Leigh FMT PRO User Manual

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Page 1

LEIGH FMT PRO

Leigh Router Joinery Jigs

User Guide

Frame Mortise & Tenon Jig

1-800-663-8932

Joining Tradition with Today

Page 2

Frame Mortise & Tenon Jig User Guide

Your New Leigh Frame Mortise & Tenon Jig (FMT Pro)

Congratulations for selecting the unique Leigh FMT Pro, the best mortising and tenoning jig available. The FMT Pro will allow you to rout a large range of sizes of mortise and tenon joints with total control over joint fit. To gain the most advantage from this unique tool, please read all of this User Guide; carefully set up the jig following the simple set-up directions, and thoroughly familiarize yourself with the basic functions and principles of operation. Use scrap wood before attempting any actual projects with valuable hardwood.

Customer Support

If you have any questions that are not answered in this user guide, please call Leigh Customer Support: 1-800-663-8932 in North America or email: [email protected]. For support contacts in your country of purchase, see Customer Support on page 69.

Reminder: If at first you don’t succeed, read the instructions!

Important! Inches and Millimeters

The Leigh FMT Pro is available in two models; Inch or Metric. The only difference is in the guides and bits used, otherwise the jig itself is identical. Text and illustrations in this English language User Guide indicate dimensions in both inches and millimeters, with “inches” first,

followed by “millimeters” in square brackets, i.e.

⁄2"x 2"[12x50mm].

Do not be concerned that the inch/millimeter equivalents are not mathematically “correct”. Just use the dimensions that apply to your

guides and bits.

Technical Bulletins

Downloadable pdfs are available at leighjigs.com on the Support page for these How To’s and more for your Leigh FMT Pro jig:

• Rout Tenons on Extra Wide Boards

• Mortise & Tenon Joints on Shaped Pieces

• FMT Pro/Super FMT – Specialty Guides

1-800-663-8932

Page 3

Contents

Frame Mortise & Tenon Jig User Guide

CHAPTER 1 Mounting the FMT Pro ................................................................. 1

CHAPTER 2 Mounting the Router

................................................................... 3

Fence Rod Mounting .................................................................... 3

Screw Mounting

CHAPTER 3 The FMT Pro Jig

The Clamp Plate and Clamping

The Table

......................................................................................14

Jig Operation Concept

Safety and Router Operation

Wood Preparation

CHAPTER 4 Mortise & Tenon Procedures

Single Mortise & Tenon, Test

Production Procedures

Small Joints

CHAPTER 5 Multiple Joints

Double In Line Joints

Twin Joints

Quadruple Joints

Triple Joints

CHAPTER 6 Workpiece and Joint Options Different Workpiece Thicknesses

Longer and Shorter Joints

Thicker and Wider Boards

CHAPTER 7 Special Joints

Angled Joints

Through Tenons Bridle Joints

Asymmetric Tenons

Haunched Joints

Doweling

.....................................................................................54

Appendix I Joint Specifications, Guide and Bit Selection Joint Specifications

Guide and Bit Selection

Appendix II Jig Adjustments

Appendix III Parts List

......................................................................................63

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iii

Appendix IV Customer Support

......................................................................69

Page 4

Frame Mortise & Tenon Jig User Guide

Add Leigh Accessories to make your jig even more versatile.

SPECIALTY GUIDES

Square Tenons

Square tenons are often used for replicating period furniture.

Item 670900

Y-Axis Mortise

In instances when mortises

need to be routed at 90º to the

clamp plate, this guide does

the trick.

Item 6701YAM

Optional Guides, Bits and Accessory Kit for Great Savings

Joint Guides

Three optional guide sets

are available increasing the

number of joint sizes you

can make to 68! 16 op

tional guides in 1/4", 3/8"

and 1/2" (6, 10 and 12mm) sizes, make a complete set.

Each guide can be purchased individually or as a set for

better value. Buy all three or as part of the accessory kit

below for even greater savings.

Item 6720 or 6820

Louver Doors

Make beautiful

louver doors with

these guides and bit.

L/R matching pair

Item 6701LGP

1/4" HSS Louver

Guide Bit, 1/2" shank

Item 168-500

Extra Clamps Save Time

Leigh Surface clamps are identical to FMT Pro clamps. Save time when

switching between mortise and tenon boards. Bonus! This tough,

versatile cam-action clamp can also be mounted on any flat surface, on

any angle or on a table saw. You can never have too many clamps.

Item SHDC1 Surface mount

(one clamp)

1/8" to 3" capacity

Router Bits

8-piece set in HSS or Solid

Carbide opens up your

possibilities for joint sizes.

Item 162-180 or 162-180C

Accessory Kit for Savings

guide set and boxed inch bit set for the best savings.

Includes an 8-piece boxed inch bit set and 16 optional

guides in 1/4", 3/8" and 1/2" (6, 10 and 12mm) sizes for

a complete set.

Visit www.leighjigs.com for more details

Item ACMT or ACMTC

Combine an optional

Routing tenons with mortise board clamps in place

Use on jigs and fixtures

Routing mortises with tenon board clamps in place Use vertically on bench

Page 5

MOUNTING THE FMT PRO

FMT PRO CHAPTER 1

Mounting the FMT Pro

Jig Assembly and Mounting

The Leigh FMT Pro comes almost fully assembled with all adjustments factory set — however, before you start to set up your Leigh FMT Pro Jig, make sure you have received all the required parts.

1. 1 The main Jig Body, complete with: 1 Table

2. 1 Router Sub-Base

3. 1 User Guide

1 DVD Video

4. 1 Box Containing: A 2 Vacuum Hose Adaptors B 4 Jig Hold-Down Nuts and Bolts B 4 U-Posts with 4 Set-Screws and

Four

B 4 1" Countersink Screws B 3 Hex Socket Button Head Screws 10x24 x B 2 Hex Socket Button Head Screws M6 C 4 High Shim Spacers C 4 Low Shim Spacers C 1 C 1 8 and 12mm Centering Mandrel D 1 E 2 Outrigger Bars with 4 Screws and Nuts F 1 Leigh Square Drive Screwdriver F 1 Leigh F 1 F 2 Router Hold-down Rods G 5

& 1 Guide Stand

H** 1 Side Stop Fence with Lever** I 2 Cam-Action Speed Clamp Assemblies

➀

➁

⁄4"-20

⁄4"Countersink Screws

⁄4"and 1⁄2" Centering Mandrel

⁄16" HSS Spiral Upcut 1⁄2" Shank

⁄8" Hex Ball Screwdriver

⁄64" Hex Key

⁄16" guides (or 6x8mm with FMT Pro-M)

⁄8"

A B C D E

F G H** I

VACUUM BOX UPDATE: Most drawings throughout this user guide show an older version of the vacuum box, clamp plate and top extrusion. All FMT Pro jigs are shipped with the newest parts. These changes are reflected in Appendix III.

** SIDE STOP UPDATE: Some illustrations show the side stop fence with a “knob”. All FMT Pro jigs are shipped with a side stop fence with a “lever”, (see H in drawing above).

Note: Any optional accessories that you ordered may also be inside the parts box, or packaged inside the main carton.

If any of these items are missing from your order, please notify your supplier or Leigh Industries immediately.

Page 6

Chapter 1 Frame Mortise & Tenon Jig User Guide

"[400mm]

35/16"[84mm]

/2"[13mm]

MOUNTING THE FMT PRO

24"[600mm]

5"[125+mm]

1-1 Mounting the FMT Pro: Prepare a flat board at least

⁄4"[20mm] thick, a minimum of 24"x5"[600x125mm]. Drill four

⁄32"[7mm] holes on 153⁄4"x35⁄16"[400x84mm] centers, 1⁄2"[13mm] in

from the front edge of the board

if board is thicker, the underside so that the four 1⁄4–20 x 1" long

➂

machine screws will project above the top surface by

. Countersink ➁, or counter-bore

➀

⁄8"[9,5mm] ➃.

1-2 Turn the jig upside down on two wooden blocks ➀ (to protect the table and sight knob). Using the four nuts and four flathead countersunk machine screws, bolt the base board to the jig

using the two nut recesses in each end housings. The front edge

to the front of the jig (of course). Now you can

➁

⁄2"[13mm]

clamp your FMT Pro to any bench.

1-3 For routing long vertical rails it may be necessary to build a jig stand to mount securely on your bench. Make the stand and bench height combination sufficient to accept the board length you have in mind. The jig stand should be bolted securely to the bench. Make up a stable platform as shown here to stand on. Do not use a collapsible step stool, these are unstable and unsafe.

■

Page 7

MOUNTING THE ROUTER

FMT PRO CHAPTER 2

Mounting the Router

Fence Rod Mounting

Screw Mounting

Foreword The threaded sub-base mounting holes on many routers are not strong enough for the stresses

produced when routing joints with the FMT Pro, so Leigh developed the Universal Fence Rod Mounting System. The Leigh FMT Pro Sub-Base provides great attachment strength and lateral anchoring. Depending on your router model, fitting the Sub-Base to your router may take up to an hour…the first time only. Once fitted, the router can be removed and reattached in about a minute. Mounting the Sub-Base correctly is critical to the accuracy of the jig, so take your time and get it right the first time. Here’s how...

Fence Rod Mounting

m The FMT Pro must only be

used with a plunge router. Never, ever use a fixed base router!

Right

Left

Rear

Left

Front

ROUTER MAKE HOLES NOTES

AEG OFS 50 2 BOSCH 1450,

1611EVS,1613EVS,1617EVS BOSCH 1619EVS BOSCH MRP23EVS CRAFTSMAN 2 DEWALT 616/618 DEWALT 621 DEWALT 625 ELU 97 1 3 1 3 ELU MOF 131 2 ELU MOF 177/02 2 ELU 3304 3 ELU 3338 2

FESTOOL 900E, 1010 7 FESTOOL OF1400 11 FESTOOL OF2000 2 FESTOOL OF2200 12 FLEX OFT2926VV 5 FREUD FT2000E 2 HITACHI M12V HITACHI M12VC HITACHI TR12 2 **8 2 **To avoid Turret MAKITA 3600B 1 MAKITA 3612BR 3 **6 **To avoid Turret MAKITA 3612C 3 MAKITA RP 0910 4 MAKIT

A RP 1100 Series MAKITA RP2301FC METABO OFE728 METABO OFE1028 3 MET

ABO OFE1229 3 MILWAUKEE 5616 RIDGID 10 RYOBI R-150 3 RYOBI RE180PL 2 RYOBI R-500 2 RYOBI R-E600 2 PORTER CABLE 693 PORTER CABLE 890, 893 PORTER CABLE 893 Type 2 PORTER CABLE 7529, 8529 5 PORTER CABLE 7539 *2 *Reverse U-Post to put screws outside rods TRITON, TRC001 3 TRITON, MOF 001 2

/4hp

LR RR LF RF

1 *1 1

1 3 1 3

2 4

4 2 3

9 9

Rear

*File notch in U-Post if req’d to avoid Turret

Requires 1/16" packing shim. See 2-9

Use 2 #5130 screws provided. See 2-30

Use 2 #5130 screws provided. See 2-30 Use 3 #6410 screws provided. See 2-30

Use 3 screws from router base. See 2-30 Use 3 screws from router base. See 2-30

Use 3 #6410 screws provided. See 2-30

Use 3 #6410 screws provided. See 2-30 Use 3 #6410 screws provided. See 2-30

Use 4 No.6677 1/4-20 x 3/8" button

head socket screws

123

Right Front

2-1 The Leigh FMT Pro Sub-Base Place your router, the FMT Pro Sub-Base and all the mounting parts on a clear bench. From the Sub-Base diagram and chart on this page, find the make and model of your router.

2-2

Mark the appropriate mounting holes on the Sub-Base. Use a non permanent medium e.g. chalk, sticky tape (ink will permanently stain the anodized surface).

Note: If the chart at left indicates your router is a “Screw mount” (routers in shaded rows) go directly to 2-30. If your router is not listed here, proceed to 2-3. For the most up-todate list of routers, go to www.leighjigs.com.

Page 8

Chapter 2 Frame Mortise & Tenon Jig User Guide

MOUNTING THE ROUTER

2-3 If you have a plunge router that is not listed in the Sub-Base list, it is essential that your router have two parallel fence rod holes through

the router base. These must be at least

⁄16"[8mm] in diameter ➀. Fit

the correct shank sized centering mandrel to your router, place it on the Sub-Base and plunge the mandrel into the base hole. Place the fence rods through the rod holes with an equal amount protruding at each end.

2-5 Most plunge routers will be mounted to the Sub-Base like this, with rods through the fence rod holes U-Posts

, but it is essential that the correct shim spacers ➂ are

➁

and clamped down with the

➀

selected.

2-4 Take the four U-Posts and by trial, establish which four Sub-Base slots or holes will serve to attach the U-Posts. Mark these with chalk or sticky tape and follow instructions 2-5 through 2-29.

2-6 Depending on the make and model of your router, the height between the underside of your router and the bottom of the rod

will vary. This dimension will determine if you need to

hole

➀

use low

or high ➁ shim spacers, or possibly both together ➂.

➀

1 2

2-7 To measure the “rod height”, place the router on a bench. Either use a calliper

, or insert a rod (flat side up) and use a good

➀

rule to measure between the bench top and the bottom of the

rod

➁

1 2 3

2-8 If rod height is between 3⁄16"[4,5mm] and 3⁄8"[9,5mm], use low shim spacers

⁄32"[13,5mm], use high shim spacers ➁. If rod height is between

⁄32"[13,5mm] and 3⁄4"[19,5mm], use both shim spacers ➂, with

. If rod height is between 3⁄8"[9,5mm] and

➀

the high one on the bottom. Note: If the rod height is less than

⁄16"[4,5mm], see 2-9.

Page 9

MOUNTING THE ROUTER

Chapter 2Frame Mortise & Tenon Jig User Guide

2-9 Note: Use of the shim stops is essential, not only to provide the correct rod height but to also act as side-to-side stops for the router

If the rod height of your router is less than

⁄16"[4,5mm] you must

➀

provide a shop-made packing shim between the router and Sub-Base. We suggest one or more sheets of sandpaper

, rough side up. Don’t

➁

forget the center hole.

1 2

2-10 Adjust the four U-Post set-screws with the set-screw end

flush inside the arch of the posts

➀

2-11 There are two lengths of U-Post screws; 3⁄4"[19mm] and

1"[25mm]. The measure. Use these for either the low or high shim spacers

⁄4"[19mm] are factory fitted as a quality control

➀

Change them for the 1"[25mm] screws if both shim spacers are

used

➁

1 2

2-13 In most cases, position the U-Post screw leg to the inside of the rod base, to the outside position

or depending on the size and shape of the router

➀

. Slide the shim-stops away from the router

➁

. These will be repositioned against the router later.

➂

2-12 Using the four selected screws, lightly attach the four U-Posts and correct shim-stop combination through the previously marked

slots or holes in the Sub-Base. The screws must enter from below

. Only very lightly tighten; you will need to move the U-Posts

➀

and the shim-stops during setup.

2-14 Place the Sub-Base flat down on the corner of a smooth bench, the handle to your near left ing the adjacent edges of the bench

and the guide pins touch-

➀

➁

Page 10

Chapter 2 Frame Mortise & Tenon Jig User Guide

1/4"

8mm

MOUNTING THE ROUTER

1/2"

12mm

2-15 Unplug the router. Note the collet size of the router. Choose the matching size centering mandrel and fit it into the router collet.

2-16 Holding the router as you would in normal use, place it base down onto the Sub-Base; the rear of the router toward the rear of the Sub-Base and large notch

. Plunge and move the router so

➀

that the large diameter of the centering mandrel fits through the Sub-Base center hole

…

2-17 …and touches flush to the bench. Lock the plunge.

m Concentricity of bit to Sub-Base bit hole is essential to FMT

Pro accuracy, so never mount the router without using the centering mandrel.

2-19 Festool 900 and 1000 Series: Align the fence rod holes to the previously positioned U-Posts.

2-18 Align the router so that the fence rod holes are parallel to the front edge of the Sub-Base (except Festool 900 and 1000 Series, see 2-19).

3 3

2-20 Loosen and raise any router fence rod knobs ➀. Move the U-Posts and adjust as necessary to slide the two hold-down rods through the

➂

➁

. Leave

U-Posts and router fence rod holes, flat side of rods on top an equal amount of rod projecting through each U-Post

m Never use the router’s fence rod knobs

to “help” secure the router.

➀

This places uneven pressure and could damage the router base.

Page 11

MOUNTING THE ROUTER

Chapter 2Frame Mortise & Tenon Jig User Guide

2-21 Using the hex screwdriver, turn down the four U-Post setscrews until there is only very slight and even pressure on each end of both rods. Leave the shim stops in the outer position.

2-23 Tighten the top U-Post set-screws a little more securely to hold the bars and router.

2-22 Check that the rods are still centered in the rod holes ➀ and check that the router collet can rotate without excessive binding in the Sub-Base hole. Mandrel touching side of hole is OK; mandrel binding tight is not! Move the router if required to allow mandrel to rotate.

2-24 Slide the router/Sub-Base assembly on the corner of the bench so that one U-Post bottom screw is overhanging the edge. Loosen this screw just slightly (if necessary) to take any pressure off the shim spacer above. Push the Shim spacer in to touch the router base and, holding it in position against the router base, firmly tighten this bottom screw.

2-25 Repeat this procedure at the other end of the same rod to position the shim stop against the router base. Re-check the collet/ mandrel for relatively free rotation. Turn the router around on the corner of the bench and repeat this procedure on the two U-Post assemblies on the second rod.

2-26 Tighten the four U-Post set-screws to the rods. The hex driver has high leverage so use common sense when tightening. The rods will bow

slightly. Objective: have the collet concentric to the bit hole; the four shim stops providing secure side thrust security, and the U-Posts clamping the rods which hold the router against the Leigh Sub-Base. Router /Sub-Base are now a unit. Release the plunge; remove and store the mandrel. You’re set to go.

Page 12

Chapter 2 Frame Mortise & Tenon Jig User Guide

MOUNTING THE ROUTER

2-27 Here’s how to remove the router for use elsewhere: Loosen the four top U-Post set-screws

Slide out the two rods ➁.

➀

Do not remove the U-Posts. In about a minute, the router is free to be used for other tasks.

2-29 Hint: If you plan to fit a different make/model router and later use the current one again, you can greatly speed up the reinstallation of the first router by marking around the original four U-Post/shim-stop positions.

■

2-28 To re-mount the router: place the Sub-Base over the corner of the bench. Make sure surfaces are clean. Place the router on the Sub-Base with the centering mandrel in the center hole. Insert the fence rods. Evenly tighten the four U-Post set-screws. Check that the mandrel rotates freely. In about two minutes the router/ Sub-Base assembly is ready for making mortises and tenons.

Screw Mounting

2-30 These routers do not have suitable through fence rod holes: Porter Cable 693, 890, 890 Type 2, 893, 7529, 8529; Flex OFT 2926VV; Festool 1400, 2200; Makita RP0910, Makita RP1100 series; Triton TRC001, MOF001. We’ve provided Sub-Base holes and screws to mount these directly to the Sub-Base. Using Porter Cable 7529 and 8529 as examples, here’s how.

PORTER CABLE

693 890

890 Type 2

893

PORTER CABLE

7529 and 8529

(FLEX OFT2926VV)

MAKITA

RP1100 SERIES

FESTOOL

1400 and 2200

2-31 Note: Porter Cable 7529 & 8529 (Flex OFT2926VV) have two sets of 3 threaded holes. Use the inner circle of FMT Pro Sub-Base holes. The outer circle holes align with threaded holes, but are not deep enough for the screws. For Porter Cable (Flex) 693 & Makita RP1100 series routers use the outer circle of Sub-Base holes. Firmly attach the Sub-Base using the three 6410 hex socket button head screws

provided

. Do not use the router’s Sub-Base screws. See 2-32.

➀

Page 13

MOUNTING THE ROUTER

Chapter 2Frame Mortise & Tenon Jig User Guide

2-32 Unplug the router. Remove the router’s plastic Sub-Base (except Festool 1400) and template guidebush adaptor from 7529 or 8529. Remove the clear plastic dust cover from 8529 router base top (screw holes are used to attach Leigh FMT Pro Sub Base). Store removed parts for future use. Fit the correct shank sized centering mandrel to collet. With the Leigh Sub-Base on a flat bench corner, place router on top and plunge mandrel through to bench and lock the plunge.

5130

2-34 Festool 1400 series routers attach using the two No. 5130 screws provided, through base holes No. 11. Festool 2200 series routers attach using the two No. 5130 screws in the No. 12 holes.

2-33 Remove the router and stand it upside down on the bench. Depending on the router design, you may need to support it in a soft-padded vise. Place the Sub-Base upside down onto the router’s metal base with the mandrel centering the router to the base through the bit hole. Rotate the Sub-Base until the correct threaded screw holes in the router base align with the counterbored holes in the Sub-Base.

2-35 m In addition to the base screws it is vital to attach the four U-Posts and four of the shim stops (either size) and position and tighten these against the edge of the router base to prevent lateral router movement. Note: You do not use the fence rods. For correct

positioning, see 2-16 through 2-18, 2-24 and 2-25. Note: Porter Cable 7529 and 8529 handles will be slightly angled (not parallel) to the FMT Pro Sub-Base.

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Page 14

Chapter 2 Frame Mortise & Tenon Jig User Guide

MOUNTING THE ROUTER

Page 15

THE FMT PRO JIG

FMT PRO CHAPTER 3

The FMT Pro Jig

The Clamp Plate and Clamping

The Table

Jig Operation Concept

Safety and Router Operation

Wood Preparation

The Clamp Plate and Clamping

3-1 The clamp plate ➀ is adjustable up to 30˚ from vertical and is held securely by two quadrant knobs

. A set-screw ➂ allows for

➁

positive return to 90˚. To ensure flush and in-plane joints, it may be necessary to adjust the clamp-plate angle. See Appendix II, Jig Adjustments. An angle scale is provided, with an indicator adjustable

➃

to zero

m The clamp plate and cam-clamps are a self contained clamping

area. Under no circumstances should any other jig component be used for clamping and no auxiliary clamping method used, other than as illustrated in this guide.

3-2 The two clamps are powerful cam-action rocking-arm clamps with capacity from zero to 3"[76mm]. The T-bolt is inserted directly into the T-slot opening

, moved to desired position and

➀

brass thumb nut lightly tightened. Normally tenon workpieces will be clamped vertically like this

➂

, or...

, and mortise workpieces horizontally

➁

3-3 …like this ➂. For clamping very small workpieces see Chapter 4, Small Joints.

3-4 Never force a cam-action clamp. It has great leverage, and using excessive force may damage the workpiece. The powerful clamp, combined with a non-slip clamping surface, requires only moderate clamping pressure to hold the workpiece securely in place.

Page 16

Chapter 3 Frame Mortise & Tenon Jig User Guide

THE FMT PRO JIG

3-5

A smooth, firm action is enough to engage the clamp.

Rule of thumb: if you can’t throw the lever comfortably by strong thumb pressure, reduce the tension. A few minutes of trial and error testing will soon give you the feel for the correct clamp tension.

3-7 The clamping pressure is the same whichever of the two directions the lever is thrown. But if the lever is uncomfortably positioned at the correct clamping pressure...

3-6

Do not use the lever as a torque arm!

Adjust the clamp pressure only with the clamp disengaged.

3-8 ...release the clamp, remove the workpiece and turn the step-washer a quarter turn. The step height in the step-washer is one quarter of the thread pitch.

3-9 Then adjust the clamp until the lever is in the correct position at the required pressure.

4 4

3-10 The clamp T-Bolt Slots and “keyholes” allow for full clamping coverage. The two lower keyholes to clamp mortise boards between 4 wide

. Always clamp with the heel and toe of the clamp over

➁

the surface area of the clamp plate

m Never allow the clamp arm heel pad in these red shaded areas

are for the rare requirement

➀

⁄4"[120mm] and 51⁄2"[140mm]

➂

➃

even if (particularly if) the mounting board or bench is there.

Page 17

THE FMT PRO JIG

Chapter 3Frame Mortise & Tenon Jig User Guide

3-11 The clamp T-bolts nuts need only be lightly finger tightened to prevent accidental clamp movement. The nuts are knurled to provide a good finger grip.

Never use a tool to tighten these nuts!

3-13 The FMT Pro’s sidestop fence is attached in all modes by a single knob and T-bolt inserted to the center clamp plate slot

➀

Most tenon pieces are routed vertically, and for that purpose the short part of the fence clamp plate

. In this mode the Leigh logo faces toward you.

➂

acts as a T-square against the edge of the

➁

3-12 The clamp plate is provided with twelve through-holes. If for any reason a facing board is required to be attached to the clamp plate, No.8 or M4 wood screws (not supplied) may be used from the rear. See chapter 4, Small Joints.

3-14 The sidestop fence is squared at the factory, but check your first

test joints. If your router/bit is not perfectly perpendicular to the table adjust the sidestop fence: slightly loosen the 'pivot' screw screw

. Adjust the angle ➂ to match the bit and retighten. Rout test

➁

and the 'lock'

➀

joints to confirm correct setting. Once locked in this position it should never need adjusting when used with that same router.

3-15 Angled Joints: Remove the knob and T-bolt. Reverse the fence so the short end faces toward you along the center clamp plate slot

. The fence may now be set at any angle

➀

by tightening the knob.

➁

m NOTE: Never rout tenons with the short part of the fence to the top, in

the bit opening.

3-16 'Mortise steady': When routing mortises in small stock the piece may 'flutter' causing poor joint fit. Invert the fence with the short end up in the bit opening short fence

which is perfectly flush with the clamp plate face ➀. When

➁

. Clamp the mortise piece against the face of the

➀

routing mortises at the end of a board, always move the table as far as possible left or right to minimize the length of unsupported workpiece.

Page 18

6"[150mm]

Chapter 3 Frame Mortise & Tenon Jig User Guide

THE FMT PRO JIG

3-17 m WARNING: Never rout tenons with the sidestop

fence in the inverted position (with the short end up in the bit opening). The inverted fence mode is only used to support small mortise stock.

3-18 The jig clamp plate has an opening on each outer edge in which to fit the included “outrigger bars” by set-screws

tightened with the hex driver.

➁

/8"[10mm]

3"[75mm]

. The bars are retained

➀

3-19 The outrigger bars allow for attachment of shop-made outrigger beams on which to mount sidestops or add pencil marks. This makes for efficient routing of multiple mortises. See Chapter 4, Production Procedures.

The Table

3-21 The table is clamped in any desired position by the Table Clamp

. Turning the clamp lever up 90˚ releases the table,

➀

which can then be moved in any direction to any position within its range. Clamp tension is factory preset. See Appendix II, Jig Adjustments.

3-20 The outrigger beams should be 3⁄8"[10mm] plywood, shaped as suggested to minimize weight. Drill as shown and attach with the small nuts and bolts provided. The top edge should just clear the underside of the locked table. Store the outriggers on a wall hanger when not in use. The deep shoulder lever support against the end of the clamp plate assembly.

provides canti-

➀

■

3-22 Adjustable Limit Stops ➀ are used to limit or prevent table movement left to right (X-axis) and front to back (Y-axis), and to precisely align double and quadruple mortises and tenons (see Chapter 4). Use Limit stops when you see these icons:

for left-to-right table movement

for front-to-back table movement.

Page 19

THE FMT PRO JIG

Chapter 3Frame Mortise & Tenon Jig User Guide

3-23 The table has a bit opening ➀ and Joint Aligning Sight ➁. Pulling the sight fully forward to its detent provides precise table positioning over joint cross-marks

. Because the human eye excels at comparisons, we can

➂

perceive differences as small as 0.004" in the space between the edges of the line and the triangles sight using slight table movements until the spaces appear the same

. That’s 0.002" off center! You can readily center the

➂

➃

3-24 To the right front is the right-hand “Pin Track” ➀. The right- hand router sub-base Guide Pin runs in this track in all routing operations. To the left front is the Guide Recess Joint Guides Pin runs in the guide slot outside of the Guides

are placed. The left hand router sub-base Guide

➂

for cutting mortises or around the

➃

, for cutting tenons.

➄

, in which all

➁

3-25 The Guide Pin cannot move horizontally outside the recess opening

3-27 Snap the Guides in like this. Use firm pressure just next to the guide latch. Note: The guides are injection molded acetal and the guide bases may vary slightly in tolerance. Some may require more pressure

, and prevents the bit from touching the sides of the bit

➀

➁

to insert. The tighter guides will become easier after a few insertions.

3-26 Two small projections on the Guide fit into undercuts on the right side of the guide recess pushed down and retained by the spring-loaded Guide Latch

. The left end of the Guide is

➀

➁

m Note: the guide end shapes are not identical. Guides can

only be installed one way as shown here.

3-28

To remove a Guide, pull back the latch ➀ and push through

the finger-hole from below with your fingertip

➁

Page 20

Chapter 3 Frame Mortise & Tenon Jig User Guide

3-29 If the finger-hole is not accessible from below, use your fingernail or a small non-metallic pry to lift the Guide up

Jig Operation Concept

➂

■

THE FMT PRO JIG

3-30 The selected guide is placed into the guide recess and the matching bit fitted to the router.

90˚

3-31 The centers of a mortise and tenon are marked with a cross.

3-32 Tenon workpieces are usually clamped vertically ➀. Mortise workpieces are always clamped horizontally

➁

3-33 The jig table is centered over the marked workpiece with the extended sight

➀

Page 21

THE FMT PRO JIG

Chapter 3Frame Mortise & Tenon Jig User Guide

3-34 Tenons are routed with the guide pin running around the outside (tenon) part of the guide

. See Chapter 4 for routing

➀

techniques.

Safety and Router Operation

3-36 Read the owner’s manual that came with your router. It is essential to understand the router manufacturer’s instructions completely.

3-35 Mortises are routed with the guide pin running in the inside mortise part of the guide

. Always rout the mortise slightly deeper

➁

than the tenon length.

Note: Only one tenon and perhaps two mortises need to be marked and sighted. Please read all of the procedural chapters to gain the utmost efficiency from your FMT Pro.

■

3-37 Always wear approved safety glasses. Always wear hearing protection.

3-38 Protect yourself from harmful dust by wearing a face mask. Connect your shop vacuum or dust collection system to the FMT Pro whenever possible.

3-39

Never drink alcohol or take medications that may

cause drowsiness when you will be operating a router.

Page 22

Chapter 3 Frame Mortise & Tenon Jig User Guide

THE FMT PRO JIG

3-40 Always disconnect the power source from the router when fitting bits, or making adjustments. Before connecting the router to the power source, make sure the bit revolves freely through the Sub-Base bit hole, and table and

3-41 Make sure the router collet does not contact the FMT Pro Sub-Base at full plunge cuts. Set the router plunge stop rod as necessary to prevent this

➀

clamp plate bit openings in all extreme guide pin positions and preset bit depths.

3-42 Do not tilt the router on the jig. 3-43 Keep the router flat on the jig assembly.

3-44 Always raise the plunge router mechanism before removing

the router assembly from the jig.

3-45 Never, never, use a non-plunge fixed base router on the FMT Pro.

Page 23

THE FMT PRO JIG

Chapter 3Frame Mortise & Tenon Jig User Guide

3-46 Do not rout at face level. 3- 47 If you have never used your router before, be sure to follow

the router manufacturer’s instructions for its use. Make plenty of simple open-face practice cuts before you try to use the router on the Leigh FMT Pro.

Wood Preparation

■

3-48 Stock for use on the Leigh FMT Pro should generally be straight, flat, of even thickness and width with square ends and edges, except where design issues dictate otherwise.

Please note that even small ridges (caused by damaged planer blades) can cause noticeable misalignment of “flush” joint faces.

3-49 You will want to test the jig, so prepare some stock with a thickness

of about 2½ to 3 times the bit diameter ➁,

➀

For example:

⁄4" [6mm] bit 5⁄8" to 3⁄4"[15-19mm]

⁄16"[8mm] bit 3⁄4" to 15⁄16"[20-24mm]

⁄8"[10mm] bit 15⁄16" to 11⁄8"[25-30mm]

⁄2"[12mm] bit 11⁄4" to 11⁄2"[30-36mm] and a stock width selected guide length

of say, 1½ bit diameters greater than the

➂

➃

■

Page 24

Chapter 3 Frame Mortise & Tenon Jig User Guide

THE FMT PRO JIG

Page 25

Routing Procedures

Production Procedures for Small Joints

See Appendix I for complete joint specifications and guide and bit selection

MORTISE & TENON ROUTING PROCEDURES

FMT PRO CHAPTER 4

Mortise & Tenon

Single Mortise & Tenon, Test

Production Procedures

Routing Joints Smaller than 1/4"

Before using your Leigh FMT Pro you must have completed all of the preparatory steps including reading the router safety recommendations on the previous pages. If you haven’t done so, it is essential that you do it now.

Single Mortise & Tenon, Test

m IMPORTANT SAFETY NOTE

Take great care to not “trap” the bit against the side of tenon

. Do not attempt to rout center tenons in rails thicker than

rails

➀

/16"[34mm] before referring to 5-39 through 5-44.

Without using the table movement as prescribed, the bit would have to be plunged into the side of the tenon rail causing the bit to powerfully “drive” the router across the jig. This could be

dangerous and can damage the jig.

90˚

4-1 Let’s make a plain single mortise and tenon. Using a fine pencil, mark a cross at the center of the required tenon and mortise. The cross lines along and across the axis lines of the joint must be at 90˚ to each other. Mark the mortise several inches[10cm] or so away from the end.

4-2 In almost all cases, it is critical to have the same side of workpieces reference against the clamp plate for each tenon and mortise. So mark one side of each workpiece to reference “this side toward the clamp plate” mark

to the required shoulder depth on the tenon workpiece. When

➁

the joint is cut, the tenon piece is rotated 180˚ to assemble

, or “away from” if you prefer. Make a pencil

➀

➂

Page 26

Chapter 4 Frame Mortise & Tenon Jig User Guide

MORTISE & TENON ROUTING PROCEDURES

4-3 If you have not yet mounted the side stop fence, do so now (see 3-13 to 3-15). Place it off center by about half the width of the tenon piece; either side, it doesn’t matter. Pull the table sight forward to its stop tion the sight over the approximate tenon piece position

. Release the table clamp ➁ and move the table to posi-

➀

. Lock

➂

the table. Always lock the table before positioning workpieces.

4-5 Release the table clamp and move the table until the sight opening is positioned equally around the cross lines on the workpiece. Lock the table. Because the human eye excels at comparisons, differences as small as 0.004" can be perceived in the space between the edges of the line and the triangles as shown here sight using slight table movements until the spaces appear the same

. You can readily center the

➀

➁

4-4 Clamp the tenon piece with the end edge lightly touching the underside of the sight. Its side edge should touch the previ- ously set side stop fence, with the marked side toward the clamp plate.

4-6 Unlock the two they touch the Stop Post and tighten both stops

front/back limit stops. Move both so

. This prevents

➀

front-to-back movement of the table when later sighting the mortise. Retract the sight.

4-7 Unplug the router. Insert the selected guide to the guide recess and matching diameter bit to the router.

4-8 Make sure the two guide pins are turned up two full turns from the lowest position!

Place the router on the jig table, the right hand guide pin in the right side track, the left hand guide pin in the near side of the guide recess.

Page 27

MORTISE & TENON ROUTING PROCEDURES

2 3

Chapter 4Frame Mortise & Tenon Jig User Guide

4-9 Adjust the right hand guide pin. Grip the right hand pin knob and move the Sub-Base back and forth to feel the “free play” of the pin across the slot width diminish slightest play can be felt

. Turn the knob down 1⁄8 of a turn at a time, to feel the “play”

➀

. When the “play” stops, turn the knob up 1⁄8 of a turn until the

➁

. The router/Sub-Base should slide freely left to

➂

right. If the right pin is a little “sticky”, turn it up a bit more.

4-11 Plunge the router so the tip of the bit is level with the pencil mark of the tenon shoulder and lock the plunge depth stop rod to its stop

. Generally, tenons are routed in one depth

➁

. Set the plunge

➀

setting, it is not necessary to make multiple passes at different depths of

m WARNING: Never rout tenons with the sidestop fence

cut.

in the inverted position

➂

4-10 Check that the left hand knob is two turns up. From this setting the actual fit setting will be established by trial and error and the result recorded for each guide/bit combination. Note: The “steps” in the height “washer” indicate numbers of “turns up”; one turn

two turns ➁ three turns

➀

➂

Never turn the knobs up more than 31⁄2 turns in use.

4-12 Read all of the next three instructions before routing.

With the guide pin in the near side of the guide recess, switch on the router power and with firm control, move it in until the bit lightly touches the tenon workpiece. Very carefully, with the bit very lightly engaging the wood surface, “climb rout” clockwise around the tenon piece very light bit contact. Do not run the guide pin on the guide yet

. Maintain

➀

➁

4-13 Control the router firmly, the router is driven clockwise by the bit rotation. This first shallow climb cut will leave a small

but clean shoulder

➀

4-14 Routing counter-clockwise, run the guide pin around the tenon guide surface. Make sure the pin contacts the entire outer surface

➀

. In these first test cuts, check the tenon for a completely smooth cut before removing the piece from the jig. Until you are confident with this procedure, we recommend as a final clean-up, you run the guide pin “off” of each guide “corner”

in both directions ➂.

➁

Page 28

Chapter 4 Frame Mortise & Tenon Jig User Guide

MORTISE & TENON ROUTING PROCEDURES

4-15 Remove the router and tenon workpiece from the jig. Position the two clamps so the mortise piece can be positioned for secure holding. Clamp to either both sides of the vacuum box Note: Leaving a “horn” on the ends of mortise pieces as in

or to one side ➁.

➀

not only makes for easy clamping, it’s good woodworking practice as the horns will be an aid in assembly gluing and clamping later.

4-17

Place the router/Sub-Base assembly on the jig, the left

hand guide pin in the mortise slot part of the guide. Now raise

the plunge stop rod slightly, say

⁄32-1⁄16"[1-1,5mm] to allow the mortise to be routed slightly deeper than the tenon to ensure perfect tenon shoulder flushness on the finished joint.

4-16 Extend the sight. With the marked side of the mortise piece toward the clamp plate, either move the board left and right

➀

to align the cross with the sight and clamp in place; or clamp in place first and move the table to align the sight you previously set the movement. For routing very small pieces

limit stops to allow only left/right

, see 3-16.

➂

. Remember,

➁

4-18 The best way to rout mortises (parallel to workpiece) is plunge full depth, slightly overlapping holes left-right-left at full depth of cut

. Do not rout left-right-left at

➁

progressively greater depths without plunging holes

, then clean out

➀

… the bit’s

➂

rotation will pull the bit off the intended mortise line with each

and the mortise may not be parallel to the workpiece.

pass

➃

4-19 Make sure the guide pin is run clockwise against both the front and rear of the mortise guide slot on the final passes. The gap between pin and mortise guide slot is greatly exaggerated in this illustration.

4-20 Remove the mortise piece and test the tenon for fit and (keeping the marked faces adjacent) for flushness. If the face sides are not flush, check the straightness of the two parts. If they are straight, the clamp plate may not be vertically parallel to the bit. See Appendix II, Jig Adjustments, A2-1 through A2-3.

Page 29

MORTISE & TENON ROUTING PROCEDURES

Chapter 4Frame Mortise & Tenon Jig User Guide

4-21

If the joint is too loose, turn the guide pin down ➀. If

the joint is too tight, turn the guide pin up

. For how much,

➁

see 4-22. Rout a complete new joint. Note: It’s possible to adjust the guide pin and rout only one new mortise or tenon part and get a good fit, but on a project this would mean routing each part at different settings. Establish ideal pin height for both mortise and tenon at one pin setting.

4-22 How much adjustment is required? One eighth of a turn of the guidepin knob will change the joint glue-line fit by

0.001"[0,025mm] the tenon thickness by 0.001"[0,025mm] (half of that per side and increase the mortise width by the same amount

, i.e. turn one-eighth up; the bit will reduce

➀

➂

➁

Dimensions and angles shown here are exaggerated.

)

4-23 The FMT Pro can provide this accuracy for settings but remember, you’re working with wood and a hand-held router, with lots of movement tolerances; it’s not a computer-controlled milling machine. Nevertheless, the FMT Pro will allow you to do very precise and consistent work.

4-25 Generally we have found the best fit differential to be

0.005"[0,13mm] “loose”. Basically, the dry joint should “push” together fairly easily, but not fall apart under its own weight. If a mallet is needed, it’s too tight.

4-24 If you have a dial or digital calliper (every shop should have one) you can literally measure the tenon and mortise and adjust accordingly. Every 0.002"[0,05mm] of difference in mortise to tenon size (that’s .001"[0,025mm] on the glue line) should require one eighth of a turn; down to tighten, up to loosen.

4-26 Once you have established the guide pin setting for a specific bit/guide combination, record the setting.

For example:

⁄16"x11⁄2"[8x35mm] “up 13⁄4 turns”. Using the same

bit and guide next time, use the recorded setting for a good fit first time. Note: As with all joinery, different wood species do not necessarily rout precisely to the same fit.

■

Page 30

TURNS UP SPECIES DATE

Chapter 4 Frame Mortise & Tenon Jig User Guide

Settings Record

TURNS UP SPECIES DATE

e.g. 1/2x2 1/2 1-7/8 cherry 01/01/2017

e.g. 10x40mm 10mm 1-3/8 mahogany Jan.1, 2017

MORTISE & TENON ROUTING PROCEDURES

Hint: Photocopy or scan this page for future records.

Page 31

MORTISE & TENON ROUTING PROCEDURES

Production Procedures

Chapter 4Frame Mortise & Tenon Jig User Guide

4-27 Production Procedures When routing frame joints it is only necessary to mark and sight a single tenon and perhaps two mortises. Once the side stop fence or outriggers are set and the table sighted for one joint, any number of similar joints may be routed without marking and without removing the router from the jig. We recommend marking the finished face which goes against the clamp plate (shown here from operator view)

➀

4-28 Tenons The router is “parked” with the guide pin in near front corner of recess

. Extend sight and use only as a tenon stop ➁ when

➀

clamping successive (unmarked) tenon pieces against side stop. Retract

and rout any number of tenons without removing router. Note:

sight

➂

If you forget to retract the sight, the Sub-Base will push it out of the way as you move it rearward, but we do not recommend this.

4-29 Mortises: Sight one mortise ➀ and set a stop block at the end of the mortise board

➁

. Set

stops to prevent unintentional table movement

limit stops and

➂

limit

4-31 Successive mortises in “ladder” type construction are quick to rout. Mark all mortises on only one piece (only one needs a front-toback mark!). Sight the first mortise (cross) to set the table and mark the top of one outrigger in line with the workpiece end. Table locked, move the workpiece, sighting each successive mortise line, marking the outrigger(s). To rout, align the unmarked board ends with the outrigger marks

➀

■

4-30 Sight the second mortise by moving the mortise piece (not the table) and set the second stop block

➁

. Rout any number of successive (unmarked) mortises without removing the router from the table.

See next page for Production routing of Small Joints.

Page 32

1/4" (6mm) Mortise & Tenon Joints Using a Two Bit Combination

1/8" (3mm) Mortise & Tenon Joints Using Two Bit Combination

Chapter 4 Frame Mortise & Tenon Jig User Guide

Production Procedures for Small Joints

MORTISE & TENON ROUTING PROCEDURES

4-32 The FMT Pro is designed so that both mortise and tenon of a particular-sized joint may be routed with the same sized bit. So

if you are making say, a single frame with a

⁄4"[6mm] guide and

bit, this works very effectively. However, it is much more efficient to rout small tenons with a larger bit, and particularly useful for production routing. This involves using two bits instead of one.

1/4" (6mm) mortise bit 1/2"(12mm) tenon bit 3/8" (9mm) guide

4-34 Example: 1/4" (6mm) Mortise & Tenon Joints with a

3/8" (9mm) Guide

Using the two bits and guide shown above,

you can rout a 1/4" (6mm) mortise and tenon. The resulting joint is 1/8" (3mm) smaller than the 3/8" (9mm) guide size. Note:

Any two bit diameters that add up to twice the guide size will produce a joint size of the smaller bit.

4-33 Two Bit Combination If you want to rout many

⁄4"[6mm] mortises and tenons, the tenons can be routed much

more quickly with a

⁄2"[12mm] bit*. The Guide and Bit Selection charts in Appendix I show how different bit combinations can crank out such extraordinary joints just as quickly and precisely as larger ones, and with adjustable joint tightness.

*Note: The maximum bit diameter used on the FMT Pro is 1/2"(12mm).

3/8" Guide (9mm)

Guide Pin

3 /8

x 1

1/4" Mortise Bit (6mm)

1/2" Tenon Bit (12mm)

3 /8

x 1

Mortise

Tenon

4-35 For example: 3/8" guide x 2 = 3/4" 1/4" mortise bit + 1/2" tenon bit = 3/4"

(9mm guide x 2 = 18mm) (6mm mortise bit + 12mm tenon bit = 18mm)

Routing Joints Smaller than 1/4"

1/8" (3mm) mortise bit 3/ 8" (9mm) tenon bit

4-36

Example: 1/8" (3mm) Mortise & Tenon Joints with a

1/4" (6mm) Guide

Using the two bits and guide shown above,

1/4" (6mm) guide

you can rout a 1/8" (3mm) mortise and tenon. The resulting joint is 1/8" (3mm) smaller than the 1/4" guide size. Note: Any two

bit diameters that add up to twice the guide size will produce a joint size of the smaller bit.

Guide Pin

1/4" Guide (6mm)

Guide Pin

1/8" Mortise Bit (3mm)

3/8" Tenon Bit

4-37 For example: 1/4" guide x 2 = 1/2" 1/8" mortise bit + 3/8" tenon bit = 1/2"

(6mm guide x 2 = 12mm) (3mm mortise bit + 9mm tenon bit = 12mm)

Mortise

(9mm)

Tenon

Page 33

MORTISE & TENON ROUTING PROCEDURES

Chapter 4Frame Mortise & Tenon Jig User Guide

4-38 The tiny 1⁄32" x 3⁄32"[0,8 x 2,4mm] mortises and tenons on this

“match frame” were formed (with machine tool bits) on a

guide. The smaller than

⁄32" tenon bit is 7⁄32" larger than 1⁄4". The 1⁄32" bit is 7⁄32"

⁄4". A similar metric set: 6mm guide; 1mm mortise bit,

⁄4"x 5⁄16"

and 11mm tenon bit to produce 1mm joints. Machine tool bits as

small as 0.010" with

⁄4" shanks and similar metric are available from

machine tool suppliers.

4-40 To hold very small workpieces ➁, make up a rabbeted holder thickness, leaving a gap at Tenon Piece Piece

with the rabbet slightly shallower than the workpiece

➂

and ➈. i.e. For Tenons: Side stop ➀

➄

Holder ➂ Clamp ➃ Gap ➄. For Mortises: Mortise

➁

, Holder ➆, Clamp ➃, Gap ➈.

➅

■

4-39 For very small joints we recommend attaching a rigid piece

of ply or MDF minimum

⁄4"[20mm] to the clamp plate, using the through screw holes in the plate. This should have its own mini side stop fence attached for tenons

➀

Page 34

Chapter 4 Frame Mortise & Tenon Jig User Guide

MORTISE & TENON ROUTING PROCEDURES

Page 35

MORTISE & TENON ROUTING PROCEDURES

FMT PRO CHAPTER 5

Multiple Joints

Double In Line Joints

Twin Joints

Quadruple Joints

Triple Joints

Double In Line Joints

m IMPORTANT SAFETY NOTE

Take great care to not “trap” the bit against the side of tenon

. Do not attempt to rout center tenons in rails thicker than

rails

➀

/16"[34mm] before referring to 5-39 through 5-44.

Without using the table movement as prescribed, the bit would have to be plunged into the side of the tenon rail causing the bit to powerfully “drive” the router across the jig. This could be

dangerous and can damage the jig.

5-1 These instructions are based on the assumption that the correct joint tightness and guide pin setting has been established and that you are thoroughly familiar with the Jig’s use for single joints.

5-2 Note: The maximum dimensions for double in line joints are:

Tenon Workpiece: 15⁄16 x 51⁄2"[34x140mm]

➀➁

Tenon: 1⁄2 x 2"[12x50mm]

➂

Tenons, both Overall: 1⁄2 x 41⁄2"[12x115mm]

➃

Page 36

Chapter 5

Frame Mortise & Tenon Jig User Guide

MULTIPLE JOINTS

5-3 Mark the two mortise and tenon centers, taking care to allow space between the joints Mark the faces that go against the clamp plate

at least equal to the tenon bit diameter.

➀

➁

5-5 Sight the left hand tenon and lock the table ➀. Set and lock both Set and lock only the right hand

post

➂

limit stops against their stop post ➁.

limit stop against its

5-4 Set the sidestop fence so that the tenon piece is clamped approximately centrally on the clamp plate

➀

5-6 Unlock the table and sight the right-hand tenon ➃ and lock the table. Set and lock the left hand the post

➄

limit stop against

Release the table clamp and move the table left and right against the

stops to double-check sight alignment to the two tenons.

Retract the sight.

5-7 Move the table left and lock. Do not rout yet. While with practise it is fairly easy to avoid routing “into” the right tenon while routing the left shop-made “guard” to prevent this or plywood. Allow a and guard

. Rout the left tenon.

➂

, we recommend that beginners use a small

➀

. Use 1⁄4"[6mm] thick MDF

⁄16"[5mm] gap between the end of the guide

➁

5-8 Move the table right and lock. Lift the left end of the (stationary) router and move the “tenon guard” left hand tenon

. Repeat as required for all tenon ends, moving the

➁

. Rout the right

➀

table “guard” piece only once for each pair. Leave the table to the right. Remove and save the guard. Note: If you change the plunge height between tenons, there’s the chance of having a step in the shoulder. We recommend leaving the bit plunged.

Page 37

MULTIPLE JOINTS

Frame Mortise & Tenon Jig User Guide

Chapter 5

5-9 Extend the sight. Position and clamp the mortise piece so the right hand mortise of the first pair is centered under the sight

➀

Either mark an outrigger or set a stop block for successive mortise pieces

. Rout the right hand mortise. Note: Outriggers are

➁

referenced in Step 3-19.

5-11 Extend the sight and unclamp. Sight the left of the other pair of mortise positions

and re-clamp. To avoid re-sighting each

➀

board, mark the left hand outrigger or set a stop at the workpiece

. Rout the mortise, then move the table and rout the right

end

➁

hand mortise. The table limit stops and outrigger marks (or stops) are now set for successive workpiece mortising.

■

5-10 Move the table left and lock. Rout the left hand mortise.

Leave the table to left.

Twin Joints

5-12 Note: The maximum dimensions for twin joints are:

Tenon workpiece: 3" x 31⁄8"+[76x79+mm]

➀ ➁

Tenon size: 1⁄2" x 21⁄2"+[12x65+mm]

➂ ➃

Min. spacing: 9⁄16"[13mm]

➄

Max. distance from board edge to center of tenon: 23⁄8" [60,3mm]

➅

5-13 Mark the two tenon centers taking care to allow space between the two joints bit diameter

➁

at least slightly greater than the tenon

➀

Page 38

Chapter 5

Frame Mortise & Tenon Jig User Guide

MULTIPLE JOINTS

5-14 Approximately center the table left to right and lock ➀. Extend the sight. Clamp the tenon piece against the sidestop fence, the tenon piece lightly touching the underside of the sight.

5-16 Unlock the table and sight the front tenon ➃ and lock the table. Set and lock the rear

stop against its post ➄. Unlock the table and move the table front to back against the stops to double-check the tenon sighting.

5-15 Unlock the table, sight the rear tenon center and lock the table post post

. Set and lock both

➀

. Set and lock the front

➁

➂

limit stops against their stop

limit stop against its stop

5-17 Move the table to the rear against the stop and lock ➀. Do not rout yet. While with practise it is fairly easy to avoid routing into the front tenon beginners use a simple shop-made “guard”

⁄4"[6mm] thick MDF or plywood. Allow a 3⁄16"[5mm] gap ➃

between the side of the guide and guard. Rout the rear tenon

while routing the rear, we recommend that

➁

to prevent this. Use

➂

➄

5-18 Move the table forward and lock ➀. Lift the left end of the router and move the “tenon guard” to the rear

. Rout the front tenon ➂.

➁

Repeat as required for all tenon ends, moving the table and guard piece only once for each pair. Leave the table forward. Note: By using two or three left-right table positions, (in addition to the front-back positions), the workpiece width and tenon width may be increased to the maximum (see Chapter 6, Longer and Shorter Joints).

5-19 Mortises Extend the sight. Position and clamp the mortise piece so the left end front mortise is centered under the sight

➀

Either mark the right hand outrigger or set a stop block for successive mortise pieces

. Rout the front mortise.

➁

Page 39

MULTIPLE JOINTS

Frame Mortise & Tenon Jig User Guide

Chapter 5

5-20 Move the table back against its stop ➀ and lock. Rout the rear mortise

Quadruple Joints

. Leave the table back.

➁

5-21 Extend the sight, unclamp and move the mortise board left so that the rear mortise of the pair at the right end of the piece is centered under the sight outrigger or set a stop

➁

and re-clamp. Mark the left hand

➀

adjacent to that end of the workpiece. Rout first the rear mortise at this (right-hand) end, then move the table and rout the front mortise. The outrigger marks or stops are now set up for successive workpiece mortising.

■

5-22 The maximum dimensions for quadruple joints are: Tenon Workpiece Tenon Size

➁

Center Spacing

: 3" x 51⁄2"[70 x 140mm]

➀

: 1⁄2 x 2"[12 x 50mm]

: 11⁄2 x 21⁄2"[38 x 63mm].

➂

5-24 Center (approximately) ➀ and clamp the tenon board on the clamp plate and set the side stop fence. Note: If the tenon board does not touch the underside of the table, extend the sight to stop the board.

5-23 Tenons Mark the four tenon and mortise centers to suit your layout. Take care to leave a space between tenons slightly greater than the tenon bit diameter

➁

➀

at least

5-25 Extend the sight, release the table clamp and move the table to sight the left hand front tenon

➀

. Lock the table. Move the right hand Move the back

stop to its post and lock ➁.

stop to its post and lock ➂.

Page 40

Chapter 5

Frame Mortise & Tenon Jig User Guide

MULTIPLE JOINTS

5-26

tenon

Release and move the table to sight the rear left-hand

➀

Note: Ensure the

stop

➁

Lock the table. Move the front

post is still touching the right-hand limit

stop to its post and lock ➂.

5-27 Unlock the table and move to the rear right-hand tenon and sight

Note: ensure the

➀

post is still touching the front limit stop ➁.

Lock the table. Move the left-hand

stop to its post and lock ➂.

5-28 All four stops are now set ➀ and provided you have sym- metrically marked out the joint, moving the table to the front right-hand tenon, the sight should automatically align with that mark

. If it does not, do not change anything. Just check the

➁

other three positions; the actual joint will be symmetrical.

5-29 With practice, it is fairly easy to avoid routing into an adjoining tenon; however, we do recommend that beginners use a simple “L”-shaped shop made guard to prevent this

MDF or plywood and allow a and guard. Rout the front right tenon

⁄16"[5mm] gap between the guide

➁

. Use 1⁄4"[6mm]

➀

5-30 Move the table to the front left against the stops and lock ➀. With the “guard” at the rear-right

, rout the front-left tenon ➂.

➁

5-31 Move the table to the rear left, and lock ➀. Move the “guard” to the front-right

. Rout the rear-left tenon ➂.

➁

Page 41

MULTIPLE JOINTS

Frame Mortise & Tenon Jig User Guide

Chapter 5

5-32 Move the table to the rear right against the stops and lock ➀. Move the “guard” to the front-left

. Rout the rear-right tenon ➂.

➁

Rout all other tenon ends required. Leave the table to the rear-right.

Triple Joints

5-33 Mortises Extend the sight, position and clamp the mortise board so that the rear right mortise is centered under the sight

➀

Either mark an outrigger or set a stop-block for successive mortise boards

. Rout all four mortises in their respective positions ➂.

➁

Note: The FMT Pro vacuum port may prove ineffective on wide mortise pieces, particularly on the front mortises.

■

5-34 Because of safety considerations it is only practical to rout

triple joints with

⁄8 bits and guides or smaller.

Maximum dimensions for triple joints are: Tenon Workpiece Tenon Size Center Spacing

: 13⁄4 x 51⁄2"[44 x 140mm]

➀

: 3⁄8 x 2"[10 x 50mm]

➁

: 7⁄8 x 21⁄2"[22 x 63mm].

➂

5-36 Tenons Center (approximately) and clamp the tenon workpiece on the clamp plate

and set the side-stop fence.

➀

5-35

Mark the three tenon and mortise centers, taking care to leave a space between tenons at least slightly greater than the tenon bit diameter

5-37

Extend the sight, release the table clamp and sight the front tenon of the pair

limit stop to the post and lock ➁. Move the back

limit stop to the post and lock

➀

. Lock the table, move the right hand

➀

➂

Page 42

Chapter 5

Frame Mortise & Tenon Jig User Guide

MULTIPLE JOINTS

5-38 Release the table clamp and sight the rear tenon of the

, making sure that the right-hand

pair

➀

post

➁

stop is against its

Lock the table. Move the front

limit stop to its post and lock ➂.

5-39 Release the table clamp and move the table to sight the third (single) tenon Set and lock the left-hand

. Lock the table.

➀

limit stop to its post ➁. Cut a small

hardwood block to the following size: Width to a snug fit between the rear

1⁄2"[13mm], Depth ➃ 5⁄16"[8mm], Length ➄: Cut to length

➂

limit stop and its stop post. This

block will be used for the “third” tenon position.

5-40 Rout the left pair of tenons in the same way as for the quadruple tenons and an L-shaped guard

(see 5-30 and 5-31), using the Limit Stops ➁

➀

in the guard recess to prevent accidental

➂

routing of adjacent tenons.

m Do not attempt routing the third tenon before reading on.

5-42 So to reduce the thickness, move the table right and rearward against the stops small “guard” piece

as if to rout a quadruple tenon. Then add a

➀

to the L-shaped guard in the guide recess.

➁

Now rout away part of the workpiece

➂

5-41 m If the tenon rail is thicker than 1

⁄16"[34mm] (as is most likely with this type), then great care must be exercised not to “trap” the bit

when routing the third tenon.

➀

i.e. The bit would have to be plunged into the side of the tenon board. This could result in the bit “driving” itself across the board which could be dangerous.

5-43 Move the table forward, keeping it to the right ➀. Flip the guards to the back workpiece

➂

. Now rout away the front-right part of the

➁

Page 43

MULTIPLE JOINTS

Frame Mortise & Tenon Jig User Guide

Chapter 5

5-44 Release the table clamp. With the table to the right, against the

stop, put the small block between the rear

and its post

. You must always use the same limit stop for all

➀

stop

other third tenons and mortises. Using a guard to avoid routing, into the other two tenons

, rout the rest of the third tenon ➂.

➁

5-45 m Mortises Triple mortises are routed the opposite way around. If the single tenon is to the right

must be to the left the same side of the stop post

, and vice-versa, using the same block on

➁

➂

, the single mortise

➀

5-46 Remember, mortises are routed the opposite way around to their matching tenon, e.g. in this illustration the single tenon is to the right

, single mortise to the left ➁. Keeping the reference faces

➀

together on the finished joint will ensure that the mortises and tenons will align not do any shaping of workpieces until after the joints are routed

. It’s much easier to clamp square section workpieces so do

➂

➃

■

Page 44

Chapter 4 Frame Mortise & Tenon Jig User Guide

Chapter 5

MULTIPLE JOINTS

Page 45

MORTISE & TENON ROUTING PROCEDURES

FMT PRO CHAPTER 6

Workpiece and

Joint Options

Different Workpiece Thicknesses

Longer and Shorter Joints Thicker and Wider Boards

m IMPORTANT SAFETY NOTE

Take great care to not “trap” the bit against the side of tenon

. Do not attempt to rout center tenons in rails thicker than

rails

➀

/16"[34mm] before referring to 5-39 through 5-44.

Without using the table movement as prescribed, the bit would have to be plunged into the side of the tenon rail causing the bit to powerfully “drive” the router across the jig. This could be

dangerous and can damage the jig.

Different Workpiece Thicknesses

6-1 So far we have only illustrated joints where the mortise and tenon workpieces are the same thickness. There will be numerous times when this is not the case, as in where the tenon piece is thinner and centered on the mortise board tenon piece is deliberately off-center on the mortise piece

, and where the

➀

➁

6-2 Single or double (in-line) mortise and tenons are straight forward. Simply mount and sight and rout all the tenons as shown before front-back position before routing

, then mount and re-sight the mortises at the desired

➀

➁

Page 46

Chapter 6

Frame Mortise & Tenon Jig User Guide

WORKPIECE AND JOINT OPTIONS

6-3 Side-by-side double and quadruple joints of different stock thicknesses require a packing piece (see 6-4) between the clamp plate and tenon piece, the thickness equal to the offset of the two pieces. For example, a 2"[50mm] tenon piece mortise piece

will require a 1⁄2"[12,5mm] packing piece

➁

centered on a 3"[75mm]

➀

. m Never

➂

attempt to achieve this alignment by re-sighting the joint and resetting the

limit stops. That would make it impossible to guarantee

twin-tenon to mortise alignment.

Longer and Shorter Joints

6-4 This packing piece should include its own side-stop fence ➀ and if required frequently, should have sandpaper glued onto its outer surface for secure workpiece clamping

➁

. Sight and rout the tenons in the usual way with the packing piece in place. Then, remove the packing piece before sighting and routing the mortises.

■

6-5 The FMT Pro table movement allows for easy routing of oddsized joints. For example, you may want to rout a 3"[75mm] joint and you only have a 2"[50mm] guide

. Use this simple formula:

➀

➁

Joint, minus Guide, divided by 2.

÷ 2 =

Example: 3" - 2" Cut a small block equal to the result; in this example,

6-7 Set the between the stops and post

⁄2"[75 - 50 ÷ 2 = 12,5mm]

⁄2"[12,5mm].

stops one at a time with the small block

. This ensures that the table move-

➀➁

ment is centered about the joint center-mark on the stock. Remove the block, but save it.

6-6 Tenons Mark the center as before. Position and sight the tenon Set the

stops against the post ➁.

, and lock the table.

➀

6-8 To rout the wider tenon:

- Move the table right, to the stop

- Rout the right-hand end of the tenon

➀

➁

Use a guard in the left end of the guide recess if necessary

➂

Page 47

WORKPIECE AND JOINT OPTIONS

Frame Mortise & Tenon Jig User Guide

Chapter 6

6-9 - Move the table left to the stop ➀.

- Rout the left-hand end of the tenon

➁

If you’re using a “guard”, flip it to the right end of the recess

- Repeat for all required tenons.

➂

6-10 Mortises Release the table clamp. Use the small block between one stop and the stop post

Center a mortise piece under the sight and clamp blocks or marks on the outriggers

and lock the table clamp.

➀

. Set side-stop

➁

➂

6-11 Move the table right to the stop ➀. Rout the right-hand end of the mortise

, using the full length of the mortise guide.

➁

6-13 For mortises and tenons shorter than the guide, reverse the calculation: Guide, minus Joint, divided by 2. Example: you may want a 1"[25mm] joint

÷ 2 =

So, 2" - 1" Make a block

⁄16"[5mm] dowel ➂ to act as a guard when routing the mortises.

⁄2 [50mm - 25mm ÷ 2 = 12,5mm].

⁄2"[12,5mm]. You will also need a short length of

using 2"[50mm] guide ➁.

➀

6-12 Move the table left to its stop ➀. Rout the left-hand end of the mortise

. Repeat for all required mortises.

➁

So to recap; for joints longer than the guides:

-move the table right and rout right,

-move the table left and rout left.

6-14 Tenons Setting the block and limit stops for the shorter tenons procedure

is exactly the same as for longer tenons

➀➁

setup, except when you come to rout.

Page 48

Chapter 6

Frame Mortise & Tenon Jig User Guide

WORKPIECE AND JOINT OPTIONS

6-15 Then it is:

-Move table right; rout to the left

-Move table left; rout to the right

➀ ➁

. .

Again, use a guard in the guide recess if necessary.

6-16 Mortises The rule is the same for mortises except you will

need to use a small piece of that guide’s mortise slot

. The dowel should be slightly longer than the

➀

⁄16"[5mm] dowel as a guard in the

difference between the guide length and joint length; in this example, slightly longer than 1"[25mm]. In this example, the joint is only 1" long and the guide mortise slot is 2". So you need a guard dowel to prevent cutting a mortise longer than required.

6-17 So, for the shorter mortises:

➁

➀

Table right; dowel right; rout left side Table left; dowel left; rout right side The length of the dowel guard allows you to rout a mortise slightly shorter than required in the first cut and to clean out in the second cut.

Thicker and Wider Boards

6-19 Make this bracket to mount and mortise a wide board face, clamp pieces greater than Leigh Clamp 3" capacity, and center mortises

on boards up to 4

41⁄2"[115mm]

➀

24"[600mm]

➁

⁄8"[115mm] wide or even 63⁄8"[162mm].

43⁄4"[120mm]

➂

9"[230mm]

➃

2"[50mm]

➄

3⁄4"[20mm]

➅

6-18 To rout long vertical boards you could build a jig stand to mount on your bench. Make the stand/bench combination high enough to accept the desired board length. Bolt securely to the bench. Make a stable platform as shown here to stand on. Don’t use a folding step, these are unstable. Other novel solutions: holes in (suspended) floor; jig bolted to deck or mezzanine railing; wall brackets.

■

6-20 Use the Leigh clamps to secure the bracket to the FMT Pro clamp face and adjust the distance below the table to slightly greater than the mortise piece thickness

➀

Page 49

WORKPIECE AND JOINT OPTIONS

Frame Mortise & Tenon Jig User Guide

Chapter 6

6-21 Use C-clamps to hold the workpiece onto the bracket, with the workpiece rear edge touching the clamp plate. Now raise the bracket so the workpiece touches the underside of the table. Re-secure with the Leigh Clamps. The widest board in which a

mortise may be centered is 4 is 4"[100mm]

➁

⁄8"[115mm] ➀.The thickest capacity

6-22 Mortises in center of boards 4 5/8

to 6 ½

[115 to

165mm] ➀: Mark mortise center on a test board ➁. Using the

guide recess front edge as mortise guide the mortise in the pin track

. Control mortise length with 3⁄16"[5mm] dowel pieces

➃

(see 6-16). Note: This is not a standard Leigh

➄

solution, but we thought it would solve this rare challenge.

, adjust the table to center

➂

■

Page 50

Chapter 4 Frame Mortise & Tenon Jig User Guide

Chapter 6

WORKPIECE AND JOINT OPTIONS

Page 51

MORTISE & TENON ROUTING PROCEDURES

FMT PRO CHAPTER 7

Special Joints

Angled Joints

Through Tenons

Bridle Joints

Asymmetric Tenons

Haunched Joints

Doweling

Angled Joints

m IMPORTANT SAFETY NOTE

Take great care to not “trap” the bit against the side of tenon

. Do not attempt to rout center tenons in rails thicker than

rails

➀

/16"[34mm] before referring to 5-39 through 5-44.

Without using the table movement as prescribed, the bit would have to be plunged into the side of the tenon rail causing the bit to powerfully “drive” the router across the jig. This could be

dangerous and can damage the jig.

90˚

45˚

90˚

10˚

7-1 The majority of frame joints are at 90˚ ➀ but the ability to angle joints is essential in, for example, chair construction. Whether these joints are single angles angle

they are easily achieved on the FMT Pro.

➃

➁

45˚

10˚

and ➂ or a compound

7-2 Angling the sidestop fence gives a single angled joint in the left-right direction.

Page 52

Chapter 7

Frame Mortise & Tenon Jig User Guide

SPECIAL JOINTS

7-3 Angling the clamp plate with vertical sidestops also gives a single angled joint in the front-back direction.

7-5 The FMT Pro clamp plate can be angled up to 30˚ but it is doubtful you will ever need to approach even 10˚ on a mortise and tenon joint. The strength of a tenon across its grain lessens considerably as the angle increases

. In addition, the length and position of

➀

the tenon is limited in slope by the angled workpiece relative to the vertical bit

(angle demonstrated in this illustration is excessive.)

➁

7-4 Angling both fence and clamp plate give a double, or compound angled joint.

7-6 However, you may for example, want to machine spline mortises or dowel holes in a stave type construction in, say, octa-

gons at 22

⁄2˚, or hexagons at 30˚, so the 30˚ capacity may prove to be useful. You can then machine precisely fitting splines on the FMT Pro and trim them to length.

■

Through Tenons

7-7 Through Tenons Occasionally, a design feature will call for through, exposed tenons, possibly “wedged” for decorative effect. The limited depth of cut of router bits can make this difficult, but the two-sized bit technique described previously, combined with the precision of the FMT Pro, makes this procedure perfectly feasible in many instances.

7-8

relative to the cutting depth and diameter of the bit. the left-right part of the joint center mark

The problem with through mortises is their great depth

However, if

is carefully squared

➀

around the mortise workpiece, it is possible to accurately plunge from both sides.

Page 53

SPECIAL JOINTS

Frame Mortise & Tenon Jig User Guide

Chapter 7

7-9 Here’s an example.

⁄4"[6mm] joint through 11⁄2"[35mm] deep mortise.

⁄4"[6mm] bit for mortises ➀.

Select

⁄2"[10mm] bit to rout the 11⁄2"[35mm] long tenon ➁.

Select

⁄8"[8mm] guide ➂ for length from the guide/bit selection

Select chart in Appendix I.

7-11 Turn the mortise piece end for end and, keeping the same reference side of the mortise board to the clamp face, carefully

sight the “vertical” mortise center mark

and lock the table .

➁

Plunge and rout to clear the through mortise.

7-10 Carefully sight the mortise taking particular care to center the “vertical” line

in the sight. Plunge and rout down deeper

➀

than half the mortise board depth.

7-12 Rout the tenons with the larger (longer) bit slightly deeper than the mortise depth.

7-13 It may even be possible to make tenons long enough to be raised if this decorative effect is desired. “Wedging” the tenons is a simple hand procedure and a nice decorative touch.

7-14 If the tenon stock is smaller than the table opening it may be possible (after sighting) to slide the tenon workpiece up to

almost touch the router base and thereby gain an extra

⁄2"[10mm] of tenon length. Assuming of course that the bit has sufficient cutting depth.

■

Page 54

Chapter 7

Bridle Joints

Frame Mortise & Tenon Jig User Guide

MORTISE

SPECIAL JOINTS

7-15 Routing bridle joints on the FMT Pro is simple. All the workpieces (with the exception of the mitered tenon)

are mounted

➀

vertically on the jig.

7-17 The mitered “tenon” is mounted at 45˚ on the clamp plate ➀. The “mortise” end miter

is cut on the table saw after routing

➁

the mortise.

TENON

7-16 Select a guide that is greater in length than the workpiece width “vertical mortise”

by at least two bit diameters. Rout right through the

➀

and across the tenon sides ➂. The bit will

➁

clear the edge of the workpiece before the guide pin reaches the rounded part of the guide.

7-18 Twin bridle joints use the technique described above combined with the table movement

(see 5-12, Twin Joints).

➀

7-19 Floating Tenons A “floating” tenon in a mitered corner allows for a greater joint glue area at the inside of the corner. On this mitred corner, the workpieces are mounted in the jig at 45˚ and the mortises routed. The floating tenon

is routed on the

➀

end of a vertically mounted scrap piece using the same guide and then sawn off.

■

Page 55

SPECIAL JOINTS

Asymmetric Tenons

Frame Mortise & Tenon Jig User Guide

Chapter 7

7-20 Asymmetric Tenons Not all tenons are centered on the long axis of the workpiece end

. This means that tenons “A”

➀

are routed at one table sighting and tenons “B” at a second table sighting. If you don’t, the two tenons will be diagonally opposed to each other

➁

7-22 …sight tenon “B” and set the left-hand limit stop to the left of the post

. Now alternately rout tenons “A” and “B”, moving

➀

the table left and right each time.

7-21 Use the

limit stops for rapid changeover from tenons “A” to tenons “B”. For example, with the workpiece centered on the jig, sight tenon “A” and set the right-hand limit stop to the right of the post

➀

then…

7-23 Of course, if you don’t trust yourself to get the sequence correct, you could rout all the “A” tenons first, then change the table one time to rout all the “B” tenons. This latter procedure would be the simplest way to rout haunched tenons (see next section).

■

Haunched Joints

7-24 Haunched Joints Frame and panel door construction can call for rails and stiles to be grooved for the panel haunched

, both for joint stability and to fill the end of the stile

➁

groove which is sometimes run right through mon as it once was. Routers and router tables now make it simple to have a stopped groove

, avoiding the need for the haunch.

➃

, and the tenons

➀

. This is not as com-

➂

7-25 Haunched mortises and tenons are “handed”, and require separate setups for each. e.g. if these two tenons the same jig setup, the result would be offset tenons

were routed with

➀

. So mark

➁

out the two types of corners as “A” and “B” mortises and tenons.

Page 56

Chapter 7

Frame Mortise & Tenon Jig User Guide

SPECIAL JOINTS

7-26 First, groove all the workpieces ➀. The groove should be less than the mortise width than the haunch recess

➂

and shallower

➁

7-28 “A” Mortises and Haunch Recesses Set right-hand

Limit Stop from the post, say, 3 quarters guide length ➀: e.g. 1"

guide, move full depth

⁄4". Table still in “mortise center” position, rout mortise

. Raise the plunge. Move table left to the stop ➂. Lower the

➁

bit to haunch depth; set router depth turret. The router is now set for both depths of cut. Rout haunch recess

. Repeat for all “A” mortises.

➃

7-27 Sight both the “A” and “B” mortises. Set stops or mark the outrigger for repeatable successive workpieces. Position and lock the

Limit Stops against the post.

3 4

7-29 “B” Mortises and Haunch Recesses Move the table left to touch the right-hand and lock the table. Move the left-hand quarters of the guide length) to the left and haunch recesses

using the table movement and the same

➃

Limit Stop against the post ➀

Limit Stop (by three

. Rout the “B” mortises ➂

➁

router depth settings.

7-30 Routing the Tenons Mark the tenon centers “A” and “B”. Remember, the tenons are “off center” and each end of the tenon pieces are marked off center in opposite directions. Prepare and make

a couple of extra (scrap) tenon pieces to use in setting haunch bit depth later.

7-31 “A” tenons. With the workpiece centered on the jig, sight the tenon center and set the right hand the post

➀

limit stop to

Page 57

SPECIAL JOINTS

Frame Mortise & Tenon Jig User Guide

Chapter 7

7-32 Move the table right to a position where the bit will clear the end of the haunch part of the guide Set the left hand

while the guide pin is still on the straight

➀

➁

limit stop to its post ➂.

7-34 Move the guard to the left end of the recess. Move the table right and rout the rest of the tenon “A” at full depth; the bit prevented from rounding the haunch off at against the guide side at

➁

by the guide pin

➀

7-33 Move the table to the left again and if necessary, set a “guard” piece in the guide recess end of the tenon

. Rout the left end of the tenon (shaded area)

➁

to prevent routing around the right

➀

at full shoulder depth.

7-35 Move the table left, remove the guard from the bit recess.

Depth: You will have to preset the plunge router depth-of-cut rod and turret so that the routed haunch exactly equals the depth of the haunch recess

. Use the scrap test tenons to achieve this

➀

setting by measurement and a little trial and error. Now rout completely around the actual tenon.

1 2

4 5

7-36 Tenons “B” on the other end are routed with the procedure reversed.

■

Page 58

Doweling

Chapter 7

Frame Mortise & Tenon Jig User Guide

SPECIAL JOINTS

7-37 Doweling Sometimes where the strength of a mortise and tenon is not required, doweling may be a suitable alternative. A bonus use of the FMT Pro is its ability to provide very precise dowel hole boring. Turn the left hand guide pin down to “zero free play” in the mortise guide slot. Simply use one or both ends of a mortise guide slot for positioning while plunging the dowel holes, or...

7-38 ...make up your own row of dowel hole guide holes in a piece of plywood or MDF which can be retained in the guide recess with small flat head screws, using the four countersunk holes through the table. Make this auxiliary “guide” dimensions:

⁄32➀ x 33⁄4➁[105 x 95mm]. Don’t forget, you can use the table

4 movement and limit stops to double or quadruple the number of hole positions in the ends or side edges of boards; all precisely indexed to each other.

■

Page 59

JOINT SPECIFICATIONS, GUIDE & BIT SELECTION

FMT PRO Appendix I

Joint Specifications,

Guide & Bit Selection

Foreword The illustrations and specifications in this Appendix show the largest tenon rail and tenon sizes possible

on the FMT Pro, either in one table position or multiple table positions as noted. For all smaller sizes, refer to the guide and bit selection chart.

Joint Specifications

A1-1 Joint Terminology The tenon sides are the “Cheeks” ➀. The tenon shoulders are called (luckily) the “Shoulders”

➁

. Unfortunately, references to dimensions of mortises and tenons do not share matching terminology, so... Long or short tenons

fit into deep or shallow mortises ➃.

➂

Tenon Length = Mortise Depth.

A1-3

Thick or thin tenons ➆ fit into wide or narrow mortises ➇.

Tenon Thickness = Mortise Width.

A1-2

Wide or narrow tenons ➄ fit into long or short mortis-

➅

Tenon Width = Mortise Length.

A1-4 Largest Single Rail and Tenon

Using One Table Position with

Workpiece thickness 15⁄16"[34mm]

➀

Workpiece width 31⁄8" [80mm]

➁

Tenon thickness 1⁄2" [12mm]

➂

Tenon width 21⁄2"[65mm]

➃

Note: To rout single tenons in stock thicker than 1

⁄2" Bit

⁄16"[34mm] would require the bit to be plunged into the edge of the workpiece and so “trapping” the bit. That could be dangerous, so follow the “Third Tenon” procedure (see 5-39 through 5-44).

Page 60

Appendix I Frame Mortise & Tenon Jig User Guide

JOINT SPECIFICATIONS, GUIDE & BIT SELECTION

A1-5 Largest Single Rail and Tenon -

Workpiece 1

Tenon Guide

*Note: Using three table positions, tenon width

⁄16" x 51⁄2"[34 x 140mm] ➀.

⁄2" x 41⁄2"*[12 x 115mm] ➁.

⁄2" x 21⁄2"[12 x 65mm].

➂

Two Table Positions.

may be up to 5"[125mm]

A1-6 Largest Tandem Double Tenon -

Workpiece 1 Tenons Guide

⁄16" x 51⁄2"[34 x 140mm] ➀.

⁄2" x 2"[12 x 50mm] ➁.

⁄2" x 2"[12 x 50mm].

Two Table Positions.

A1-7 Largest Side-by-Side Twin Tenon -

Workpiece 3" x 5 Tenons

Guide

⁄2"[76 x 140mm] ➀.

⁄2" x 21⁄2

⁄2" x 21⁄2"[12 x 65mm].

"[12 x 65+mm]

Two* Table Positions.

➁

*Note: Add left-right table positions to the two front-back settings, for maximum workpiece and tenons extension. See A1-5

A1-9 Largest Triple Tenon -

Workpiece 1 Tenons Guide

⁄4 x 51⁄2"[44 x 140mm] ➀.

⁄8" x 2"[10 x 50mm] ➁.

⁄8" x 2"[10 x 50mm].

Five* Table Positions.

*Note: To avoid “trapping” the bit on larger workpieces it is necessary to rout the third tenon in three different

table positions. See

Chapter 5, Triple Joints.

A1-8 Largest Quadruple Tenon -

Workpiece 3" x 5 Tenons

Guide

⁄2"[76 x 140mm] ➀.

⁄2" x 2"[12 x 50mm] ➁.

⁄2" x 2"[12 x 50mm].

Four table positions.

A1-10 Thickest Mortise Board and Mortise Centers –

table positions

Thickness 3"[75mm]

4 Mortises 2 Mortises Spacing

⁄2" x 2"[12 x 50mm] ➁.

⁄2" x 41⁄2"[12 x 115mm] ➂.

⁄16" to 1"[13 x 26mm] ➃.

➀

Board Width Clamping Capacity: 5"[128mm].

Four

Page 61

JOINT SPECIFICATIONS, GUIDE & BIT SELECTION

Appendix IFrame Mortise & Tenon Jig User Guide

A1-11 Maximum Mortise Board Width and Thickness for Mortising to Center

Width up to 45⁄8"[115mm] ➀. Thickness up to 4"[100mm]

➁

Note: See 6-21 mounting instructions for these pieces.

Guide and Bit Selection

A1-12 Maximum Width Mortise Board for Mortising to Center

Width from 45⁄8"[115mm]

up to 6 See 6-22 for special instructions.

⁄2"[165mm]

➀

■

Guide and Bit Selection

Use the following charts to select appropriate guide and bit combinations.

➔

Page 62

Appendix I Frame Mortise & Tenon Jig User Guide

Directions: Joints routed with a single bit are shown shaded. In addition to the joint sizes listed in the charts, any tenon width (mortise length) can easily be achieved by using the jig’s quick-acting table movement and limit stops as described in Chapter 6, Longer and Shorter Joints. By using combinations of machine tool bits, even more sizes of small and miniature joints may be routed. See information on small joints in Chapter 4.

INCH GUIDE AND BIT SELECTION CHART

JOINT SPECIFICATIONS, GUIDE & BIT SELECTION

JOINT

SIZE

1/16" x 1/8"

1/16" x 3/16"

1/16" x 5/16"

1/16" x 7/16"

1/16" x 9/16"

1/16" x 13/16"

1/16" x 1-1/16"

1/16" x 1-5/16"

1/8" x 3/16"

1/8" x 1/4"

1/8" x 5/16"

1/8" x 3/8"

1/8" x 1/2"

1/8" x 9/16"

1/8" x 5/8"

1/8" x 13/16"

1/8" x 7/8"

1/8" x 1-1/16"

1/8" x 1-1/8"

1/8" x 1-5/16"

1/8" x 1-3/8"

3/16" x 1/4"

3/16" x 5/16"

3/16" x 3/8"

3/16" x 7/16"

3/16" x 9/16"

3/16" x 5/8"

3/16" x 11/16"

3/16" x 7/8"

3/16" x 15/16"

3/16" x 1-1/8"

3/16" x 1-3/16"

3/16" x 1-3/8"

3/16" x 1-7/16"

MORTISE

BIT

1/16

1/8

3/16

TENON

BIT

7/16

3/8

1/2

3/8

1/2

3/8

1/2

3/8

1/2

3/8

1/2

3/8

5/16

7/16

5/16

7/16

5/16

7/16

5/16

7/16

5/16

7/16

5/16

GUIDE

SIZE

1/4" x 5/16"

1/4" x 3/8"

1/4" x 1/2"

1/4" x 5/8"

1/4" x 3/4"

1/4" x 1"

1/4" x 1-1/4"

1/4" x 1-1/2"

1/4" x 5/16"

1/4" x 3/8"

5/16" x 1/2"

1/4" x 1/2"

1/4" x 5/8"

5/16" x 3/4"

1/4" x 3/4"

5/16" x 1"

1/4" x 1"

5/16" x 1-1/4"

1/4" x 1-1/4"

5/16" x 1-1/2"

1/4" x 1-1/2"

1/4" x 5/16"

1/4" x 3/8"

5/16" x 1/2"

1/4" x 1/2"

1/4" x 5/8"

5/16" x 3/4"

1/4" x 3/4"

5/16" x 1"

1/4" x 1"

5/16" x 1-1/4"

1/4" x 1-1/4"

5/16" x 1-1/2"

1/4" x 1-1/2"

JOINT

SIZE

1/4" x 5/16"

1/4" x 3/8"

1/4" x 7/16"

1/4" x 1/2"

1/4" x 5/8"

1/4" x 11/16"

1/4" x 3/4"

1/4" x 7/8"

1/4" x 15/16"

1/4" x 1"

1/4" x 1-3/16"

1/4" x 1-1/4"

1/4" x 1-3/8"

1/4" x 1-7/16"

1/4" x 1-1/2"

1/4" x 1-7/8"

1/4" x 2-3/8"

5/16" x 1/2"

5/16" x 3/4"

5/16" x 15/16"

5/16" x 1"

5/16" x 1-1/4"

5/16" x 1-7/16"

5/16" x 1-1/2"

5/16" x 1-15/16"

5/16" x 2-7/16"

3/8" x 1"

3/8" x 1-1/2"

3/8" x 2"

3/8" x 2-1/2"

1/2" x 1"

1/2" x 1-1/2"

1/2" x 2"

1/2" x 2-1/2"

MORTISE

BIT

1/4

5/16

3/8

1/2

TENON

BIT

1/4

3/8

1/4

3/8

1/4

1/2

3/8

1/4

3/8

1/4

1/2

3/8

1/4

1/2

5/16

7/16

5/16

7/16

5/16

7/16

3/8

1/2

GUIDE

SIZE

1/4" x 5/16"

1/4" x 3/8"

5/16" x 1/2"

1/4" x 1/2"

1/4" x 5/8"

5/16" x 3/4"

1/4" x 3/4"

3/8" x 1"

5/16" x 1"

1/4" x 1"

5/16" x 1-1/4"

1/4" x 1-1/4"

3/8" x 1-1/2"

5/16" x 1-1/2"

1/4" x 1-1/2"

3/8" x 2"

3/8" x 2-1/2"

5/16" x 1/2"

5/16" x 3/4"

3/8" x 1"

5/16" x 1"

5/16" x 1-1/4"

3/8" x 1-1/2"

5/16" x 1-1/2"

3/8" x 2"

3/8" x 2-1/2"

3/8" x 1"

3/8" x 1-1/2"

3/8" x 2"

3/8" x 2-1/2"

1/2" x 1"

1/2" x 1-1/2"

1/2" x 2"

1/2" x 2-1/2"

LEIGH BIT ITEM NO.

HSS Solid Carbide Mortise Size HSS Solid Carbide Shank Spiral Upcut Spiral Upcut Cutting Diameter Cutting Depth Cutting Depth Diameter

162 N/A 1/16" 3/16" - 1/4"

164 164C 1/8" 3/8" 1/2" 1/4"

166 166C 3/16" 5/8" 3/4" 1/4"

168 168C 1/4" 1" 1-1/8" 1/4"

170-500 170-500C 5/16" 1" 1-1/4" 1/2"

173-500 173-500C 3/8" 1-1/4" 1-1/4" 1/2"

177 177C 7/16" 1-3/4" 1-3/4" 1/2"

180 180CL 1/2" 1-1/2" 2-1/8" 1/2"

INCH BIT SPECIFICATIONS

Page 63

JOINT SPECIFICATIONS, GUIDE & BIT SELECTION

METRIC GUIDE AND BIT SELECTION CHART

Appendix IFrame Mortise & Tenon Jig User Guide

JOINT

SIZE

2 x 4

2 x 6

2 x 11

2 x 16

2 x 21

2 x 26

2 x 31

2 x 36

3 x 5

3 x 7

3 x 12

3 x 17

3 x 22

3 x 27

3 x 32

3 x 37

4 x 6

4 x 8

4 x 11

4 x 13

4 x 16

4 x 18

4 x 21

4 x 23

4 x 26

4 x 28

4 x 31

4 x 33

4 x 36

4 x 38

5 x 7

5 x 9

5 x 14

5 x 19

5 x 24

5 x 29

5 x 34

5 x 39

MOR

TISE

BIT

TENON

BIT

GUIDE

SIZE

6 x 8

6 x 10

6 x 15

6 x 20

6 x 25

6 x 30

6 x 35

6 x 40

6 x 8

6 x 10

6 x 15

6 x 20

6 x 25

6 x 30

6 x 35

6 x 40

6 x 8

6 x 10

8 x 15

6 x 15

8 x 20

6 x 20

8 x 25

6 x 25

8 x 30

6 x 30

8 x 35

6 x 35

8 x 40

6 x 40

6 x 8

6 x 10

6 x 15

6 x 20

6 x 25

6 x 30

6 x 35

6 x 40

JOINT

SIZE

6 x 8

6 x 10

6 x 13

6 x 15

6 x 18

6 x 20

6 x 23

6 x 25

6 x 28

6 x 30

6 x 33

6 x 35

6 x 38

6 x 40

7 x 14

7 x 19

7 x 24

7 x 29

7 x 34

7 x 39

8 x 15

8 x 20

8 x 23

8 x 25

8 x 30

8 x 33

8 x 35

8 x 40

8 x 43

8 x 53

8 x 63

10 x 25

10 x 35

10 x 45

10 x 55

10 x 65

12 x 25

12 x

12 x 45

12 x 55

12 x 65

MORTISE

BIT

TENON

BIT

GUIDE

SIZE

6 x 8

6 x 10

8 x 15

6 x 15

8 x 20

6 x 20

8 x 25

6 x 25

8 x 30

6 x 30

8 x 35

6 x 35

8 x 40

6 x 40

8 x 15

8 x 20

8 x 25

8 x 30

8 x 35

8 x 40

8 x 15

8 x 20

10 x 25

8 x 25

8 x 30

10 x 35

8 x 35

8 x 40

10 x 45

10 x 55

10 x 65

10 x 25

10 x 35

10 x 45

10 x 55

10 x 65

12 x 25

12 x 35

12 x 45

12 x 55

12 x 65

METRIC BIT SPECIFICATIONS

Important Note: Due to limited availability of metric bits in North America, Leigh does not stock

or sell metric bits. Contact the national Leigh distributor or local supplier in your region.

Page 64

Appendix I Frame Mortise & Tenon Jig User Guide

JOINT SPECIFICATIONS, GUIDE & BIT SELECTION

Page 65

JIG ADJUSTMENTS

FMT PRO Appendix II

Jig Adjustments

90˚

A2-1 Clamp Plate The Clamp Plate is factory set square to the table

. However, this does not guarantee perfectly in-line

➀

joints. If your router shaft and bit are not perpendicular to the router sub-base and the Leigh Sub-Base, then the bit will not be square to the Jig Table (nor parallel to the Clamp Plate). This will cause a tiny “step” in the joint alignment

. This is because the

➁

tenon center mark is now offset from the mortise center mark in the assembled joint

. For clarity, the angle and step in this example

➂

is highly exaggerated.

A2-2

Check your test joints for alignment with a straightedge.

The cross represents the inside face toward the clamp face. The left example shows the clamp plate should be adjusted in toward the jig body plate should be adjusted away from the jig body

. The right example shows the clamp

➀

. Test and

➁

adjust the Clamp Plate angle (see A2-3) until the workpieces are in the same plane, with no joint misalignment.

A2-3 The adjusting screw for setting the clamp plate is in the lower center of the plate. Loosen the quadrant knobs. Use the hex screwdriver to turn the screw counterclockwise to move the plate

. Turn the screw clockwise to move the plate out ➁. The screw

➀

is treated with Loctite™ to prevent accidental rotation. When the clamp plate is square, re-zero the angle indicator if necessary

➂

A2-4 Joint Alignment

The Clamp Plate is precision-set parallel

to the table at the factory and should never need attention. However,

if it should need adjustment, here’s how. First, loosen the two quadrant knobs and tilt the Clamp Plate up approximately 1/4" and re-tighten the knobs. Then slightly loosen the three screws holding the right end quadrant using the square drive screwdriver turn the setscrew in this hole Clamp Plate in toward the jig then tighten the quadrant screws

clockwise to move the right end of the

➁

; counterclockwise to move it out ➃,

➂

. The adjusting screw is 28 pitch;

➀

. Use the hex driver to

➀

one turn is 0.036"[,9mm]. That’s a lot. If adjustment is ever necessary it will likely be a small fraction of a turn.

Page 66

Appendix II Frame Mortise & Tenon Jig User Guide

JIG ADJUSTMENTS

A2-5 Table Clamp Setting

The setting for this is factory pre-set

using a torque tool. Should you need to adjust the pressure, lock the table and lightly tighten the two clamp screws equally

➀

. Do not adjust these screws with the table unlocked. You should be able to work the table lock lever with quite light pressure. When locked, it should not be possible to move the table with firm side to side hand and arm pressure. When unlocked, it should be easy to position the table without sticking. The screws are treated with Loctite™ to prevent accidental rotation.

A2-7 Jig Maintenance

Very little maintenance is required. Fine dust build-up in the front and rear sight stops should be removed from time to time. The end of the small hex key or a piece of wire will do the trick. At the front position at

. Dusting off with compressed air (if available) will

➁

and with the sight to the rear

➀

keep the jig clean.

A2-6 Sight Position

The sight position is factory set. If you ever need to reset it here’s how. Clamp a straight vertical rail that projects through the table bit opening four small hex cap screws that hold the two sight rails

. Slightly loosen the

➀

using

➁

the provided hex key. Move the table forward until the rear edge of the bit opening the table. Pull the sight and rails against the wood piece

firmly touches the vertical rail ➀, and lock

➂

; at the

➃

same time centring the rear end of the sight in the recess. Tighten the four screws.

A2-8 The sidestop fence is squared at the factory, but check your first test joints. If your router/bit is not perfectly perpendicular to the table adjust the sidestop fence: slightly loosen the 'pivot' screw screw

. Adjust the angle ➂ to match the bit and retighten. Rout test

➁

and the 'lock'

➀

joints to confirm correct setting. Once locked in this position it should never need adjusting when used with that same router.

■

Page 67

CUSTOMER SUPPORT

FMT PRO Appendix III

FMT Pro Parts List

Foreword See the following pages for part drawings and part numbers. Please call Leigh to order parts.

Page 68

Appendix III Frame Mortise & Tenon Jig User Guide

QUANTITY PART NO. PER JIG PART DESCRIPTION

311 2 1/2" x 3" Compression Springs 371 4 1/4" x 7/8" x .031" Nylon Washers 371R 2 9/32" x 7/8" x .016" Nylon Washers 501 3 8-32 x 3/8" Square Socket No.2 Robertson

5100 2 Sub-Base Fence Rods 8.453" long, 7mm dia. 5130 2 M6x14mm Hex Socket Button Hd Cap Screws (for Festool) 6001 1 LH End Housing 6006 1 RH End Housing 6011 1 Top Extrusion 6015 1 Bottom Extrusion 6020 3 10 x 1-1/4" Self tapping No.2 Robertson Oval Hd Screws 6030 6 1/4 - 20 Hex Nuts (for Quadrant Knobs & Jig Hold-down) 6040 2 Limit Stop Posts 6050 1 Angle Indicator Decal 6055 1 UHMW Strip Long 6056 3 UHMW Strip Short 6060 4 1/4-20 x 1" Flat Hd Machine Screws (Jig Hold-down)

CUSTOMER SUPPORT

6101 1 Clamp Plate 6106 1 Vacuum Box 6107 1 Vacuum Box Swivel 6108 1 Vacuum Hose Adaptor – Small 6109 1 Vacuum Hose Adaptor – Large 6110 1 LH Quadrant 6115 1 RH Quadrant 6120 2 Quadrant Bushings 6125 3 Hex Socket Flat Point Set Screws 1/4-28 x 3/8" 6130 2 Outrigger Bars 6135 1 Quadrant Angle Indicator 6140 8 6-32 x 3/8" Hex Socket Button Hd Screws 6145 3 10 x 1-1/4" Self Tapping No.2 Robertson SQ Drive Pan Hd Screws 6155 5 Hex Socket Flat Point Set Screw 1/4-28 X 5/8" 6166A Side Stop Fence Assembly complete 6027 1 Washer - 3mm 6166 1 Side Stop Fence Body 6171 1 Side Stop Squaring Block 6191 1 T-Bolt 6199 2 Washers 6410 2 10-24 x 3/8" Hex Socket Button Hd Cap Screw 9530 1 Lever 6410 4 10-24 x 3/8" Hex Socket Button Hd Cap Screws (for attaching vacuum box) 6195 8 8-32 x 3/4" Flat Hd Machine Screws (for Outrigger & Low Shim Spacers) 6196 4 8-32 Hex Nuts (for Outriggers) 6200 2 Clamp T-Bolts 3/8"-16 6205 3 3/8" x 3/4" x .062" Nylon Flat Washers 6210 2 3/8-16 Clamp T-Bolt Brass nuts 6220 2 Clamp Arm 6225 2 Clamp Arm Heel Pads 6230 2 Clamp Arm Toe Pads 6235 2 Clamp Swivel Pads 6240 2 Clamp Lifters 6245 2 Clamp Lifter Springs 7025 2 Quadrant Knobs 7145 8 10 x 1-1/4" Self Tapping No.2 Robertson SQ Drive Pan Hd Screws 7225R 1 Top Extrusion Stop Post Screw 801-375 2 Cam-Action Speed Clamps 802-375 2 Speed Clamp Step Washers

Page 69

CUSTOMER SUPPORT

6335 6330 6320 6300

6310 6315 6056 6040

6335 6310 6315

6315 6310

Appendix IIIFrame Mortise & Tenon Jig User Guide

6001

6050 371R 371

7025

7145

6325 6315 6310

6055 6056 6040 6011

371 6415 6420 6455 6205

6108

6015 6030

7225R 6445

6400 6406

501

6325

371 6415 6425 6407

6056

6107 6410 6106

6405 6410

6006

6120 6115 6145

6030

6109

6060

6140 6135

6110

6020

6125

6155

6125

6101

Page 70

Appendix III Frame Mortise & Tenon Jig User Guide

QUANTITY PART NO. PER JIG PART DESCRIPTION

6300 1 Intermediate Plate Assembly c/w pressed-in Pins 6310 4 pairs Wedge Blocks 6315 4 Wedge Block Compression Springs 6320 4 Limit Stops 6325 4 Limit Stop Nuts 6330 4 10-24 x 3/8" Hex Socket Nyloc Flat Hd Machine Screws 6335 2 UHMW Glides

6400 1 Table Clamp Rod 6405 1 Table Clamp Handle 6406 1 Clamp Handle Sleeve - Lower 6407 1 Clamp Handle Sleeve - Upper 6410 6 10-24 x 3/8" Hex Socket Button Hd Cap Screw 6415 2 "Pull Down" Clamp Block 6420 1 LH "Push-Up" Clamp Sleeve 6425 1 RH "Push-Up" Clamp Sleeve 6430 2 Hex Socket Hd Shoulder Screws 1/4" x 3/4" (10-24) 6435 2 1/4" Flat Washers SS 6440 2 1/4" Fiber Washers 6445 1 5/32" x 1" Spring Pin 6455 1 Snap Ring 3/8" x .035" thick

CUSTOMER SUPPORT

6500 1 Table Plate Assembly c/w Decals & Teflon Pads 6505 1 Sight 6510 1 LH Sight Rail 6515 1 RH Sight Rail 6530 2 Sight Rail Spring Detents 6535 1 RH Guide Pin "Track" 6540 4 Teflon Decal Pads 6550 1 Guide Latch 6555 1 Guide Latch Spring

6600 1 Sub-Base Plate Assembly c/w Decals & Teflon Pads 6605 1 LH Teflon Pad 6611 2 Teflon Discs 6615 2 Guide Pins 6620 2 Guide Pin Bushes 6625 2 Guide Pin Knobs 6626 2 Guide Pin Height Washers 6630 2 O-rings 4.5mm I.D. x 1mm 6633 2 O-rings 7.0mm I.D. x 1mm 6635 4 Sub-Base U-posts ( includes screws 6155 and 6195) 6640 4 "Low" Shim-Spacers 6645 4 "High" Shim-Spacers 6655 4 8-32 x 1" No.2 Sq Dr Flat Hd Machine Screws (for High-Shims) 6660 1 Sub-Base Handle 6665 1 "INCH" Mandrel (1/4" and 1/2") 6670 1 "METRIC" Mandrel (8mm and 12mm)

Page 71

CUSTOMER SUPPORT

6155 6635 5100 6640 6645

6140 6625 6626 6615 6633 6630 6620

6200

6205 6210

311

6240

6230 6245 6225

Appendix IIIFrame Mortise & Tenon Jig User Guide

6220

6235

802-375 801-375

6600

6660

6605

501

6430 6435 6440

6540 6140 6550 6555 6500

6140 6505 6510 6530

6195 6655

6515

6530 6320 6330

6410

6611

6540 6535

6540

6665 6670

170-500

5130

6196

6700

6191 6171

6166 6027 9530

6199

6410

6166A

6130 6195

670508 670512

670516

670520

670524

FMT-M "Metric" Guides

6325

550

3156

6905

680815 680820

680825

680830

680835

680840

Page 72

Appendix III Frame Mortise & Tenon Jig User Guide

QUANTITY PART NO. PER JIG PART DESCRIPTION

670508 1 5/16" x 1/2" Template Guide 670512 1 5/16" x 3/4" Template Guide 670516 1 5/16" x 1" Template Guide 670520 1 5/16" x 1-1/4" Template Guide 670524 1 5/16" x 1-1/2" Template Guide

FMT Pro-M Metric Guides 680815 1 8 mm x 15 mm Template Guide 680820 1 8 mm x 20 mm Template Guide 680825 1 8 mm x 25 mm Template Guide 680830 1 8 mm x 30 mm Template Guide 680835 1 8 mm x 35 mm Template Guide 680840 1 8 mm x 40 mm Template Guide

6700 1 Template Guide Stand

CUSTOMER SUPPORT

6900 1 User Guide, Fully illustrated, English 6950 1 DVD Video, Instructional, English 6905 1 Leigh 1/8" Ball End Hex Screwdriver 3156 1 5/64" Hex Key (for No.6 Button Hd) 550 1 Leigh No.2 Robertson Screwdriver 170-500 1 5/16" dia. x 1/2" Shank HSS Spiral Upcut Bit

GUIDES 6700

6900

6950

6905

3156 550 170-500

Page 73

CUSTOMER SUPPORT

FMT PRO Appendix IV

Customer Support

Our Commitment to You Leigh Industries takes pride in its commitment to providing excellence in customer service and support. This

user guide is designed to provide you with the answers to any questions you have. However, if you require assistance, please feel free to contact our technical support staff or a distributor listed below.

Manufacturer: Canada/USA

NOTE:

TEL/FAX

Customer Service and Technical Support

800-663-8932

604-464-2700 (Tel.) 604 464-7404 (Fax.)

Distributors

(Canada/USA)

EMAIL/WEB

Customer Service

[email protected]

Technical Support

[email protected]

Website

www.leighjigs.com

Email can be useful, but

technical queries usually raise queries from us. A phone call is the quickest and most convenient way to get queries answered, either directly to Leigh (toll free in N. America) or to your national distributor.

–Thanks!

MAILING ADDRESS

Leigh Industries Ltd.

P.O. Box 357

Port Coquitlam, B.C.

Canada V3C 4K6

LOCATION

Leigh Industries Ltd.

1615 Industrial Ave.

Port Coquitlam, B.C.

Canada V3C 6M9

AUSTRALIA & NEW ZEALAND

Maxis Distribution 128 Ingleston Rd., Wakerley, Qld., 4154 Australia Tel: 1300 767 366 Tel (Int.) +61 7 3292 0392 Email: [email protected] Web: www.maxis.com.au

CHINA

Harvey Industries Co., Ltd. 68-10 Suyuan Avenue Jiangning District Nanjing 211100, China Tel: (0)86 5792 8869 / 5792 8021 Fax: (0)86 5792 8826 Email: [email protected] Website: www.harveyworks.cn

FRANCE

Ets Bordet 23 Rue Traversiere 93556 Montreuil Cedex, France Tel: 01 48 58 28 39 Fax: 01 48 58 48 58 Email: [email protected] Web: www.bordet.fr

GERMANY, AUSTRIA & SWITZERLAND

Hacker GmbH Holzbearbeitungsmaschinen Traberhofstraße 103 D-83026 Rosenheim Deutschland Tel: 08031 269650 Fax: 08031 68221 Email: [email protected] Web: www.leigh.de

ITALY

Ferrari Macchine Legno SRL Via Gallarata 74/76/78 20019 Settimo M.se (MI) Italy Tel: 39 02 335 010 95 Fax: 39 02 335 005 27 Email: [email protected] Web: www.ferrarimacchine.com

JAPAN

Off Corporation Inc. 323-1 Yanbara, Shimizu-ku, Shizuoka-shi Shizuoka-ken, Japan 424-0002 Tel: 81-50-3816-0115 Fax: 81-54-367-6515 Email: [email protected] Web: www.off.co.jp

KOREA

Leigh Korea 1st Floor, Yongyu Building, 25-3

Neung Pyung-Ri, Opo-Eup, Kwangju-Si Kyunggi-do, Korea Tel: 82 (0) 70-8252-0988 Fax: 82 (0) 31-765-5602 Email: [email protected] Web: www.leigh.co.kr

NETHERLANDS, BELGIUM & LUXEMBOURG

Houtbewerking Krielaart 9217RR Nijega, Netherlands Tel: +31 512 354 770 Email: [email protected] Web: http://www.leighjigs.nl

RUSSIA

Unicom Ltd. Nikitskij Boulevard 12 Moscow, 119019, Russia Tel: 7 (495) 690 0454 Email: [email protected] Web: www.leighjigs.ru

SOUTH AFRICA

Hardware Centre PO Box 4059, Randburg 2125 South Africa Tel: +27 011 791-0844/46 Fax: +27 011 791-0850 Email: [email protected] Web: www.hardwarecentre.co.za

SWEDEN

Toolbox Sweden AB Bruksgatan 3, S-597 30 Atvidaberg, Sweden Tel: 46 120 854 50 Fax: 46 120 854 69 Email: [email protected] Web: http://www.toolbox.se

UNITED KINGDOM & IRELAND

Axminster Tools & Machinery Headquarters, Unit 10, Weycroft Avenue Axminster, Devon EX13 5PH United Kingdom Tel: 0800 371822 Text: 07786 200699 Email: [email protected] Web: www.axminster.co.uk/leigh

© 2002 Leigh Industries Ltd. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, recording, or otherwise, without the prior written permission of Leigh Industries Ltd. Updated 04/2017

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Joining Tradition with Today

Leigh Router Joinery Jigs

Printed in Canada