Woodstock W2000 User Manual 2
COPYRIGHT © 1995 BY WOODSTOCK INTERNATIONAL, INC., REG.# TX 3 360-515
WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE
OR FORM WITHOUT THE WRITTEN APPROVAL OF WOODSTOCK INTERNATIONAL, INC.
PRINTED IN TAIWAN
REPRINTED FEBRUARY 1999
P.O. Box 2309
Bellingham, WA 98227
ROUTER TABLE
ITEM W2000
OPERATING MANUAL
®
W2000 Rebel
®
– 1
TABLE OF CONTENTS
I. INTRODUCTION ..................................................................................................................................2
A. SAFETY INSTRUCTIONS FOR ALL TOOLS ............................................................................2
B. ADDITIONAL SAFETY RULES FOR THE REBEL
®
................................................................3
C. COMMENTARY ............................................................................................................................4
D. UNPACKING ..................................................................................................................................5
E. PIECE INVENTORY ......................................................................................................................5
II. ASSEMBLY ............................................................................................................................................6
A. STAND ............................................................................................................................................6
B. FENCE ............................................................................................................................................7
C. SAFETY GUARD ..........................................................................................................................8
D. MITER GAUGE ..............................................................................................................................9
E. ELECTRICAL SWITCH (OPTIONAL) ........................................................................................9
F. MOUNTING THE ROUTER ..........................................................................................................9
G. WIRING THE ROUTER ..............................................................................................................10
III. ADJUSTMENTS ..................................................................................................................................11
A. ROUTER TABLE INSERT ..........................................................................................................11
B. FENCE ADJUSTMENT................................................................................................................12
C. SAFETY GUARD ........................................................................................................................13
D. MITER GAUGE ............................................................................................................................14
IV. OPERATIONS ......................................................................................................................................15
A. SITE PLANNING..........................................................................................................................15
B. WORKING HEIGHT ....................................................................................................................15
C. SAFETY ........................................................................................................................................16
D. GENERAL OPERATIONS ..........................................................................................................16
E. STRAIGHT EDGE SHAPING......................................................................................................17
F. MITER GAUGE WORK ..............................................................................................................17
G. FREEHAND WORK ....................................................................................................................18
H. USING STOP BLOCKS................................................................................................................20
V. MAINTENANCE ..................................................................................................................................21
VI. PARTS BREAKDOWN........................................................................................................................22
VII. PARTS LIST..........................................................................................................................................23
VIII. WARRANTY AND RETURNS ..........................................................................................................24
2– W2000 Rebel
®
For Your Own Safety, Read Instructions Before Using The Rebel
®
A. Safety Instructions For All Tools
These safety rules cannot cover every situation in a workshop. Consider your individual workshop conditions
when setting up or operating any machine.
• Always wear eye protection
• Always feed against the rotation of the cutter
• Use overhead guard when fence is not in place
• Keep fingers away from rotating cutters
• Do not use awkward hand positions
7. KEEP CHILDREN AND VISITORS
AWAY. All children and visitors should be kept
a safe distance away from your work area.
8. MAKE WORKSHOP CHILD-PROOF with
padlocks, master switches, or by removing
starter keys.
9. DO NOT FORCE TOOL. Tools work better
and more safely when they are allowed to work
at their own speed.
10. WEAR PROPER APPAREL. Do not wear
loose clothing, gloves, neckties, or jewelry that
might get caught in moving parts. Non-slip
footwear should be worn. Wear a hat or other
protective head wear if your hair is long.
11. NEVER STAND OR LEAN ON TOOL.
12. USE SAFETY GLASSES AND EAR PROTECTION. Also use a DUST MASK if the cut-
ting operation is dusty.
1. KNOW YOUR POWER TOOL. Read the
owner’s manual carefully. Learn the tool’s
applications and limitations, as well as its particular hazards.
2. KEEP ALL GUARDS IN PLACE and in
working order.
3. GROUND ALL POWER TOOLS. If an
adapter is used to accommodate a two-prong
receptacle, the adapter plug must be attached
to a known ground. Never remove the grounding prong.
4. REMOVE ADJUSTING KEYS AND
WRENCHES. Make it a habit to check that
keys and adjusting wrenches are removed from
the machine before turning it on.
5. KEEP WORK AREA CLEAN. Cluttered
areas and benches invite accidents.
6. AVOID DANGEROUS ENVIRONMENTS.
Do not use power tools in damp or wet locations or expose them to rain. Keep your work
area well lighted.
I. Introduction
W2000 Rebel
®
– 3
B. Additional Safety Rules For The Rebel
®
18. NEVER LEAVE THE TOOL RUNNING
UNATTENDED - TURN POWER OFF. Do
not leave the tool until it comes to a full stop.
19. DO NOT OPERATE THE TOOL IF USING
DRUGS, ALCOHOL, OR MEDICATION.
20. DO NOT WORK IN HASTE or operate
machine if you are mentally or physically
fatigued.
21. IF THERE IS SOMETHING YOU DO NOT
KNOW OR UNDERSTAND, DO NOT
OPERATE MACHINE! Ask for help first.
Confusion is dangerous.
22. BAD HABITS ARE DANGEROUS. Review
all safety procedures often.
13. DO NOT OVERREACH. Keep proper footing
and balance at all times.
14. MAINTAIN TOOLS IN TOP CONDITION.
Keep tools sharp and clean for best and safest
performance. Follow instructions for lubricating
and changing accessories.
15. DISCONNECT TOOLS FROM POWER
before servicing and when changing accessories,
such as blades, bits, and cutters.
16. AVOID ACCIDENTAL STARTING. Make
sure the switch is in the “OFF” position before
plugging in the cord.
17. CHECK DAMAGED PARTS. Do not operate
the machine until you are certain it is in perfect
running condition.
1. Always feed against the rotation of the cutter.
For most routers and bits, the direction of feed
is from right to left as you face The Rebel
®
.
2. Always cut the end grain first before putting an
edge all the way around any stock such as a
table top or raised panel to guard against grain
tear-out as the workpiece clears the bit.
3. Use quality material. Wood that is cupped,
warped, bent or split will not machine properly and can present many safety hazards. Do not
shape or rout material that contains loose or
unsound knots.
4. The router collet must be securely tightened
against the router bit. A loose router bit can
cause serious injury. Periodically check to see
if the router bit is held securely in the collet.
5. Always use the safety guard and incorporate
feather boards, hold downs or other safety
devices when using your router table.
6. When shaping end grain there is a greater tendency for kick-back. Hold the workpiece firmly using clamps, jigs or fixtures and feed evenly.
7. Wear ANSI approved safety equipment such as
eye, face, ear and respiratory protection.
8. Use sharp router bits. The old adage is true: A
sharp tool is a safe tool.
9. Plan your work. Figure your steps out before
you start cutting
10. Do not shape material that is too small to be
safely processed without a jig or fixture to hold
the piece
11. Make sure that all fasteners used in assembly
have not vibrated loose.
12. A starting pin or starting block must be used
when shaping irregular workpieces.
The following are important safety considerations when using The Rebel®.
4– W2000 Rebel
®
Woodstock International, Inc. is proud to offer the
W2000 Rebel
®
Router Table. The Rebel®, named
because of its radical design and construction features,
is substantially different to what is currently available
in the market place. You won’t find any tin, plastic or
wood construction that looks as if it’s been hammered
out in someone’s garage. Instead you will find an inherent ruggedness which denotes strength and durability.
The Rebel
®
represents countless hours of research,
development and hands-on testing by skilled woodworkers. The effort that went into the development of
this router table will be appreciated every time you use
it.
The Rebel
®
, in conjunction with your router is truly a
versatile woodworking tool. This combination will
allow you to utilize the full potential of your router. The
Rebel
®
will allow you to joint, rabbet, slot, flute cove,
bead, miter, mold, tenon and perform many other tasks
that are necessary for fine quality woodworking. Best
of all, The Rebel
®
can be used by anyone at any level of
woodworking. The beginner as well as the master
craftsman will appreciate its versatility and will come to
depend upon its quality construction, ruggedness and
durability.
Woodstock is committed to offering top quality
products and supporting them through customer service
and technical documentation. The manual you now
have represents our latest effort to produce the best documentation possible. If you have any criticisms or comments you feel we should pay attention to in our next
printing, please write us at the address below.
Manager, Technical Documentation
Woodstock International, Inc.
P.O. Box 2309
Bellingham, WA 98227
FAX 1-800-647-8801
Phone 360-734-3482
If you have any parts problems or requests, please contact your Woodstock distributor or call Woodstock
International at 1-800-840-8420 between 8am and 5pm
Pacific Standard Time, Monday through Friday.
The specifications, drawings, and photographs illustrated in this manual represent the Model W2000 as
supplied when the manual was prepared. But owing to
Woodstock’s policy of continuous improvement,
changes to the Model W2000 may occur at any time
with no obligation on the part of Woodstock. Should
you receive a manual update, please insert it into the
manual and keep it for reference.
We have included some important safety measures
which we believe to be essential to this tool’s
operation. While most safety measures are generally
universal, Woodstock reminds you that each work
environment is different and safety rules should be
considered
as they apply to your situation.
We also believe additional information sources are
very important to better realize the full potential of this
tool. Trade journals, woodworking magazines, and
your local library are good places to start.
The Model W2000 was designed for shaping. It must
never be modified and/or used for any other purpose.
Modifications or improper use of this tool will void
all warranties. If you are confused about any aspect of
the Rebel
®
, DO NOT use it until you have resolved
any questions you might have.
C. Commentary
To operate this, or any tool, safely and efficiently, it is essential to become as familiar with its
characteristics as possible. Take as much time as
necessary to become acquainted with the W2000
Rebel
®
Router Table. The time you invest before
you begin to use it will be time well spent. Also,
read all of the safety procedures. If you do not
understand them, DO NOT use your Router
Table. Serious personal injury may occur.
W2000 Rebel
®
– 5
The Rebel®is designed for heavy-duty use, yet it
weighs only 35 pounds and is completely portable.
However, when lifting, we must caution against
improper lifting techniques. Always keep your back
straight and lift with your legs. If you are limited by the
amount of weight you can lift and carry, please refrain
from moving The Rebel
®
until you get the necessary
assistance.
At this time, slide the solid foam packing out. The parts
are arranged in two layers of packing. Remove the
parts in an orderly fashion. This will simplify identification and make inventory and assembly that much
easier. When removing the parts, please take care not
to destroy the foam and cardboard carton. It is a good
idea to save the carton for future storage or shipment if
necessary. After you have completed your inventory,
inspect all the parts (especially the contact areas) for
burrs and other irregularities which might hinder the
assembly process. If you find any burrs or flash left
over from the machining or casting process, simply
sand or file them flat. Please note that while this is not
a common occurrence, it is possible that one or more of
the parts could have been missed during the machining
and deburring process.
Carefully remove the items packed in the carton. It
may be a good idea to save the carton and packing
material in case it might be needed in the future. Upon
removal of all items from the package, you should
have:
In the event that any non-propriety parts are missing
(e.g. a bolt or nut etc..) we would be glad to replace it.
For expediency, replacements can be obtained from
your local hardware store.
Figure 1. Rebel®parts ready for assembly.
Contents of the bolt bag.
1 Working Table
4 Legs
4 Rubber Feet
2 Short Side Panels
2 Long Side Panels
2 Aluminum Fences
2 Wood Facings
4 Fence Lock Handles
4 T-Nuts (Bagged)
1 Plastic Insert Assembly
1 Starting Pin
1 Safety Guard
1 Safety Guard Bracket
1 Safety Guard Rod
2 Cap screws
1
/4 - 28 x 1''
1 Miter Gauge
1 Miter Gauge Handle
1 Bolt Bag
Description:
Cap Screws:
Setscrews:
Hex Nuts:
Flat Washers:
Flat Head Screws:
Hex Bolt:
Size:
1
/4'' - 28 x 5/8''
1
/4'' - 28 x 3/4''
10 - 32 x
3
/4''
10 - 32
1
/4'' - 20
1
/4''
5
/16''
1
/4'' - 20 x 11/4''
5
/16'' - 18 x 3/4''
Qty:
20
2
4
4
2
10
1
4
1
E. Piece InventoryD. Unpacking
6– W2000 Rebel
®
Assembly of The Rebel® is extremely straight forward
and can be accomplished with just a few simple hand
tools. In fact, the only tools you will need are a regular
screwdriver, Phillips
®
screwdriver, adjustable wrench,
3
⁄16" Allen®wrench and a good quality straight edge.
The design of The Rebel
®
is such that most of the parts
are joined together with socket head cap screws. We
recommend that you assemble The Rebel
®
in the order
presented here. Use the exploded parts diagram for
visual reference during assembly. We suggest that you
use a table or work bench that has sufficient surface
area to hold all of your tools and the finished Rebel
®
safely and securely. It is also best to have a well lighted area to reduce eye strain during assembly.
The stand is made up of four legs, two side pieces and
a front piece and back piece. All similar parts are interchangeable with one another.
Step 1 - Turn the working table up side down and
loosely bolt on all four legs using the
1
⁄4"-28 x
5
⁄8" socket head cap screws provided.
Step 2 - Mount the short and long side panels between
the legs using the
1
⁄4"-28 x 5⁄8" socket head cap
screws provided. Figure 2.
Step 3 - Use a
3
⁄16" Allen®wrench to assist in starting
and tighten all cap screws down.
Step 4 - Attach the feet to the legs. Figure 3.
Step 5 - Turn the stand assembly over and move on to
the next section.
A. Stand
Figure 2. Mounting legs and side panels to the work-
ing table.
Figure 3. Attaching the feet to the legs.
II. Assembly
W2000 Rebel
®
– 7
Figure 4. Attaching the fence.
The Rebel®has a two-part, split fence designed for
either straight-line or offset shaping. Assembling the
fence is quite simple and straightforward.
Step 1 - Choose one of the fence halves. Select two
fence lock handles and insert the threaded
ends into the
1
/4'' flat washers and two holes
on the bottom of the fence. Select two T-nuts
and loosely thread onto the ends of the lock
knobs. Line up the T-nuts with the slots in the
router table and slide the fence onto the router
table. Figure 4. Roughly lock the fence in
position. Repeat this process for the other
fence half.
B. Fence
Step 2 - Attach the wood facings to the fence using the
flat head screws, flat washers and hex nuts
provided. Figure 5. Tighten for now; howev-
er, you will notice that there are slots in the
back of the fence for side to side adjustment.
Side to side adjustment of the wood facings is
dependent upon the overall diameter of the
router bit. For maximum safety and support,
adjust the wood facings as close to the router
bit as possible. Check clearance before starting the router.
Figure 5. Attaching the wood facing.
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