Page 1
SETUP & OPERATION MANUAL
FEATURES
16" x 27" cast-iron router extension table can
be installed on 27”-29” table saws with cast-iron
tables*.
Includes self-adhesive mounting hole drilling
guide/template for easy installation.
Standard 9 1/4" x 11 3/4" router plate opening
with phenolic router plate included.
Two sturdy, flip-up, adjustable-length steel support legs.
Deluxe 27” router fence has 2 1/4” dust collection outlet and adjustable scales.
Kit Includes: 16" x 27" table (#40-070), set of two
adjustable-length steel support legs (#40-068),
deluxe router fence (#40-065) and 9 1/4" x 11
3/4" phenolic router insert plate (#40-114).
* Depending on mounting location, some drilling or
modifications may be required.
SPECIFICATIONS
CAST-IRON ROUTER EXTENSION KIT
FOR TABLE SAWS
• Table size
16" x 27" (902 x 686 mm)
• Router plate size
9 1/4" x 11 3/4"
• Fence size (each)
3" x 15 1/4" x 3/4" (76 x 387 x 19 mm)
• Maximum fence travel
6" (152 mm)
• Dust outlet
2 1/4" (57 mm)
• Distance between t-slots & spindle center
3/4”: 5 1/16” (135 mm)
3/8”: 6 9/16” (167 mm)
• Distance from spindle center to front edge
of table
8" (205 mm)
• T-slot dimensions
3/4” x 3/8” (19 x 10 mm)
3/8” x 1/4” (10 x 7 mm)
• Table opening sizes (diameter)
With insert ring: 1/2" (38 mm)
Without insert ring: 3 3/4" (95 mm)
Version 1 - 29th January 2014
© Copyright General International
MODEL
#
40-070EK
Page 2
GENERAL® INTERNATIONAL
8360 Champ-d’Eau, Montreal (Quebec) Canada H1P 1Y3
Telephone (514) 326-1161 • Fax (514) 326-5555 • www.general.ca
THANK YOU
for choosing this General® International model 40-070EK
router table. This cast-iron table 40-070EK has been carefully tested and inspected before
shipment and if properly used and maintained, will provide you with years of reliable service.
For your safety, as well as to ensure optimum performance and trouble-free operation, and to
get the most from your investment, please take the time to read this manual before assembling,
installing and operating the unit.
The manual’s purpose is to familiarize you with the safe operation, basic function, and features
of this router table as well as the set-up, maintenance and identification of its parts and
components. This manual is not intended as a substitute for formal woodworking instruction,
nor to offer the user instruction in the craft of woodworking. If you are not sure about the safety
of performing a certain operation or procedure, do not proceed until you can confirm, from
knowledgeable and qualified sources, that it is safe to do so.
Once you’ve read through these instructions, keep this manual handy for future reference.
Disclaimer: The information and specifications in this
manual pertain to the unit as it was supplied from the
factory at the time of printing. Because we are committed to making constant improvements, General® International reserves the right to make changes to components, parts or features of this unit as deemed necessary,
without prior notice and without obligation to install any
such changes on previously delivered units. Reasonable care is taken at the factory to ensure that the specifications and information in this manual corresponds
with that of the unit with which it was supplied. However,
special orders and “after factory”modifications may
render some or all information in this manual inapplicable to your machine. Further, as several generations
of this model of router table
manual may be in circulation, if you own an earlier or
later version of this unit, this manual may not depict
your unit exactly. If you have any doubts or questions
contact your retailer or our support line with the model
and serial number of your unit for clarification.
and several versions of this
Page 3
GENERAL® INTERNATIONAL WARRANTY
All component parts of General® International and Excalibur by General International® products are
carefully inspected during all stages of production and each unit is thoroughly inspected upon completion of assembly.
Limited Lifetime Warranty
Because of our commitment to quality and customer satisfaction, General® International agrees to
repair or replace any part or component which upon examination, proves to be defective in either
workmanship or material to the original purchaser for the life of the tool. However, the Limited Lifetime
Warranty does not cover any product used for professional or commercial production purposes nor for
industrial or educational applications. Such cases are covered by our Standard 2-year Limited Warranty only. The Limited Lifetime Warranty is also subject to the “Conditions and Exceptions” as listed below.
Standard 2-Year Limited Warranty
All products not covered by our lifetime warranty including products used in commercial, industrial
and educational applications are warranted for a period of 2 years (24 months) from the date of purchase. General® International agrees to repair or replace any part or component which upon examination, proves to be defective in either workmanship or material to the original purchaser during this
2-year warranty period, subject to the “conditions and exceptions” as listed below.
To file a Claim
To file a claim under our Standard 2-year Limited Warranty or under our Limited Lifetime Warranty,
all defective parts, components or machinery must be returned freight or postage prepaid to
General® International, or to a nearby distributor, repair center or other location designated by General® International. For further details call our service department at 1-888-949-1161 or your local distributor for assistance when filing your claim.
Along with the return of the product being claimed for warranty, a copy of the original proof of purchase and a “letter of claim” must be included (a warranty claim form can also be used and can be
obtained, upon request, from General® International or an authorized distributor) clearly stating the
model and serial number of the unit (if applicable) and including an explanation of the complaint or
presumed defect in material or workmanship.
CONDITIONS AND EXCEPTIONS:
This coverage is extended to the original purchaser only. Prior warranty registration is not required but
documented proof of purchase i.e. a copy of original sales invoice or receipt showing the date and
location of the purchase as well as the purchase price paid, must be provided at the time of claim.
Warranty does not include failures, breakage or defects deemed after inspection by General®
International to have been directly or indirectly caused by or resulting from; improper use, or lack of or
improper maintenance, misuse or abuse, negligence, accidents, damage in handling or transport, or
normal wear and tear of any generally considered consumable parts or components.
Repairs made without the written consent of General® International will void all warranty.
Page 4
TABLE OF CONTENTS
Rules for safe operation ..................................................................................................... 5
Identification of main parts and components .................................................................. 6
Basic functions .................................................................................................................. 7
Unpacking ...................................................................................................................... 7-9
List of contents .................................................................................................................................................. 7-9
Cleaning............................................................................................................................. 9
Assembly instructions ................................................................................................... 9-19
Installing the router table support legs ............................................................................................................ 9
Installing the router table ................................................................................................................................. 10
Assembly the router table and support legs ................................................................................................. 12
Installing the router fence ................................................................................................................................ 13
Phenolic insert plate assembly ....................................................................................................................... 15
Leveling and locking the router plate ............................................................................................................ 16
Insert ring removal ............................................................................................................................................ 17
Installing the starting pin .................................................................................................................................. 17
Basic adjustments and controls ...................................................................................... 17
Adjusting the fence along the rails ................................................................................................................ 17
Adjusting the sliding scale on the rails ........................................................................................................... 17
Adjusting the fence faces ................................................................................................................................ 17
Operating Instructions ................................................................................................ 18-19
Using the spacer bars for jointing ................................................................................................................... 18
Jointing ............................................................................................................................................................... 18
Groove cutting .................................................................................................................................................. 19
Profile cutting ..................................................................................................................................................... 19
Recommended optionnal accessories ........................................................................... 20
Parts list & diagrams ................................................................................................... 21-23
Contact information ........................................................................................................ 24
Page 5
RULES FOR SAFE OPERATION
To help ensure safe operation, please take a moment to learn the machine’s applications and limitations,
as well as potential hazards. General
harmless for any injury that may result from the improper use of it’s equipment.
1. Make sure that the operator has been properly
trained and has read and understands the Owner’s Manual before operating any machinery.
2. Be sure to read, understand, and follow all instructions, warnings, and safety guidelines supplied
with your table saw and router.
3. Keep the work area well lit, clean, and free of
debris.
4. STAY ALERT! Give your work you undivided attention.
Even a momentary distraction can lead to serious
injury.
5. Do not wear loose clothing, gloves, bracelets, necklaces, or other jewelry. Wear protective hair covering to contain long hair and wear non-slip footwear.
6. Keep hands and other body parts well away from
bits or cutting tools. When working close to the cutting tool, always use a feather board or push-stick
to hold or guide the workpiece. Do not clear chipsand sawdust away with hands; use a brush.
7. Fine particulate dust is a carcinogen that can be
hazardous to health. Always work in a well ventilated area and whenever possible use a dust collector.
8. Be sure the router bit and/or saw blade has gained
full operating speed before feeding the workpiece.
9. Keep children and visitors at a safe distance when
the table saw is in operation – do not permit them
to operate the table saw.
10. Childproof and tamper-proof your shop and all
machinery with locks, master electrical switches
and switch keys, to prevent unauthorized or unsupervised use.
11. Never stand or lean on your table saw. Serious injury can occur if the table saw is tipped or if unintentional contact is made with the spinning saw blade
or router bit.
®
International disclaims any real or implied warranty and hold itself
12. Keep all guards and safety devices in place and in
good working order. If a guard must be removed
for maintenance or cleaning make sure it is properly re-installed before using the machine again.
13. Hold the workpiece firmly against the table and use
suitable support if the workpiece does not have a
flat surface.
14. Feed the stock into the bit against the rotation direction of the bit. Never run the stock between the
fence and the bit.
15. Do not operate the router with a damaged bit
and/or the table saw with a damaged blade.
16. Always disconnect the router and/or the table
saw from the power source before changing accessories or before performing any maintenance
and adjustments or if the machine will be left unattended.
17. Be sure that all adjustment tools, wrenches, or other clutter are removed from the table surface and
safelystored before sawing or routing.
18. Make sure the router and/or table saw switch(es)
is (are) in the “OFF” position before plugging in to a
power source.
19. Avoid working from awkward or off-balance positions. Do not overreach and always keep both feet
firmly on the floor.
20. Never leave the table saw and/or router unattended while running or with the power “ON”.
21. Do not use this router extension wing/router fence
for any purposes other than its intended use.
22. If used for other purposes, General® International
disclaims any real or implied warranty and holds
itself harmless for any injury which may result from
such use.
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IDENTIFICATION OF MAIN PARTS AND COMPONENTS
FRONT VIEW
F
E
C
A
B
M
G
L
D
H
I
J
A. CAST-IRON ROUTER TABLE
B. FENCE RAIL WITH SLIDING SCALE
C. SLIDING ADJUSTABLE FENCE FACE
D. FENCE LOCKING HANDLE
E. DUST SHIELD LOCK KNOB
F. DUST SHIELD
G. FENCE BODY
K
H. 3/4” X 3/4” MITER T-SLOT (FOR MITER GAUGE)
I. 3/8” MITER T-SLOT (FOR SHOP MADE JIGS)
J. SUPPORT LEG
K. LEG ADJUSTMENT LOCK KNOB
L. LEG SWIVEL LOCK KNOB
M. PHENOLIC ROUTER INSERT PLATE
6
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BASIC FUNCTIONS
The Excalibur by General International model 40-070EK Cast-Iron Router Extension Kit for Table Saws is designed
to provide you with the full features and functionality of a stand-alone shop router table along with space-saving
convenience and easy bolt-on installation directly to the end of your existing table saw.
The 40-070EK is designed to either be fit onto the end of, or to replace one of the existing cast-iron extension wings
on your table saw. Though 40-070 cast-iron table measures 27” the unit can also be installed centered on table
saws with 28” or 29” tables with only a slight protrusion of the saw table beyond each end. To facilitate such installations, a self adhesive center-marked drilling template is included to allow you to locate and mark the mounting
holes that may need to be drilled into your saw table or extension wing.
Deciding whether to install the wing to the left or right of the saw is entirely a matter of personal preference, and
will be determined by your own shop space considerations as well as the configuration, type, and model of saw
you are installing it on. Whichever side you choose, here are a few factors to consider before installing:
1. Some cabinet saws have motor cover doors that extend underneath beyond the main table, this may prevent
the router from being hung from that side of the saw, or may require lifting the router out of the table to allow
opening the motor cover door.
2. The distance between the 40-070EK support legs and the cabinet door should also be verified to ensure adequate clearance for the door.
3. Table saw rip fence rails that go beyond the width of the table saw may cause obstructions at one or both
ends, preventing installation of the router fence rails. Depending on your specific saw, the fence rails may need
to be repositioned or shortened, or you may be obliged to install the 40-070EK on one specific end of the saw.
4. At least 3 of the pre-drilled mounting holes in the 40-070 should be used to secure it to the saw table. One near
the front, middle, and rear. If mounting to the main table of your saw, drilling mounting holes into the lip of your
saw table may not be required. However if mounting to the end of the saw’s extension wing, mounting holes
will be required and an appropriate sized drill bit and mounting hardware are included.
UNPACKING
Carefully unpack and remove the components of the following 4 packages - that make up a complete Excalibur
40-070EK Router Table and check for damaged or missing items as per the list of contents below.
TIP: PLEASE REPORT ANY DAMAGED OR MISSING ITEMS TO YOUR GENERAL® INTERNATIONAL DISTRIBUTOR IMMEDIATELY.
INSERT PLATE (#40-114)
LIST OF CONTENTS QTY
A. ROUTER INSERT PLATE ................................................... 1
B. INSERT WRENCH ........................................................... 1
C. FLAT HEX SOCKET HEAD SCREW .................................. 2
D. INSERT RING .................................................................. 1
E. STARTING PIN ................................................................ 1
SUPPORT LEGS (#40-068)
LIST OF CONTENTS QTY
SWIVEL LOCK KNOB ................................................................ 2
A.
B. LEG ADJUSTMENT LOCK KNOB .............................................. 2
C. SUPPORT LEG ........................................................................... 2
D. LEG MOUNTING BRACKET....................................................... 2
E. EXTENSION LEG ....................................................................... 2
F. HARDWARE BAG/END CAPS ................................................... 1
D
A
E
A
B
C
B
C
D
F
E
7
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ROUTER FENCE (#40-065)
LIST OF CONTENTS QTY
A. DUST SHIELD .................................................................. 1
B. 1⁄4” DUST COLLECTION OUTLET. ................................... 1
C. FENCE LOCKING HANDLE ........................................... 2
D. FENCE BODY .................................................................1
E. FENCE FACE .................................................................. 2
F. FENCE SIDE RAIL W/SCALE........................................... 2
G. FENCE MOUNTING BRACKET ....................................... 2
H. SPACER BARS (FOR JOINTING WORK) ........................2
I. LOCK KNOB .................................................................. 8
J. T-BOLT (LONG) .............................................................. 6
K. CAP SCREW .................................................................. 6
L. PLASTIC SPACER ............................................................ 2
M. FLAT WASHER (SMALL) ................................................ 14
N. T-BOLT (SHORT) ............................................................. 2
O. PHILLIPS HEAD SCREW .................................................. 2
P. HEX NUT (LARGE) ......................................................... 2
Q. FLAT WASHER (LARGE) ................................................. 2
R. SQUARE NUT ................................................................. 8
S. HEX HEAD BOLT ............................................................ 6
D
G
H
A
B C
E
F
N
I
K
S
R
CAST-IRON ROUTER TABLE (#40-070)
LIST OF CONTENTS QTY
CAST-IRON TABLE 16” X 27” ..................................................... 1
A.
B. FLAT HEAD CAP SCREW ........................................................ 10
C. HEX NUT ................................................................................. 10
D. FLAT WASHER ............................................................................ 4
E. LOCK WASHER ......................................................................... 4
F. CAP SCREW ............................................................................ 4
G. HEX BOLT .................................................................................. 3
H. FLAT WASHER ............................................................................ 6
I. LOCK WASHER ......................................................................... 3
J. HEX NUT ................................................................................... 3
K. DRILL TEMPLATE AND DRILL BIT ............................................... 1
A
C
D
J
L
O P Q
M
G
B
H
I
E
F
J
K
8
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ADDITIONAL REQUIREMENTS FOR SET UP
PERSON FOR HELP WITH LIFTING
A.
B. PHILLIPS AND FLAT HEAD SCREWDRIVERS
C. ALLEN KEY (4 & 6 MM)
D. DRILL
E. COMBINATION WRENCHES (8,10 & 16 MM)
F. PEN
G. 8 MM DRILL BIT
H. MEASURING TAPE
CLEANING
CLEANING THE CAST-IRON TABLE
The protective coating on the cast-iron table, prevents rust from forming during shipping and storage.
Remove it by rubbing with a rag dipped in kerosene,
mineral spirits or paint thinner. (Dispose of potentially
flammable solventsoaked rags according to manufacturer’s safety recommendations). A putty knife, held flat
to avoid scratching the surface, may also be used to
scrape off the coating followed by clean-up with solvent. To prevent rust, apply a light coating of paste wax
or use regular applications of any after-market surface
protectant or rust inhibitor.
A
D
B
C
F
G
E
H
TIP: WITH A SCREW DRIVER, PUSH A SOLVENT-SATURATED RAG INTO THE
T-SLOTS TO REMOVE THE GREASE.
ASSEMBLY INSTRUCTIONS
ROUTING MAY PRESENT SERIOUS INJURY HAZARDS TO UNTRAINED USERS. BE SURE TO READ, UNDERSTAND AND
FOLLOW ALL INSTRUCTIONS AND SAFETY RULES SUPPLIED WITH YOUR ROUTER.
SUPPORT LEG ASSEMBLY
C
D
1. Screw the lock knob C into the weld-nut nut on the
bracket D as shown.
I
J
K
E
L
K
M
D
2. Attach the leg mounting bracket E to the opposite
end of the leg D as shown using the bolt, washer and lock nut. Note: Alignment pins K should
point in same direction as bolt
9
Page 10
H
G
3. Install the pivot lock knob with the bolt and the
washer as shown. Note: the two lock knobs must
be on the same side as shown in step 5.
G
C
D
5. Insert the leg extension G to the leg D and tighten
the lock knob C. Assemble the other leg following
the same steps.
ATTACHING THE ROUTER TABLE TO THE SAW
4. Insert the end cap into the end of the leg G (ignore
the hole H).
6. Assemble the other leg following the same steps.
TIP: IF YOUR TABLE SAW MEASURES 27’’ SKIP STEP 2 & 3 AND SIMPLY STICK THE DRILL TEMPLATE TO THE VERTICAL EDGE OF YOUR
SAW WITH THE ARROWS POINTING UP.
TIP: IF YOU ARE ATTACHING THE ROUTER TABLE TO THE SAWS MAIN TABLE (TO REPLACE A REMOVED EXTENSION WING) STEPS
2 AND 3 WILL NOT BE NECESSARY. HOLD THE ROUTER TABLE UP AGAINST THE SAW’S MAIN TABLE AND LINE UP THE MOUNTING
HOLES IN SAW WITH THE 3 CORRESPONDING PRE-DRILLED HOLES IN THE ROUTER EXTENSION AND PROCEED TO INSTALLATION
STEP 8 AND 9 - BOLT AND LEVEL THE ROUTER TABLE TO THE MAIN TABLE.
1. Clean the vertical edge of the table as shown.
10
A
2. If your saw measures more than 27”, measure and
mark the midpoint of the saw table as shown, A.
Page 11
TIP: THREE MOUNTING HOLES WILL BE REQUIRED TO SECURE THE ROUTER TABLE TO THE SAW. THE CENTER HOLE AS WELL AS ONE
8
10 9
B
A
C
HOLE AT EACH END OF THE TEMPLATE SHOW WHAT IS CONSIDERED TYPICAL HOLE PLACEMENT.
A
3. Peel the backing from the drilling template, line up
the saw and template center marks and stick the
template to the table with the arrows pointing up
as shown.
NOTE: IF RIBBING OR OBSTRUCTIONS PREVENT DRILLING ANY OF THE HOLES, FOLLOW STEPS 5 & 6. IF NOT, PROCEED TO STEP 7.
4. Reach under the lip of the table to confirm that
there is a flat surface for the nut and washer to
rest on and that there is no cast ribbing in the drilling area, A. If no obstructions are found, drill the
mounting holes starting with an 8mm (or smaller)
pilot hole, B. Use the supplied 11mm bit to drill the
holes to final size.
B
B
5. Set the router table down on the saw with the pre-
drilled mounting holes facing you. Remove the
drilling template from the saw and stick it as shown
to the router table. From the pre-drilled holes in the
router table, select and mark as shown B on the
template the next closest hole to any holes that
could not be drilled because of ribbing.
TIP: FOR CONVENIENCE, IT IS RECOMMENDED TO INSTALL THE LEVELING SCREWS BEFORE INSTALLING THE TABLE.
7. Screw 10 leveling screws on the router table as
shown.
6. With the new hole location(s) marked on the drilling template, transfer the template back to the saw
table and check behind the new hole locations
for ribbing/obstructions. If obstructions are found
again, repeat step 5. If no obstructions are found
drill the mounting holes as described in step 4.
Note: The leveler screws need to be inserted from
the bottom as shown. The two outside holes are for
the leveling screws C and the middle hole is used to
secure a plate, or the lift, to the table
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TIP: STEPS 8 AND 9 REQUIRE THE ASSISTANCE TO HANDLE THE TABLE TOP FOR MOUNTING ON THE TABLE SAW.
B
8. Place the router table against the table saw and
tighten the mounting screws B into the holes you
drilled as shown A.
INSTALLING THE ROUTER FENCE AND SUPPORT LEGS
TIP: YOU HAVE TO START BY THE INSTALLATION GUIDE TWO RAILS TO PLACE THE SUPPORT LEGS.
A
9. Use a straightedge to check the router table for
level with the rest of the table. If needed, loosen
the bolts slightly and make adjustments manually.
In some cases shims between the router table and
the saw may be required to level the tables. Simple shims made from small strips of aluminum foil
can be used.
A
C
B
C
1. Attach the two fence side rails with scale A to their-
mounting brackets B, using 3 hex head bolts with
flat washers and square nuts C, in the assembly order shown in D.
3. Adjust the height of the 3 bolts in the slotted holes in
the rail brackets so that the rails are leveled with the
table as shown.
12
2. Attach the fence mounting brackets to the underside of the table, using 3 bolts C.
K
4. Place the leg bracket against the guide rail as
shown. Note: The two pins K will help you for a
perfect positioning.
Page 13
5. Lock leg adjustment lock knob of the leg et lock
the leg swivel lock knob to stabilize the positioning.
A
B
6. Drill two mounting holes of the leg as shown with a 11
mm bit and tighten the two mounting screws of the
bracket with two 11 mm combination wrenches.
7. Insert an orange plastic spacer A with the short
end down on one short T- bolt B, then insert the
head of the bolt in the front upper slot in the fence
body as shown.
A
B
C
9. Install the orange dust shield A on the two bolts
and secure in place using two flat washers B and 2
lock knobs C as shown.
8. Slide the 2 bolts and spacers to the middle of the
fence body (approx.)
10. Secure the dust shield in place by tightening the
two lock knobs.
13
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B
A
11. Insert a long T-bolt A through all 6 holes in the fence
body B and, from the other side of the fence, loosely attach a flat washer C and lockknob B. Note:
Do not tighten down the lock knobs, leave the
T- head of the bolts protruding from the fence.
C
B
A
12. Slide the slot of one fence face onto the 3 elongat-
ed bolt heads. Tighten the lock knobs on the other
side of the fence.
C
A
B
13. Tighten the 6 lock knobs A on the other side of the
fence.
B
A
15. Insert the square nut in the fence body slot, A. In-
sert the other square nut in the slot on the other
side of the fence, B.
14. Insert a Phillips head screw A through both dust
outlet mounting holes. Loosely thread a square nut
B on both screws as shown C.
A
B
16. Center the dust outlet with the hole in the fence
body A, then tighten the two phillips head screws B.
14
Page 15
A
B
C
C
17. Insert a locking handle A with large flat washer
C in the T-slot at one end of the fence, then from
below, loosely thread a large hex nut B as shown.
Note: Don’t forget the flat washer C.
INSTALLING A ROUTER
SERIOUS PERSONAL INJURY COULD OCCUR IF YOU CONNECT THE MACHINE TO THE POWER SOURCE BEFORE YOU
HAVE COMPLETED THE INSTALLATION AND ASSEMBLY STEPS. DO NOT CONNECT THE MACHINE TO THE POWER SOURCE
UNTIL INSTRUCTED TO DO SO.
18. Slide the hex nut in the fence rail as shown. Repeat
steps 16 and 17 on the other end of the fence,
then fully tighten the locking handle to lock the
fence in position.
1. Make sure the router is off and disconnected from
the power source. and install a 1/2 inch straight
router bit into the routers collet,
3. Scribe around the base of the router, locating
where you will need to position the plastic base
of your router to transfer your mounting hole locations to the plate.
2. Position the router on the underside of the plate
with the router bit inserted through the hole in the
insert ring, this will “centre the router”.
Note: You may need to position the router’s handles
so that they will pass though the hole in the table
top. Make a reference mark on the plate and the
plastic base of your router to help relocate this position later in the installation.
15
Page 16
4. Unscrew the plastic base as shown.
TIP: IF NECESSARY, RE-DRILL MOUNTING HOLES IN THE ROUTER BASE AND USE LONGER STRONGER FASTENERS (WE SUGGEST A
FINE THREADAND NYLOCK NUTS) TO SECURE THE ROUTER TO THE INSERT PLATE.
5. Remove the plastic base from your router.
8. Drill holes as shown.7. Align the router base with the reference mark to
the drawing on your insert plate, and transfer the
router mounting hole locations to the insert plate.
DO NOT MOUNT ROUTER UNLESS YOU ARE SURE IT IS SAFE TO USE. MAKE SURE THE ROUTER WILL NOT COME LOOSE
FROM THE ROUTER PLATE.
LEVELING AND LOCKING THE ROUTER PLATE
A
B
1. Using a straightedge check that the router plate is
level with the main table, A. Adjust the 10 leveling
screws B in the table opening as needed to level
the plate on all four sides.
C
2. With the router plate leveled to the table, lock the
plate in place using the two supplied hex socket
head screws C in the threaded holes on both sides
of the plate.
16
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INSERT RING REMOVAL
INSTALLING THE STARTING PIN
A
B
A
1. Insert the two pins of the wrench in the two holes
on the insert ring then turn clockwise to unlock the
ring, A and lift the insert ring up and out of the table insertion, B.
1. Install the starting pin A into the threaded hole on
the router plate as shown. The starting pin can be
used as needed for freehand or template routing
only.
BASIC ADJUSTMENTS & CONTROLS
ADJUSTING THE FENCE ALONG THE RAILS
B
ADJUSTING THE SLIDING SCALE ON THE RAILS
A
The fence can be slid along the rails A. Loosen locking
handles B, slide fence then lock in position by re-tightening the locking handle. Repeat on the other extremity of the fence.
ADJUSTING THE FENCE FACES
A
B
C
D
The scale on the rails can be adjusted along the rails
C. Loosen lock knob D, slide the fence up to where you
need it to be, then lock in position by re-tightening the
lock knob. Repeat for the sliding scale on the other rail.
C
Depending on the size of the workpiece and the bit being used, the white fence faces can be adjusted along the
fence body A. Loosen the 3 lock knobs, B on one side of the fence and then slide the fence face up to where you
need it to be. Then lock in position by re-tightening the lock knobs. Repeat with the second fence face on the other
side of the fence body. Note: Do not slide the fence faces too far and off the first T-bolt head, as shown in C.
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OPERATING INSTRUCTIONS
USING THE SPACER BARS FOR JOINTING
A
B
1. Jointing the edge of a board involves using a
straight cutting router bit to remove material from
the edge face of a board. The result is a perfectly
flat and square edge.
1,5 mm
0,7 mm
Note: Both spacer bars should be used in the top
and bottom t-slots in the fence body as shown. Take
care to install them in matching offset positions;
both at 0.7mm or both at 1.5mm.
3. Each spacer bar has two sides which allow you
to offset the outfeed fence by either 0.7 mm or 1.5
mm staggering.
JOINTING
2. Two spacer bars A are supplied with the fence
system to facilitate jointing, by offsetting the outfeed fence B to the infeed fence and providing a
straight path for the workpiece to follow as it is machined, fully supported at its start and end.
Note: When not in use, the spacer bars can be
stored on the t-track on the back of the fence body
as shown.
A
1. Loosen but do not remove the outfeed fence face and install the spacer bars between the outfeed fence and
the fence body. With the router unplugged and the safety switch in the off position, follow the instructions supplied with your router and install a straight cutting bit in the router.
2. Adjust the height of the lift to raise or lower the bit as need until the bit is slightly higher than the workpiece.
3. Loosen the fence locking knobs, and using a straightedge, position the outfeed fence aligned flush with the
bit, A. Rotate the bit by hand to validate alignment with the “highest” point of the cutting edge on the bit, then
tighten the knobs to lock the fence in position.
4. Adjust the height of the safety shield to make sure it clears the bit and the workpiece slightly.
5. If needed, loosen the lock knobs on the back of the fence and adjust the faces to adjust the gap between the
fence faces and the bit leaving a clearance of roughly 1/4” between the bit and each fence face, B. Plug in
and turn on the router and make a test cut on a waste sample before jointing your “good” workpieces.
B
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Page 19
GROOVE CUTTING
Note: Beading is commonly defined as cutting a
groove or bead in the face of a board.
1. If installed, remove the spacer bars on the outfeed
fence.
2. With the router unplugged and the safety switch in the
off position, follow the instructions supplied with your
router and install a cutting bit in the router.
3. Raise or lower the router bit to the desired height.
4. Loosen the knobs and adjust the opening between
the fences to allow the bit to clear the edge of bothfences.
5. Adjust the main fence until the center of the bit has reached the desired distance, A.
6. Align the infeed and outfeed fences parallel to eachother using a machinist square or a straightedge..
PROFILE CUTTING
Profile cutting is usually performed using a bit with a guide
bearing. The guide bearing controls the depth of cut into
the edge face of a board. A good example would be a
chamfer bit A. The bearing rides along the uncut edge of
the board while the cutter removes the wood.
1. Follow steps 1 and 2 from previous section “ Groove
Cutting ”.
2. Adjust the fence back and away from the bit only
enough to allow the guide bearing to control the
depth of cut or use the starting pin as a support for the
work piece, as shown B.
3. Adjust the fence as close as possible to the bearing.
The fence will serve as a backup support, reducing
the chance of an accident.
B
A
A
NOTES
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Page 20
RECOMMENDED OPTIONAL ACCESSORIES
Here is a sampling of optional accessories available from your local General International dealer to help you
increase convenience, productivity, accuracy and safety when using your machine.
For more information about our products, please visit our website at www.general.ca
DUST COLLECTOR
We offer a wide selection of top quality dust
collectors to suit all your
shop needs. Dust collectors contribute to a
cleaner more healthful
workshop environment.
Item #40-120
STOCK PUSHER
For Excalibur router
fence #40-065 (bench
top model) & #40-080
(floor model).
Item #40-175
HORIZONTAL
FEATHERBOARD
For Excalibur router
table.
Item #40-125
ROUTER LIFT
Heavy-duty massive
router lift with 9 ¼" x 11
¾" aluminum top plate.
Stable 4 post/lift screw
design & chain drive
lifting system control
ling all 4 corners simultaneously.
-
Item #40-160
VERTICAL
FEATHERBOARD
For Excalibur router
table.
Item #40-115
9 1/4” X 11 3/4” ALUMINUM INSERT PLATE
For Excalibur router
tables.
Item #40-076
4 PC INSERT RING SET
1⁄4”, 1⁄2”, 2 1⁄2” &
1 3/8” (30 MM FOR
#40-099)
Item #40-074
4 PC ZERO CLEARANCE INSERT RING
SET
For Excalibur 9 1/4” x
11 3/4” router plates
Item #40-090
FLIP STOP
For Excalibur router fence
#40-065 (bench top model) & #40-080 (floor model).
Item #40-099
9 PCS BRASS PRECISION
TEMPLATE GUIDE SET
Designed for most routers.
Included accessories:
• 1 locking nut
• 8 guides: 1 1 19⁄64”,
5/8”, 27⁄32”, 17⁄32”, 17⁄64”,
9⁄32”,11⁄32”, 13⁄32”.
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Page 21
PARTS LIST
8
8
5 5
6
6
5
5
15
15
14
14
13
13
13
13
12
12
1
1
3
3
2
4
2
2
2
7
7
9
9
10
11
10
11
4
(Left Side)
(Right Side)
Support legs (#40-068)
IMPORTANT: When ordering replacement parts, always give the model number, serial number of the
machine and part number. Also a brief description of each item and quantity desired.
PART # REFERENCE # DESCRIPTION SPECIFICATION QTY
1 27160070 LEG BRACKET 2
2 917M04010 LOCK PIN M4 X 10 MM 4
3 904M08050 HEX BOLT M8 X 50 MM 2
4 27160071 LEG 30 X 30 X 500 MM 2
5 9145161802 FLAT WASHER M8 4
6 912M08000 NYLOCK NUT M8 2
7 909M08050 CARRIAGE BOLT M8 X 50 MM 2
8 939M08000 LOCK KNOB M8 2
9 940M08020 LOCK KNOB M8 X 20 MM 2
10 27160072 LEG 25 X 25 X 500 MM 2
11 27160073 TUBE PLUG 2
12 904M06020 HEX BOLT M6 X 20 MM 4
13 914M061301 FLAT WASHER M6 8
14 915M06000 LOCK WASHER M6 4
15 910M06000 HEX NUT M6 4
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Page 22
PARTS LIST
AST-IRON TABLE 27”X 16”
Cast-iron table (#40-070)
1
3
2
4
5
6
7
12
11
8
10 9
13
10
IMPORTANT: When ordering replacement parts, always give the model number, serial number of the
machine and part number. Also a brief description of each item and quantity desired.
PART # REFERENCE # DESCRIPTION SPECIFICATION QTY
40070-01 2716U014 CAST-IRON TABLE 16” X 27” 1
40075-02 903M06030 FLAT HEAD CAP SCREW M6 X 30 MM 2
40075-03 910M06000 HEX NUT M6 10
40075-04 905M06020 FLAT HEAD SCREW M6 X 20 MM 10
40075-05 914M061602 FLAT WASHER M6 6
40075-06 915M06000 LOCK WASHER M6 6
40075-07 901M06016 CAP SCREW M6 X 16 MM 6
40070-08 T2716020 DRILLING TEMPLATE 1
40070-09 904M10035 HEX BOLT M10 X 35 MM 3
40070-10 9014382503 FLAT WASHER M10 6
40070-11 915M10000 LOCK WASHER M10 3
40070-12 910M10008 HEX NUT M10 3
40070-13 953M11000A DRILL BIT Ø11 1
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Page 23
PARTS LIST
2
34
4
7
4
16
33
33
32
16
6
17
3
5
35
35
1 1
17
6
6
17
10
4
7
8
15
9
13
12
18
16
17
19
20
35
35
1
14
5
2
15
13
14
9
16
17
19
18
12
8
Router fence(#40-065)
IMPORTANT: When ordering replacement parts, always give the model number, serial number of the
machine and part number. Also a brief description of each item and quantity desired.
PART # REFERENCE # DESCRIPTION SPECIFICATION QTY
4006501 27160032A FENCE BODY 780 MM 1
40080-02 60100001A LOCK HANDLE 5/16” 2
40065-03 T2716002 SCALE 780 MM 1
40080-04 32240052A T-BOLT 6
40080-05 9145162302 FLAT WASHER M8 2
40080-06 939M08000B LOCK KNOB M8 8
40080-07 32240034 LOCK NUT M8 2
40080-08 27160035A H SPACER 388 MM 2
40065-09 27160036 FENCE FACES 388 MM 2
40080-10 32240037 SAFETY GUARD 1
40065-11 32240038 FENCE SPACER 2
40065-12 27160039 SIDE BRACKET BASE 240 MM 2
40065-13 27160040 SIDE BRACKET 280 MM 2
40065-14 27160041 RULE PLATE 205 MM 2
40065-15 T2716003 SCALE 205 MM 2
40080-16 935014000 SQUARE NUT 1/4" 8
40080-17 9140141602 FLAT WASHER M6 14
40080-18 901M06012 CAP SCREW M6 X 12 MM 8
40080-19 904014058 HEX BOLT 1/4" X 5/8” 6
40080-20 940M06012 LOCK KNOB M6 X 12 MM 2
40080-32 32240013A DUST PORT 1
40080-33 906014034 PHILLIPS HEAD SCREW 1/4" X 3/4" 2
40080-34 32240033A T-BOLT 2
40080-35 32240060 FLUOROWAY PAD 1
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8360 CHAMP-D’EAU, MONTREAL (QUEBEC) CANADA H1P 1Y3
TEL.: (514) 326-1161
FAX: (514) 326-5565 - PARTS & SERVICE / (514) 326-5555 - ORDER DESK
ORDERDESK@GENERAL.CA
WWW.GENERAL.CA
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