECTRICAL
OUTLET AT THIS TIME. IF IT IS, UNPLUG IT.
• MAKE SURE THAT THE ROUTER SWITCH IS IN
THE OFF POSITION.
1. Plug the router power cord into one of the electrical
outlets on the back of the switch assembly.
2. Form the excess power cord into a coil.
3. Wrap two pieces of friction tape or cable ties around
the coiled cord at opposite sides of the coil.
4. Allow some slack so that the cord does not become
stretched when it is plugged into the switch box
outlets.
5. If desired, at this time plug the power cord from an
accessory, such as a wet/dry vac or light, into the
other outlet on the back of the switch assembly.
MAKE SURE THAT POWER
CORDS FROM THE ROUTER, ACCESSORIES, THE
SWITCH CASE, AND THE EXTENSION CORD DO
NOT AND CANNOT COME IN CONTACT WITH THE
ROUTER OR ANY MOVING PARTS OF THE
ROUTER.
• This switch has a 15-amp rating and is
intended only for turning the router and
connected accessories such as a wet/dry
vacuum “ON” and “OFF.”
SWITCH OPERATION
This section explains the operation and features of
the switch prior to plugging the power cord into an
extension cord. The intent is to familiarize the user
with the switch operation without actually turning ON
the router.
The switch incorporates two positive features to
prevent inadvertent switching ON of the router and the
unauthorized, and possibly hazardous, use by others:
• There is a transparent cover over the actual switch to
prevent the accidental switching ON of the router. This
cover allows you to see a small red light on the switch
toggle when the switch is turned ON. The switch can
be turned OFF quickly by pushing the cover.
• The light is ON when the switch is ON.
• The light is OFF when the switch is OFF.
• The lockout key must be completely inserted into
the side of the switch case before the switch can be
turned ON.
To operate the switch:
MAKE SURE THAT THE EXTENSION CORD IS NOT
PLUGGED INTO AN ELECTRICAL OUTLET
BEFORE PROCEEDING ANY FURTHER.
1. Insert the lockout key into the side of the switch case.
See Figure 17 on page 21.
2. To turn the router ON, lift the switch cover and
toggle switch to ON (RESET) position. See A above.
Gently lower the switch cover. Letting the switch
cover drop closed may cause the switch to turn OFF.
3. To turn the router OFF, press the switch cover. The
switch toggle will be in the OFF position, as shown in
B above.
NEVER LEAVE THE ROUTER
UNATTENDED WHILE IT IS RUNNING OR BEFORE
IT COMES TO A COMPLETE STOP.
4.To lock switch in the OFF position, press the cover
to turn the switch OFF and remove the lockout key
completely from the side of the switch case. The red
slide panel should cover the top half of the switch, as
shown in C above.
With the lockout key removed and the red slide panel
covering the top half of the switch toggle, the switch
CANNOT be toggled to the ON position.
OFF
ON (RESET)
OFF
ON (RESET)
OFF
ON (RESET)
A
B
C
With the lockout key in place and the
cover raised, the switch can be toggled
to the ON (RESET) position. Note that
the red slide panel is fully retracted
from the switch.
With the lockout key in place and the
cover raised, the switch can be toggled
to the OFF position. The switch can
also be turned OFF by pressing on the
cover. Note that the red slide panel is
fully retracted from the switch.
With the lockout key removed, the red
slide panel covers the top portion of the
switch, locking it in the OFF position.
The switch cannot be toggled to the
ON (RESET) position without first fully
inserting the lockout key.
Red slide
panel
22
23
Router Table Operation
BEFORE PROCEEDING ANY
FURTHER, MAKE SURE THE SWITCH ON THE
ROUTER IS IN THE OFF POSITION AND THE
SWITCH LEVER IS IN THE OFF POSITION.
The switch power cord can now be plugged into the
extension cord.
MAKE SURE THAT POWER
CORDS FROM THE ROUTER, ACCESSORIES, THE
SWITCH CASE, AND THE EXTENSION CORD DO
NOT AND CANNOT COME IN CONTACT WITH THE
ROUTER OR ANY MOVING PARTS OF THE
ROUTER.
ROUTER AND SWITCH OPERATION
This section explains operation of the switch with the
power cord plugged into the extension cord.
The router will turn ON when the toggle switch is
toggled to the ON (RESET) position.
1. Position the ON/OFF switch on the router in the ON
position. On certain routers this will require the use
of the switch trigger and “LOCK-ON” button. (Consult
router owner’s manual.) Make sure the switch on
the switch case is in the OFF position when
doing this.
2. To turn the router ON, lift the switch cover and toggle
the switch to the ON position. See A on page 22.
3. To turn the router OFF, push on the switch cover.
See B on page 22.
NEVER LEAVE THE ROUTER
UNATTENDED WHILE IT IS RUNNING OR BEFORE
IT COMES TO A COMPLETE STOP.
NOTE: In the event of an overload, the internal switch
circuit breaker will trip the switch to the OFF position.
This will interrupt power to the router and any
accessory plugged into the switch itself. If this
occurs, proceed as follows:
1. Unplug the switch cord from the extension cord.
2.Remove the workpiece from the router table.
3.Correct the cause of the overload situation (i.e. the
load exceeds the rated capacity of the switch).
4.Plug the switch power cord into the extension cord.
5.Restart the router as described in the section
ROUTER AND SWITCH OPERATION.
WHEN THE ROUTER TABLE IS NOT IN USE
1.Press the switch cover to turn the switch OFF.
2.Remove the lockout key.
3.Store the lockout key in a safe location where it is
not available to children and other unauthorized
persons.
4.Unplug the switch cord from the extension cord.
5.Remove the router bit from the router.
6.Position the router collet assembly below the top of
the router table.
NOTE: If the key should become lost or damaged,
replacement keys are available from your local
Bosch dealer.
INSTALLATION OF A WET/DRY VAC TO THE
DUST COLLECTOR
The guard/dust collector assembly has a port for
connecting a wet/dry vac hose with a 2
1
⁄2″ nozzle.
To attach, simply push the nozzle into the port while
holding the fence assembly in place.
Operating the router table without
a wet/dry vac can result in an excessive buildup of
sawdust and wood chips under the fence assembly
and overhead guard, reducing the performance of the
router table and fence assembly.
RECOMMENDATION: To maximize performance,
regardless of whether a wet/dry vac is being used,
remove the sawdust and wood chips from under the
fence assembly and overhead guard as needed.
RECOMMENDATION: It is always a good practice to
keep the work area clean. As necessary, remove any
accumulated sawdust and wood chips from the top of
the router table, as well as from the surrounding work
area and floor.
DO NOT REACH INTO THE AREA
OF THE BIT WHILE THE ROUTER IS PLUGGED IN!
INSTALLING A WET/DRY VAC
Router Table Operation
INSTALLING THE ROUTER BIT (CUTTER)
ALWAYS MAKE SURE
THAT THE ROUTER IS TURNED OFF AND
THE POWER CORD IS UNPLUGGED BEFORE
MAKING ANY ADJUSTMENTS.
I
nstall the router bit according to the instructions
included with your router. Because of the large variation of router bits, certain router bits may not always
operate in the desired manner with this router table.
To ensure that the most popular bits will perform
satisfactorily, install the bit so that the router collet
engages 3/4″ of the router bit shank. If the shank
of the router bit bottoms out in the collet, back out
the router bit approximately 1/16″ to allow for
proper tightening.
NEVER INSTALL ROUTER BITS WITH LESS THAN
3/4″ OF SHANK ENGAGEMENT IN THE COLLET.
ASSEMBLING THE FEATHERBOARDS
(Figs. 18–20)
NOTE: The top/front side of each featherboard is
marked to indicate proper feed direction.
Fence Featherboard (Figs. 18 and 19)
1.Insert two 1/4-20 x 1
1
⁄2″ carriage bolts (31)
through the slotted holes in the featherboard (19).
See Fig. 18.
2.Slide a large washer (27) onto each carriage bolt and
thread a small clamping knob (17) three or four turns
onto each carriage bolt.
3.To install on the fence, slide a spacer (16) over the
head of each carriage bolt, aligning the tabs on the
spacer with the slot in the featherboard (Fig. 19).
Then slide the carriage bolt heads into the T-slot
on the top of the fence.
Tabletop Featherboard (Fig. 20)
1.Insert two 1/4-20 x 1
1
⁄2″ carriage bolts (31) through
the slotted holes in the featherboard (19).
2.Slide a large washer (27) onto each carriage bolt and
thread a small clamping knob (17) three or four turns
onto each carriage bolt.
3.To install the featherboard in the miter channel on
the tabletop, insert the heads of the carriage bolts
into the desired pair of keyhole slots on the tabletop
(located in the miter channel). Then tighten the
clamping knobs securely.
FIG. 18
FIG. 19
FIG. 20
31
16
19
17
17
31
27
242725
Router Table Operation
ROUTING USING FEATHERBOARDS
(Fig. 21)
Featherboards are helpful in controlling the workpiece
while routing and assist in keeping the workpiece flat
on the tabletop. The table featherboard, combined with
the fence featherboard, helps keep the workpiece
pressed against the fence and tabletop. The best
location for the featherboards varies according to
your application, workpiece size, and other factors.
1.Loosely install the featherboard(s) as described
on page 24.
2.Place the workpiece on the router table so that it is
squarely against the fence.
3.Position the feather board so that the featherboard
is snug against the workpiece and tighten the
clamping knobs.
4.The workpiece should move with some resistance
but without requiring a great effort.
5.For wider workpieces, the tabletop featherboard
cannot be used. The second featherboard may also
be positioned on the fence, if desired.
Additional featherboards, model RA1187, can be
purchased from your Bosch retailer.
• Featherboards are an aid in holding the workpiece in
position when routing on a router table.
• They are NOT intended to hold the workpiece in
place alone when the workpiece is in contact with the
bit, or at any other time when the bit is turning.
• NEVER let go of the workpiece when routing using
the featherboards until the cut has been completed
and the workpiece is completely clear of the bit.
FOR ACCURACY IN ROUTING
AND IMPROVED CONTROL, THE WORKPIECE
SHOULD BE HELD AGAINST THE ROUTER TABLE
FENCE WHEN ROUTING.
ADJUSTING THE FENCE FACING (Fig. 22)
The right and left fence facings are attached to the front
face of the router table fence, and can be adjusted
inward or outward from the router bit to allow proper
clearance for different sized bits. To provide the best
support during routing operations, the fence facings
should be as close to the bit as possible without being
able to come in contact with the bit (typically about 1/4″
from the bit is a suitable distance).
1.Loosen the two clamping knobs on the backs
of the fence facings and slide the facings inward
or outward from the router bit as needed.
ALWAYS MAKE SURE THAT THE
FENCE, FENCE FACINGS, AND GUARD CANNOT
COME IN CONTACT WITH THE ROUTER BIT.
FAILURE TO DO SO WILL RESULT IN DAMAGE
TO THE ROUTER TABLE AND CAN CAUSE
PERSONAL INJURY.
2.Once the fence facings are in the desired position,
tighten the clamping knobs SECURELY.
DIRECTION
OF FEED
FIG. 22
FIG. 21
26
Router Table Operation
ADJUSTING DEPTH AND HEIGHT OF CUT
(Fig. 23)
1.Select a board that is smooth and straight, with good
square edges.
2.Mark lines “A” and “B” on the end of the board, as
shown in Detail 23.
• Line “A” indicates the desired height of cut.
• Line “B” indicates the desired final depth of cut.
• The area outlined by “A,” “B,” and the edge of the
board is the area that will be cut away.
3.If the desired depth of cut can be cut in a single pass,
loosen the fence clamping knobs and move the fence
forward or backward until the outermost cutting edge
of the router bit is aligned with line “B.” It may be
necessary to reposition the guard to provide
clear access.
NOTE: For deeper cuts, do NOT attempt to make the
cut in a single pass. Make multiple shallower cuts
passes, progressively moving the fence backward
until the desired depth of cut is reached.
4.Use the scales on the tabletop as a guide to align the
fence; then SECURELY tighten both fence
clamping knobs.
ALWAYS MAKE SURE THAT THE
FENCE AND GUARD CANNOT COME IN CONTACT
WITH THE ROUTER BIT. FAILURE TO DO SO WILL
RESULT IN DAMAGE TO THE ROUTER TABLE AND
CAN CAUSE PERSONAL INJURY.
5.Following the instructions that came with your router,
adjust the router height of cut until the top of the
router bit lines up with line “A”.
6.Once all adjustments have been made, double-check
that:
• The router is SECURELY tightened in the
router base.
• The router bit is SECURELY tightened in
the router collet, with at least 3/4″ shank
engagement.
• The router base is SECURELY tightened to the
router mounting plate.
7.Remove the board from the table.
NOTE: When making adjustments, use a piece of
scrap wood to make trial cuts before making the cut
with the actual workpiece.
AREA OF
DETAIL 23
SCRAP WOOD
FIG. 23
DETAIL 23
A
B
27
Router Table Operation
FULL EDGE CUTTING OR JOINTING
(Figs. 24 and 25)
For maximum strength and accuracy, boards that are
to be joined together should be smooth and true. The
edges should be true to the workpiece surface. You
can true the edges using the router table with a
straight bit.
NOTE: Use the jointing shim(s) to provide continuous
support for the workpiece as it is fed past the router bit.
ALWAYS MAKE SURE THAT
THE ROUTER IS TURNED OFF AND THE POWER
CORD IS UNPLUGGED BEFORE MAKING ANY
ADJUSTMENTS.
1. Loosen the clamping knobs on the left fence facing.
2. Align the slot in the jointing shim(s) with the holes
in the fence facing, and slide the jointing shim(s)
between the fence and the left fence facing
(Fig. 24).
Use one jointing shim for a 1/16″ offset, or both
jointing shims for a 1/8″ offset
3. Install a straight bit in the router.
4. Position both fence facings so that they clear the bit
by 1/4″.
5. Tighten the four clamping knobs holding the fence
facings in place.
6. Place a straight edge or a straight piece of wood on
the table so that it rests against the left fence facing.
7. Move the fence back until the straight edge lines up
with the cutting edge of the bit and is still in contact
with the left fence facing.
8. Tighten the clamping knobs.
9. Remove the straight edge or board.
10.Adjust the height of the bit so that it will cut the
complete thickness of the workpiece.
11. Position the featherboards, if desired. See
ROUTING USING FEATHERBOARDS on page 25.
12.Remove the board from the table and lower the
overhead guard to the operating position.
Tighten the guard clamping knobs SECURELY.
NOTE: When making adjustments, use a piece of
scrap wood to make trial cuts before making the cut
with the actual workpiece.
13.Make sure that both the router and switch box are
OFF; then plug the router into the switch box.
14.While firmly holding a piece of scrap wood
against the fence and down against the router
table, feed a piece of scrap wood toward the bit
in the direction shown by the arrow in Fig. 25.
15.Using the switch box, turn the router OFF. If any
adjustments are needed, unplug the power cord and
repeat steps 6–11 until all adjustments are correct.
Once you are satisfied with all settings, make the
cut with the actual workpiece.
WORKPIECE
JOINTING
SHIM(S)
FIG. 24
FIG. 25
28
Router Table Operation
EDGE CUTTING WITH NONPILOTED
ROUTER BITS (Figs. 26 and 27)
ALWAYS MAKE SURE THAT THE
ROUTER IS TURNED OFF AND THE POWER CORD
IS UNPLUGGED BEFORE MAKING ANY
ADJUSTMENTS.
NOTE: If the jointing shim is installed, remove it
before proceeding.
When using nonpiloted router bits, the fence is used to
set the depth of cut. For deep cuts, do not try to cut the
total depth all in one pass. Repeat the cut, taking
multiple smaller cuts.
1. Install the desired bit in the router.
2. Follow the instructions on page 26 to set the desired
depth of cut and height of cut (Fig. 26). Make sure
that the fence and router are SECURELY in place.
3. Position both fence facings so that they clear the bit
by 1/4″.
4. Tighten the four clamping knobs holding the fence
facings in place.
5. Position the featherboards, if desired. See
ROUTING USING FEATHERBOARDS on page 25.
6. Remove the board from the table and lower the
overhead guard to the operating position.
Tighten the guard clamping knobs SECURELY.
NOTE: When making adjustments, use a piece of
scrap wood to make trial cuts before making the
cut with the actual workpiece.
7. Make sure that both the router and switch box are
OFF; then plug the router into the switch box.
8. While firmly holding a piece of scrap wood
against the fence and down against the router
table, feed a piece of scrap wood toward the bit in
the direction shown by the arrow in Fig. 27.
9. Using the switch box, turn the router OFF. If any
adjustments are needed, unplug the power cord and
repeat steps 2–8 until all adjustments are correct.
Once you are satisfied with all settings, make the
cut with the actual workpiece.
WORKPIECE
FENCE
FACING
ROUTER BIT
DEPTH OF CUT
HEIGHT
OF CUT
Guard not shown for clarity
FIG. 26
FIG. 27
Router Table Operation
29
EDGE CUTTING WITH PILOTED ROUTER
BITS (Figs. 28 and 29)
ALWAYS MAKE SURE THAT
THE ROUTER IS TURNED OFF AND THE POWER
CORD IS UNPLUGGED BEFORE MAKING ANY
ADJUSTMENTS.
NOTE: If the jointing shim is installed, remove it
before proceeding.
1. Install the desired piloted bit in the router.
2. Follow the instructions on page 26 to set the desired
height-of-cut (Fig. 28). Make sure that the router is
SECURELY in place.
3. Adjust the router table fence back just enough that
the pilot on the router bit will control the depth-ofcut. The router bit pilot should just barely protrude
past the fence facings. Tighten the fence clamping
knobs SECURELY.
4. Position both fence facings so that they clear the bit
by 1/4″.
5. Tighten the four clamping knobs holding the fence
facings in place.
6. Remove the board from the table and lower the
overhead guard to the operating position.
Tighten the guard clamping knobs SECURELY.
NOTE: When making adjustments, use a piece of
scrap wood to make trial cuts before making the cut
with the actual workpiece.
7. Make sure that both the router and switch box are
OFF, then plug the router into the switch box.
8. While firmly holding a piece of scrap wood
against the fence and down against the router
table, feed a piece of scrap wood toward the bit in
the direction shown by the arrow in Fig. 29.
9. Using the switch box, turn the router OFF. If any
adjustments are needed, unplug the power cord and
repeat steps 2–8 until all adjustments are correct.
Once you are satisfied with all settings, make the
cut with the actual workpiece.
PILOTED
ROUTER BIT
DEPTH OF CUT
HEIGHT
OF CUT
ROUTER BIT
PILOT
CLEARANCE
BETWEEN
FENCE AND BIT
WORKPIECE
Guard not shown for clarity
FIG. 28
FIG. 29
Loading...