General Tools 870 User Manual v.2 [en, es, fr]

No. 870

USER’S MANUAL

(U.S. PATENTS APPLIED FOR)

PLEASE READ THESE INSTRUCTIONS FULLY BEFORE USING THIS JIG

For more information and video instructions visit

www.generaltools.com/mortise-tenon

CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Anatomy of the Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Anatomy of the “Quick Change” Router Base Bushing Assembly . . . . . . 4

Preparing the Router . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 6

Mounting the Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 12

Capacity and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 3

What’s in the Jig Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Safety Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installing the “Quick Change” Guide Sleeve . . . . . . . . . . . . 5

Centering the Base Plate and the

“Quick Change Guide System” . . . . . . . . . . . . . . . . . . . . . . . 5

Setting the Cutting Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1. Marking Joint Centers and Location . . . . . . . . . . . . . . . . 7

2. Centering the Stock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3. Positioning the Stock using the Positioning Bars . . . . . . 8

4. Setting the Joint Length . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Length of Mortise & Tenon Chart . . . . . . . . . . . . . . . . . . . 9

5. Setting the Depth of the Router Bit . . . . . . . . . . . . . . . . . 10

6. Routing the Tenon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

7. Routing the Mortise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Routing Other Size Mortise and Tenons . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Customer Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Spanish Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 – 28

French Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 – 42

Sample Mortise & Tenon Joints

INTRODUCTION

Thank you for purchasing General Tools & Instruments’ E-Z™Pro Combination Mortise & Tenon Jig (M&T Jig)— the woodworking industry’s first integrated jig capable of making matching mortise

and tenon joints of professional quality “right out of the box.” The jig makes creating Mortise & Tenon joints—the sturdiest of all wood joints—for furniture, cabinets and frames – an easy, simple and fast process.

The Mortise & Tenon Kit comes with a fully assembled jig and includes a 1/4" straight upcut router bit and 1/4" tenon Guide Bushing. Also included are the guide bushings for cutting 3/8" and 1/2" joints. You will need to supply your own 3/8" and 1/2" upcut router bits.

The M&T Jig has a one-piece heat treated, high grade aluminum body with adjusting bolts, upcut fasteners and bit made of steel to SAE specifications. The unit’s adjustable Positioning Bars and Router Bushing assembly are also made of solid steel.

Capacity and Specifications:

Accommodates stock from 1/2" to 1½" thick and any length Mortise and Tenon thickness: 1/4", 3/8" and 1/2" Minimum length M&T Joint: 1" +/- 1/8" (depending on bit used) Maximum Length M&T Joint: 3" +/- 1/8" (depending on bit used)

What’s in the M&T Jig Kit

1. The fully assembled jig

2. “Quick Change” Router Base Bushing assembly consists of:

• One “Quick Change” 1-3/16" Guide Sleeve and Locking Nut

• One 1/4" Guide Bushing (1-1/4" OD)

• One 1/4" shank Centering Pin

• One flat Spanner Wrench for guide sleeve

Locking Nut adjustment

• One 3/8" Guide Bushing

• One 1/2" Guide Bushing

3. One 1/4" straight Upcut Spiral Carbide

Router Bit

4. Alignment Tool

It is highly recommended that you familiarize yourself with the nomenclature in Fig. 1 and Fig. 2 on p. 4 before proceeding.

ANATOMY OF THE E-Z PRO MORTISE & TENON JIG

Fig. 1

IG ASSEMBLY IN PROFILE

JIG ASSEMBLY

MORTISE SECTION

1 - Jig Assembly

1A - Centering Marks 1B - Centering Notches 1C - Template Positioning Indicators

2 - Mortise Section Templates 2B - Template Position Rule 2C - Template Lock Screws

3 - Tenon Section Templates

4 - Centering Wall, [4A] Markings,

[4B] Serrations, [4C] Thumb Screws 5 - Face Clamp Thumb Screws 6 - Positioning Bars

6A - Positioning Bars deployed 6B - Positioning Bars retracted for storage

and cutting

7 - Face Clamps 8 - Mounting Flange

ANATOMY OF THE “QUICK CHANGE” ROUTER BASE BUSHING ASSEMBLY:

Fig. 2

TENON SECTION

R1 - Lock Nut R2 - 1-3/16" Router Base Guide Sleeve R3 - 1-1/8" O.D. Router Guide Bushing for

the 1/4" Tenon (as well as for all mortises)

R4 - Centering Pin 4

R5 - Flat Spanner Wrench R6 - 7/8" O.D. Router Guide Bushing

for the 3/8" Tenon

R7 - 5/8" O.D. Router Guide Bushing

for the 1/2" Tenon

R8 - 1/4" Upcut Routing Bit

PREPARING THE ROUTER

SAFETY OVERVIEW

1. KNOW YOUR ROUTER. Read the owner’s manual that came with your router before you use it.

Understand the machine’s applications and limitations, as well as the specific potential hazards inherent in its use. Before using the router, check that none of its moving parts is broken, loose or misaligned.

NOTE: General Tools & Instruments is not responsible for router misuse or the disregard of standard safety precautions associated with using a router.

Installing the “Quick Change” Guide Sleeve

The E•Z Pro M&T Jig is designed to be used with plunge routers with base plates with a 1-3/16" center hole and a 1-3/8" counter-bore. This is to accommodate the included “Quick Change” guide sleeve and bushing. If your router base cannot mate with the guide sleeve, you can purchase a “Universal Router Plate” with the appropriate center hole dimensions to attach to or replace your current router base.

Fig. 3

With the proper base plate installed:

1. Insert the Guide Sleeve [R-2] into the base

plate.

2. Secure the Lock Nut [R-1] firmly with

the flat Spanner Wrench Provided.

3. Screw the 1-1/8" Router Guide Bushing [R-3]

into the center of the Guide Sleeve and hand tighten. (Fig. 3)

Centering the Base Plate and the “Quick Change Guide System”

1. With your router upside down, plunge the base plate and lock it.

2. Insert the 1/4" Centering Pin [R-4] in the router chuck and tighten it securely.

3. Loosen the mounting screws of the base plate just enough to allow a little movement. (Fig. 4)

4. Carefully release the plunge lock and gently guide the plunge base to extension on the cone section of the Centering Pin; (Fig. 5) this allows the loosened base plate to move on its screw holes to a perfect centering position.

BASE PLATE WITH 1-3/16" CENTER HOLE AND A 1-3/8" COUNTER

Fig. 4

Fig. 5

5. Tighten the base plate screws securely.

Fig. 6

• Once you have completed this centering

operation, remove the Centering Pin from the router and replace it with the router bit (Fig. 6).

Setting the Cutting Depth

• Set the depth of your plunge router for the desired depth of your mortise and tenon.

• When the stock is correctly mounted in the jig, its top edge will be 1/2" below the top (working)

surface of the jig (Fig.7a).

• Accordingly, add 1/2" to the desired depth of the mortise and tenon when setting the “plunge”

depth of the router (Fig.7b).

FROM THE FACE OF THE BASE PLATE TO THE

Fig. 7A

POSITIONING ARM SHOWN DEPLOYED

TIP OF THE CUTTING BIT EQUALS THE DEPTH OF THE JOINT PLUS 1/2"

Fig. 7B

ROUTER IN THE FULLY PLUNGED POSITION

MOUNTING THE JIG

The M&T Jig can be mounted directly on the edge of a bench using the integral mounting flange [9] (Fig. 8A), or secured to a mounting board which can then be clamped to a bench (Fig. 8B).

Fig. 8A

WORK BENCH

Fig. 8B

OPERATING INSTRUCTIONS:

1. Marking Joint Centers and Location

Mark the stock with center marks at the positions for the length of the tenon and the mortise. These marks will be needed to center the tenon and the longitudinal position of the mortise on the stock. If you have correctly set the Centering Wall for the thickness of the stock, the stock will automatically be centered** for stock thickness when clamped in the jig.

**Tip: if there is a variation in the thickness of the stock used, you may adjust for this by use of appropriate shims or by readjusting the Centering Bar.

CENTER POSITION OF THE MORTISE

Fig. 9

MORTISE SECTION

2. Centering the Stock

• Centering the stock in the jig is

accomplished by adjusting the Centering Wall [4] (Fig.10) for the thickness of the stock.

• The jig will handle stock with

a thickness between 1/2" and 1-1/2".

• Using the lumber industry’s

nomenclature, these two thicknesses, designated as, “2 quarter” (1/2") and “6 quarter” (1-1/2"), indicating the number of 1/4" increments of thickness.

CENTER POSITION OF THE TENON

TENON SECTION

INNER WALL

Fig. 10

• The markings are on the tenon end of the Centering Wall [4A]. Use these “quarter” units to adjust

for the thickness of your stock in “quarters”. For example: if you are using 3/4" (three quarter) stock, align the number “3” with the inner wall of the jig (Fig. 11), and the stock will be at its nominal center in the templates.

• When adjusting the Centering Wall, and to maintain parallel

alignment, always make sure the bar is correctly seated on the jig body with its serrated matching surface [4B] (Fig.11) in the jig.

Tips: to assure an accurate joint alignment, particularly if you are making a Face Frame or similar matching surface type joint, always keep the

Fig. 11

matching faces to the same side of the jig.

3. Positioning the Stock Using the Positioning Bars

When in the deployed position (Fig 12), the Positioning Bars serve two basic purposes:

1. Then position the stock at the correct depth below the underside of the template for routing

2. Then align the stock so it is squared, at 90 degrees, to the jig longitudinally

Fig. 12

Fig. 13

The Positioning Bars [Fig 12 and 13] are stored along the inside edge of the underside of the jig’s top when routing.

1. To extend the bars, use the Positioning Bar handles [6A], located under the outside top edge.

2. After you fully deploy the Positioning Bars, you’re

Fig. 14

ready to place the stock in the jig. Insert the stock gently up against the deployed Positioning Bars (Fig. 14) and tighten the Thumb Screws [5] just enough so the stock is held loosely by the Face Clamps [7].

3. Center the stock longitudinally using the jig’s Centering Marks [1A] on the jig (Fig. 15). Before tightening the Face Clamps, be sure the stock is flat and square against the Positioning Bars (but not too tight), and correctly centered.

4. Tighten the Face Clamps, enough to secure the stock from moving.

5. Using their handles, return the Positioning Bars to their storage position (Fig15).

Fig. 15

IN USE POSITION

STORED FOR ROUTING

4. Setting the Joint Length

The M&T jig has two working sections, the mortise section and the tenon section (Fig. 16).

Fig. 16

MORTISE SECTION

TENON SECTION

Both the mortise section and the tenon section of the jig are equipped with left and right Adjustable Sliding Templates [#2 & #3] (Fig.16) that are used to set the length of the joint. Visible are the numbers 1, 2 and 3 along with associated ruled markings on each template’s edge [2B].

To adjust the templates for the desired joint length, loosen the Lock Screws [2C] on the right and left templates on both sides of each joint and slide them to the desired opening indication (as referred to in the chart based on your bit diameter). All four (4) sliding templates should be at the same setting. Re-tighten the screws.

The numbers 1, 2 and 3 on the adjustable sliding templates directly correlate to the 3/8" bit reference in the chart that follows. For example, if you set the template positions to #2 you will

create a 2" long joint. Set the templates to #1 and you’ll create a 1" long joint. If you’re using a 1/4" or 1/2" diameter bit, refer to the settings in the chart for the actual size of the

joint at these same markings. The chart compensates for the difference in bushing size and bit diameter from a 3/8" bit. For example, using a 1/4" bit with the templates positioned at #2 would produce a joint that is 1-7/8" long. Similarly, using a 1/2" bit with the templates at the #2 position would produce a 2-1/8" long joint.

Notes:

1. The chart below indicates the exact length of each joint for each marking on the template and for each bit size.

2. When you set the size of the opening, make sure that ALL of the templates indicate the same measurement; this assures that both the mortise and the tenon will be the same size. (Fig. 16)

Length of Mortise and Tenon Chart

Joint

Thickness

1/4" 2-7/8 2-5/8 2-3/8 2-1/8 1-7/8 1-5/8 1-3/8 1-1/8 7/8 3/8" 3 2-3/4 2-1/2 2-1/4 2 1-3/4 1-1/2 1-1/4 1 1/2" 3-1/8 2-7/8 2-5/8 2-3/8 2-1/8 1-7/8 1-5/8 1-3/8 1-1/8

3 2-3/4 2-1/2 2-1/4 2 1-3/4 1-1/2 1-1/4 1

Template Position Markings

Both the tenon and mortise sections have has two Centering Marks [1A] (Fig. 17) which indicate the longitudinal center of the templates. There are also Centering Notches [1B] on the deployed

Positioning Bars [6]; they indicate the center of the template’s width.

TIP: It may be advisable to size the mortise slightly longer than the tenon (or the tenon slightly

shorter than the mortise) for ease of insertion, adjustment and gluing.

Fig. 17

Fig. 18

The Alignment Tool (Fig. 18) is used to help center the uncut wood in the jig. Before securing the wood in the jig, place the Alignment Tool as shown and align it with the Centering Marks [1A] on the jig (Fig19).

The Alignment Tool can also be used to more accurately align the Adjustable Sliding Templates

Fig. 19

[#2 & #3] to the Template Positioning Indicators [1C].

5. Set the Depth of the Router Bit

(See also “Setting the Cutting Depth” on page 6)

To set the “plunge” depth of the router (Fig. 20) and subsequently the cutting depth of the bit, remember to add 1/2" to the desired depth of the joint. Therefore, if you’re setting the joint depth to be 1" then your measurement would be a total of 1-1/2" from the face of the base plate to the tip of the bit.

FROM THE FACE OF THE BASE PLATE TO THE TIP OF THE CUTTING BIT EQUALS THE DEPTH OF THE JOINT PLUS 1/2"

Fig. 20

6. Routing the Tenon

When routing the tenon, make sure the Guide Bushing [R-3] only rides against the outer edges of the tenon template [3] (Fig. 21) at all times.

1. Start the cut by putting the guide bushing into the end of the template.

2. With the Guide Bushing in the end of the template and the router base squarely on the jig surface, turn the router on.

3. Plunge the router to a workable depth and guide the router bit clockwise through the cutting process making sure to keep the Guide Bushing tight to the outer edge at all times.

1/4" UP CUT BIT SHOWN

Fig. 21

R-3 GUIDE BUSHING

NOTE: You can make successive plunges to any depth while moving the Guide Bushing clockwise around the tenon template always riding against the edge to make the cleanest joint possible. We recommend making successive shallow plunges and cutting sweeps to avoid over stressing the cutting bit. (Fig. 21 & 22)

Caution: before retracting the router bit from the cut, be sure to turn the router off.

Tip: depending on the actual thickness of your stock, you may at times get a “fence” or “flash” around the edge of your tenon (Fig 23). Be sure to cut, file or sand it off cleanly to ensure a tight fit.

Fig. 22

Fig. 23

Fig. 24

7. Routing the Mortise

Tip: when routing the mortise, it is advisable to increase the depth of cut slightly more than that of

the tenon to allow space for glue to be put on the tenon before inserting it into the mortise.

The Guide Bushing [R-3] fits the Mortise Template [2] (Fig. 24) exactly to prevent it from wandering out of line. It will be used for all mortises regardless of size.

Fig. 25

1. Before turning on the router, place the Guide Bushing in the end of the mortise template and slide it through the template to be sure it moves freely. (Fig. 25)

2. With the Guide Bushing in the end of the template and the router base squarely on the jig surface, turn the router on.

3. Plunge the router and guide the router bit through the cutting process.

NOTE: We recommend cutting the mortise in successive overlapping plunges to depth and

then repeatedly move the bit back and forth to clean up the mortise slot.

ROUTING OTHER SIZE MORTISE AND TENONS

The E•Z Pro Mortise and Router Guide Bushing Tenon Jig Kit includes the guide sleeve with

Locking Nut [R2, R1], a 1-1/8" Router Guide Bushing for 1/4" joints [R3], a 1/4" Upcut Spiral Router Bit and a Centering Pin [R4]. These parts will permit you to make 1/4" mortises and tenons

suitable for 3/4" thick board (Fig 26). The kit also includes the Guide Bushing you will need to make mortises and tenons of 1/2" [R7] or 3/8" [R6] (Page 4), however, you will need to make a separate purchase of the corresponding Upcut Spiral Bits. Please see sizing chart on Page 10.

• To make a 3/8" tenon, you’ll need a 3/8" Upcut Spiral Bit and the 7/8" Guide Bushing [R6].

• To make the matching 3/8" mortise, change to the 1-1/8" Guide Sleeve [R-3]. (Fig. 27)

• To make a 1/2" tenon, you’ll need a 1/2" Upcut Spiral Bit and the 5/8" Guide Bushing [R7].

• To make the matching 1/2" mortise, change to the 1-1/8" Guide Sleeve [R-3]. (Fig. 28)

NOTE: Guide Bushings can be changed without removing router bit.

Fig. 26

1/4" JOINT (shown on 1" stock)

Fig. 27

Fig. 28

3/8" JOINT (shown on 1-1/4" stock)

1/2" JOINT (shown on 2" stock)

MORTISE

TENON

MORTISE

TENON

CUSTOMER SUPPORT

Please visit our website at www.generaltools.com/woodworking to obtain additional woodworking information, instructional videos and product manual.

http://www.generaltools.com/mortise-tenon

WARRANTY INFORMATION

The No. 870 Mortise & Tenon Jig Kit from General Tools & Instruments is warranted to the original purchaser to be free from defects in material and workmanship for a period of one year. Subject to certain restrictions, General will repair or replace this product, if, after examination, it is determined by General to be defective in material or workmanship.

+ 32 hidden pages

General Tools 870 User Manual v.2 [en, es, fr]

Specifications and Main Features

Frequently Asked Questions

User Manual