Kreg PRS3038 User Manual [en, fr, es]
Precision Router-Table
Insert Plate
INSTALLATION INSTRUCTIONS
Item # PRS3034
[Fits Triton TRA001 and MOF001, all Porter-Cable 7500 series*]
Item # PRS3036
[Fits Bosch 1617, Porter-Cable 690 and 890 series]
Item # PRS3038
[Not drilled]
*Lock-down screw holes and countersinks must be
enlarged for Porter-Cable 7500-series routers.
See the section Before you start in these instructions.
R
Tools Required:
• Phillips Screwdriver
• Masking Tape
• Double-faced Tape
• Drill press
• Drill Bits, Countersink Bit
• Router, top-bearing pattern bit
www.kregtool.com • 800.447.8638
Parts:
• Insert Plate
• (3) Reducing Rings: 1", 13⁄16" (guide bushing), 2⅝"
• Ring Wrench
• (4) ¼-20 x 1¾" fl athead machine screws (lock-down screws)
• ¼-20 x ¾" set screw
• Brass starting pin
• ⅛" hex wrench
• Router-base mounting screws (pre-drilled insert plates only)
WARNING: This product contains one or more chemicals known
to the State of California to cause cancer and birth defects or
other reproductive harm. Wash hands after handling.
NK8090
Version 1 - 4/2013
1.
Precision Insert Plate Installation
Before you start...
These instructions show you how to mount your router on the Kreg Precision Router-Table Insert Plate and
install the insert plate in a shop-built router table. There are two installation methods:
• Create an opening with a rabbeted edge that accepts the insert plate.
• Create a straight-sided opening and install Kreg Precision Router Table Insert Plate Levelers
(item# PRS3040, sold separately).
The section Drill the Insert Plate applies to the undrilled PRS3038 insert plate. The PRS3034 and PRS3036
insert plates are pre-drilled to accept most Triton, Bosch, and Porter-Cable routers. For these plates, simply
fasten your router base to the insert plate using the screws provided with the plate. The PRS3034 insert plate
is pre-drilled for the ¼-20 fl athead machine screws used to mount Triton routers. Porter-Cable 7500-series
routers have the same hole pattern, but use 5/16-18 machine screws. To use a PRS3034 insert plate with
Porter-Cable 7500-series routers, enlarge the router-mounting holes and countersinks to accommodate the
larger machine screws.
Drill the Insert Plate. (PRS3038 only)
A
Double-faced tape
B
Router sub-base
1. Place the insert plate on your workbench with the target
pattern facing up. Remove the sub-base from your router
and select a drill bit that fi ts the mounting holes. If your router
is equipped with a built-in lift system, also select a bit that
fi ts the lift-access hole. Apply several small pieces of doublefaced tape to the sub-base. Center the sub-base on the
insert-plate, using the target pattern as a guide [Drawing A].
Keep in mind where you want the router controls positioned.
Make sure that none of the holes you are about to drill align
with the threaded hole for the starting pin. Press the subbase fi rmly onto the insert plate.
2. Place a scrapwood backer board under the insert plate
and securely clamp the insert plate and backer to your drillpress table. Using the holes in the sub-base as guides,
drill holes in the insert plate [Drawing B]. With the holes
drilled, remove the sub-base from the insert plate. Flip the
insert plate over and countersink the mounting holes so the
mounting-screw heads sit slightly below the plate surface
when tightened. Store the router sub-base in a convenient
place. You will need it when you remove your router from the
router table for hand-held routing.
C
3
⁄8"
Precision Insert Plate Installation
3
1
⁄
4
"
3
1
⁄
4
"
Router table top
2.
Form the insert-plate opening in your router table top
Rabbeted opening method
1. Position the insert plate on your router table top, squaring the
plate with the table. Trace around the plate with a pencil. Remove
the plate. To form areas to anchor the four ¼-20 x 1 ¾" fl athead
machine screws (lock-down screws) that secure the insert plate to
the router table top, draw 45° lines across each corner of the outline
to form triangles with 1 ¾"-long legs [Drawing C]. Draw lines ⅜"
inside and parallel to the traced insert-plate outline.
D
E
Masking
tape shim
Drill 1½" hole
⅜" deep
Routing guide
Double-faced tape
Drill bit
touches guides
2.
To provide clearance for installing and removing the insert plate,
adhere strips of masking tape to all four edges of the plate. Then
apply small pieces of double-faced tape to one face. (Use just
enough tape to keep the plate in place. Too much tape will make
the plate hard to remove later.) Reposition the insert plate on your
router table top and fi rmly press it into place.
3.
Cut four ¾ x 3½ x 15½" scrapwood routing guides. Apply double-
faced tape and adhere the routing guides to the router table top
with the edges against the masking tape strips on the insert plate
edges [Drawing D]. Remove the plate. Chuck a 1½" Forstner bit
into your drill press. Drilling test holes in the area of the router-table
top you’ll remove for the insert plate, set the drilling depth to ⅜".
With the edge of the bit just touching the inside faces of the routing
guides, drill a ⅜"-deep hole into the router-table top at each corner
[Drawing E].
4. Drill a blade-start hole inside the pencil lines. With the outside
edge of your jigsaw base riding on the routing guides and the inside
edge supported by a ¾"-thick scrapwood block, cut just inside the
lines, leaving the ⅜"-wide area inside the insert-plate outline as well
as the triangular areas at each corner.
3.
Precision Insert Plate Installation
F
Radius corner formed by
Forstner bit
Routing Guides
5. Chuck a top-bearing pattern bit with a ¾" cutting length into your
router. Adjust the cutting depth to the thickness of the insert plate
plus the routing guide. Make test cuts in scrap stock to ensure that
the cut depth exactly matches the thickness of the insert plate. Rout
the perimeter rabbet and the corner triangles in several passes until
the pattern-bit guide bearing runs smoothly against the edges of
the routing guides [Drawing F]. Be sure to stop routing along each
side where the ¾"-radius corners formed by the drilled holes meet
the routing guides. Carefully remove one routing guide and test-fi t
the insert plate in the opening. If the rabbet is too shallow, replace
the guide, adjust the routing depth, and re-rout the rabbet. A toodeep rabbet can be shimmed with tape. When satisfi ed with the fi t,
remove the routing guides.
6.
With the insert plate in place, use the countersunk corner holes
as guides to drill ¼" holes through the triangular corner areas in
the table top. Secure the plate with the lock-down screws and your
own washers and hex nuts or wing nuts. For greater convenience,
remove the insert plate, enlarge the holes in the table top, and
install T-nuts.
Precision Insert Plate Installation
4.
Kreg Precision Router Table Insert Plate Levelers method
Note: This method requires the purchase of Kreg Precision Router Table Plate Levelers (Item # PRS3040) from
your Kreg dealer. These levelers feature eight leveling screws that work with four lock-down screws to keep the
insert plate fl ush with the router-table surface.
G
Masking
tape shim
H
Routing guide
Double-faced tape
Drill bit
touches guides
1. To provide clearance for installing and removing the insert plate,
adhere strips of masking tape to all four edges of the plate. Then
apply small pieces of double-faced tape to one face. (Use just
enough tape to keep the plate in place. Too much tape will make
the plate hard to remove later.) Position the insert plate on your
router table top, squaring the plate with the table, and fi rmly press it
into place.
2. Cut four ¾ x 3½ x 15½" scrapwood routing guides. Apply
double-faced tape and adhere the routing guides to the router table
top with the edges against the masking tape strips on the insert
plate edges [Drawing G]. Remove the plate. Chuck a 1½" Forstner
bit into your drill press. With the edge of the bit just touching the
inside faces of the routing guides, drill a hole all the way through
the router-table top at each corner [Drawing H].
3. Rough-cut the opening with a jigsaw, staying ⅛" inside the
routing guides and cutting from corner hole to corner hole. For best
results, support the inside edge of the jigsaw base with a ¾"-thick
scrapwood block.
Drill 1½" hole all
the way through
I
Routing guides
Router table top
Radius corner formed
by Forstner bit
4. Chuck a top-bearing pattern bit into your router. With the guide
bearing running against the routing guides, rout the edges of the
opening [Drawing I]. Stop routing where the ¾"-radius corners
formed by the drilled holes meet the routing guides. If the thickness
of your router-table top is greater than the reach of your pattern bit,
switch to a bottom-bearing fl ush-trim bit, fl ip over the router-table
top, and fi nish the cut with the fl ush-trim bit guide bearing running
against the surface routed with the pattern bit. Remove the routing
guides.
Pattern bit
5.
J
Precision Insert Plate Installation
Install the Insert Plate
Rabbeted opening method
1. Attach the router base to the insert plate, using the screws that
were used to attach the sub-base to the router base. Depending
on the thickness of your router sub-base, it may be necessary to
purchase longer screws. Make certain that the screws are long
enough to fully thread into the router base. For fi xed-base routers,
install the motor unit in the router base and install the insert plate,
with router attached, in the table.
2. Drop the four lock-down screws through the countersunk holes in
the insert plate and thread them into the hex nut, wing nut or T-nut.
Tighten the screws.
Kreg Precision Router Table Insert Plate Levelers method
1. With the table top upside down, position an insert-plate leveler
in one corner of the table-top opening, mating the curve on the
raised portion of the leveler with the radius corner of the opening.
Firmly holding the leveler in place and using the three mounting
holes in the leveler fl ange as guides, drill pilot holes into the table
top. Fasten the leveler to the tabletop with three 1¼" coarse-thread
screws provided [Drawing J]. Repeat with the remaining levelers.
Router table top
Mating Curves
Note: The 1¼" coarse-thread screws provided with the levelers
are for use on router table tops with a minimum thickness of 1". For
thinner tops, use your own shorter screws.
2. Using the ⅛" hex wrench, drive a ¼-20 x 1½" socket-head set
screw into each outside hole in each leveler, threading them in
from the bottom until the tips are ⅜" below the table surface.
3. For Kreg PRS3034 and PRS3036 Precision Insert Plates, fasten
the router base to the insert plate using the screws supplied with
the plate. For the Kreg PRS3038 Precision Insert Plate, use the
screws that were used to attach the sub-base to the router base
to attach the router base to the insert plate. Make certain that the
screws are long enough to fully thread into the router base. It may
be necessary to purchase longer screws. For fi xed-base routers,
install the motor unit in the router base.
Precision Insert Plate Installation
6.
K
Set screw
L
Insert plate
Lock-down screw
Hex wrench
4. Place the insert plate with the router attached in the table-top
opening, resting it on the eight set screws. Using the hex wrench,
adjust the set screws from under the table to align the surfaces of
the plate and the table. Check the alignment with a straight edge.
Make sure all eight set screws are in equal contact with the insert
plate.
5. Thread the four ¼-20 x 1¾" machine screws (lock-down screws)
through the countersunk holes in the insert plate and into the
center hole on each leveler and snug them down [Drawing K].
Some adjustment of the lock-down screws and set screws may be
necessary to fi ne-tune the alignment.
Finishing Up
1. Thread the ¼-20 x ¾" set screw into the bottom of the brass
starting pin using a fl at-blade screw driver and ⅛" hex wrench, until
the two are tightly secured together [Drawing L]. When ready for
use, thread the starting pin assembly into the threaded hole in the
insert-plate and tighten it.
M
Unlock
Reducing ring
Starting pin
Set screw
Lock
2. To install a reducing ring, simply drop it into the insert-plate
opening and turn it by hand until it drops fl ush with the plate
surface. Insert the pegs at the ends of the arms of the ring wrench
into the mating holes in the reducing ring and rotate the ring
counterclockwise [Drawing M]. Rotation of about ⅜" is suffi cient
to lock the ring in place. To remove the ring, turn the wrench
clockwise and lift the ring out of the opening.
Note: The Kreg Precision Insert Plate includes three Level-Lock
reducing rings for fl exibility in matching the size of the insert-plate
opening to the diameter of the router bit in use. The ring with the
rabbeted opening accepts standard universal-style guide bushings,
allowing you to use your router table for pattern routing. A set of
four additional reducing rings plus a blank disk for making a zeroclearance ring is available from your Kreg dealer
(Item #PRS3050).
Wrench
Safety Guidelines
· Failure to follow these rules may result in serious personal injury.
· Woodworking machines are dangerous, and can cause
personal injury if not used properly.
· Completely read the operating manual and safety instructions
for the machine before use. Learn the applications and
limitations of the machine as well as the hazards specifi c to it.
Operating the machine before understanding safe and proper
use could result in serious personal injury.
· Keep all guards and safety devices properly installed while using
the machine.
· Always wear safety glasses.
· Keep hands well away from the rotating bit when operating the
machine. Never overreach.
· Avoid awkward hand positions, where a sudden slip could cause
contact with cutting edges.
· Kickbacks occur when the workpiece binds while being
machined, causing it to twist, jump, and possibly become
airborne. To avoid kickbacks and potential injury, always follow
proper technique, use sharp bits, keep the machine aligned
and maintained properly, and adequately secure and support
the workpiece. To free both hands for tool operation, use clamps
or a vise to hold work when it is practical and safe.
· Turn off the machine before making adjustments. Never adjust
the fence, plate, reducing rings, or any other part of the machine
while it is running.
· Make sure the machine comes to a complete stop before
adjusting the position of a workpiece.
· Ground electric machines. If the machine is equipped with a
three-prong plug, it should only be plugged into a grounded
three-hole electrical outlet. If the proper outlet is not available,
have one installed by a qualifi ed electrician. Never remove the
third prong or modify the provided plug in any way.
· Do not operate the machine in a dangerous or unclean
environment. Do not use the machine in damp or wet locations,
or expose it to rain. Keep the work area well-lit, un-cluttered, and
clean.
· Keep all children and visitors at a safe distance from the work
area. Children and visitors should not operate machinery under
any condition.
· Use the right machine for the task. Never “force” a machine to
do work for which it was not intended. If used properly under
safe conditions, the machine will produce better results in less
time.
· Wear proper apparel. Avoid loose clothing, gloves, neckties,
rings, bracelets, or any other jewelry that could get caught in
moving parts. Wear non-slip footwear and protective hair
covering specifi cally designed as safety gear.
· Secure machinery to prevent tipping or sliding.
· Keep proper footing and balance to avoid slipping or sliding
when you turn on machinery.
· Maintain tools in top condition. For the highest quality and safest
performance, keep bits sharp and clean and machinery properly
maintained. Follow all lubrication and accessory maintenance
practices detailed in the instruction manual.
· Disconnect the machine from electrical power before servicing.
When changing accessories such as bits and clamps, making
any sort of physical assessment of the machine, or when the
motor is being mounted or connected, disconnect the machine
from the power source.
· Check for damaged parts. Before using the machine, make
a careful assessment of all guards and other parts to ensure that
the machine will operate properly and perform as intended.
Check moving parts for alignment, binding, breakage, mounting,
and any other conditions that may affect its operation. A guard or
other part that is damaged should be properly repaired or
replaced as soon as possible, preceding any further use. Do not
use the tool if you are not qualifi ed to make these assessments.
· Never leave a running machine unattended. Always turn off the
machine after operation. Do not leave the tool until it comes to a
complete stop.
· Drugs, alcohol, medication warning: Do not operate machinery
while under the infl uence of drugs, alcohol, or any medications.
· This machinery system is designed only for certain applications.
Kreg Tool strongly recommends that this system NOT be
modifi ed and/or used for any applications other than those
for which it is designed. If you have any questions relative to the
application of the machinery system, DO NOT use the system
until you have written, phoned, or e-mailed Kreg Tool and have
been advised accordingly.
· Make your workshop “child-proof”. Use padlocks, master
switches, or other means necessary to prevent unauthorized
use of machinery.
www.kregtool.com • 800.447.8638
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