3400 to 3440 Scarfing Sled Owners Manual

3400 to 3440 Scarﬁ ng Sled Owners Manual Please Read Carefully!

Parts List: Please identify and verify that you have all of the hardware shown. Please refer to photos in the instructions for the parts listed below: Part Description Quantity 3400A Angle Guides (8-1, 10-1 & 12-1 ratios) . . . 1 3400B Brackets, 4 pc. set (2 pairs) ...... 1 3400C Glide Bracket ...... 2 3400G Glide ...... 2 3000P NoDrill Plate ...... 1 4973 NoDrill Plate Hdw...... 1 4406 6" Ultra Track ...... 2 4012 12" Double Track ...... 2 4016 16" Double Track ...... 2 4032 32" Double Track ...... 2 Model 3400 (15" capacity) also includes: 4424 24" Ultra Track ...... 2 Model 3410 (27" capacity) also includes: 4436 36" Ultra Track ...... 2 Model 3420 (39" capacity) also includes: 4448 48" Ultra Track ...... 2 Model 3430 (51" capacity) also includes: 4460 60" Ultra Track ...... 2 3430B 36" Brace ...... 1 Model 3440 (63" capacity) also includes: 4472 72" Ultra Track ...... 2 3440B 48" Brace ...... 1 Part# Description Qty. Part# Description Qty. PAD1 Glide Pad 16 5860 Ratchet Handle 6

Part# Description Qty. Part# Description Qty. Part# Description Qty. 5770B 1/2” Screw 7 MF006 5/8" screw 4 5760B Oval Nut 49

Part# Description Qty. 5590 Knob 2 Part# Description Qty. Part# Description Qty. Part# Description Qty. 5771B 3/4” Screw 4 MF010 3/4" screw 8 WB002 Washer 18

Part# Description Qty. Part# Description Qty. Part# Description Qty. Part# Description Qty. MP087 7/8” Screw 4 HB020 3/4" Bolt 14 MF020 1-1/4" screw 20 BUSH050 3/8” Spacer 8 BEFORE BEGINNING Identify and verify that you have all the parts listed. You'll 1 need a 1/4" drill, 1/2" countersink, a 7/16" wrench and a #3 4012 Phillips screwdriver for assembly. You will also need to sup- Double Track ply material for a mounting base (see instructions) to mount the Scarfing Sled to and a flat work surface on which to use it. Read the instructions carefully before beginning. Ultra Track

ASSEMBLY - TRACK SLED 3400B Install a washer (WB002) on the eight 3/4" bolts (HB020). Bracket In the Brackets (3400B - 4 pieces, 2 pairs), insert the bolts from the opposite side of the countersunk holes, through the non- countersunk holes. Start an oval nut (5760B - flat side first) on the end of each bolt. With the Ultra Track (4424, 4436, 4448, 4460 or 4472 depending on model purchased) laying on its 3" face on a flat surface, mount a pair of Brackets to each Ultra Track. The angled end of each Bracket should be next to the end of the Ultra Track. Slide the Bracket into the T-slot of the Ultra 2 Track, position each Bracket flush with the end and edge of the Ultra Track, then tighten the bolts. See fig. 1. Insert the 3/4" flat head screws (MF010) in the countersunk holes in the Brackets and start an oval nut (5760B - flat side first) on the end of each screw. Remove the paper backing and install two glide pads (PAD1 - 8 total), on each end of both Double Tracks (4012). With one of the Ultra Tracks laying on its 3" face on a flat surface, slide a 12" Double Track on to the oval nuts on each bracket. Check that the Double Track is square to the Ultra Track and flush with the upright edge of Space brackets the Bracket, then tighten the screws. Flip the assembly 90º so 3-5/8" apart. it setting on the Double Tracks and attach the remaining Ultra Track/Brackets to the opposite end of the Double Tracks. Space the inside ends of the Brackets 3-5/8" apart for now and tighten the screws. This completes what will now be referred to as the Track Sled. See fig. 1 & 2. 3

ASSEMBLY - ROUTER PLATE Follow the directions in the 4973 Plate Hardware and attach your router to the Router Plate (3000P). The router does not need to be perfectly centered on the plate. You can use a 3000P plunge or standard base router. Position your router on the plate Router Plate so the router handles (if you haven't removed them) are parallel to one of the router plate edges and position the router to take the best advantage of the plates mounting slots and router control locations. Mark the position of the router on the router plate with a timing mark so you can return it to the same location, then temporarily remove the router. See fig. 3. An optional drill style plate (PN 3000PD) is available for semi-permanent mounting of your router, but it requires drilling mounting holes in the plate. 4 4406 Select the mounting locations for the 6" Ultra Tracks on the router plate. The Ultra Tracks mount on opposite sides from each other and parallel to the router handles. From the underside of the router plate insert the 5/8" flat head screws (MF006) in the four selected countersunk holes. Start an oval nut (5760B - flat side first) on the end of each screw. Slide a 6" Ultra Track (4406) on to two of the oval nuts, position it flush with the router plate at it's ends and edge, then tighten the screws. Repeat for the second Ultra Track on the opposite side. See fig. 4. 4406

1 Remove the paper backing and install the glide pads (PAD1 - 2 on each track, extras included) where shown on 5 Place a glide pad on the outside corner of each Ultra Track, near to where the plate meets the track. Set the Router Sled aside for now. See fig. 5. the lower corners of each 6" track. ASSEMBLY - ROUTER SLED Insert a 1-1/4" flat head screw (MF020) through the countersunk hole in each Guide Bracket (3400C). Place a 3/8" spacer (BUSH050) on each screw, attach a knob (5590) to each screw PAD1 and tighten. See fig. 6 & 7. Attach each Guide (3400G) to a Guide Bracket using two 7/8" screws (MP087). Insert the screws through the two holes in the thickest part of the Guide Bracket. Be careful not to over- tighten the screws and strip the threads in the Guide. See fig. 6. Insert a washer (WB002) on each 3/4" screw (5771B), insert two screws through the holes in each Guide Bracket and start an oval nut (5760B - flat side first) on the end of each 6 screw. Slide each Guide Bracket on to the top of each 6" Ultra Track (4406), with the oval nuts engaged in the T-slot of the 3400C Guide track. Center the Guide Bracket on the length of the track and Bracket tighten. This completes what will now be referred as the Router 3400G Sled. See fig. 5 to 7. MP087 Screw Glide ADJUST - ROUTER SLED & TRACK SLED On the Track Sled, loosen the four screws (two at each end) that hold just one of the Ultra Tracks/Brackets to the two 12" Double Tracks. Place the Router Sled between the two Ultra Tracks of the Track Sled. Position it so the ribs in the two Guides (one on each Guide Bracket) are engaged in the top T-slot of the two Ultra Tracks and resting on them. See fig. 7. Loosen one pair of screws holding one Guide Bracket to a 6" Ultra Track, lightly squeeze the 6" Ultra Track (at the bottom 7 near the router plate) against the Ultra Track of the Track Sled Router Sled and retighten the screws. Repeat on the opposite side. Check that the Router Sled glides smoothly the length of the Track Sled. See fig. 7. Position the Router Sled at one end of the Ultra Tracks of the Track Sled and retighten the two screws that fasten them to Track Sled the 12" Double Track. Repeat at the opposite end of the Track Sled. Check that the Router Sled glides smoothly the length of the Track Sled. Remove the Router Sled from the Track Sled for now. See fig. 7.

2 ASSEMBLY - TRACKS TO ANGLE GUIDES Select the pair of Angle Guides (3400A, in ratios of: 8 8-1, 10-1 or 12-1) you wish to use. You may also make your 3400A own custom angle guides, using our guides to assist. Insert the 1-1/4" flat head screws (MF020) in the countersunk holes in the Angle Guides and start an oval nut (5760B - flat side first) on the end of each screw. Slide a 16" Double Track (4016) on to the oval nuts along the bottom of both Angle Guides. Position 4016 the Double Track so it's flush with the wide end and the bottom edge of the Angle Guide, then tighten the screws. Slide a 32" Double Track (4032) on to the oval nuts along the slanted top edge of both Angle Guides. Position the Double Track so it's 4032 end protrudes 6" past the narrow end of the of the Angle Guide and 1/4" below the top edge of the Angle Guide, then tighten the screws. See fig. 8. 9 ASSEMBLY - ANGLE GUIDES TO BASE Cut a base to mount the Angle Guides to. The base should be made out of 3/4" thick flat sheet stock such as MDF or particle board. The base should measure 24" wide by the length of the Ultra Tracks (24", 36", 48", 60" or 72"). After cutting the base to size, place it bottom side up on a bench. Draw two lines on center (19-3/4", 31-3/4", 43-3/4", 55-3/4" or 67-3/4" on center - depending on length of Ultra User supplied Tracks) across the 24" width of the base and centered on the base length of the base. Measuring from a long edge, draw an inter- secting line on both previously made lines at 1", 8" and 15" from the long edge. Drill and countersink holes at these six locations to accept the 1-1/4" flat head screws (MF020). Insert the screws and start an oval nut (5760B- flat side first) on the end of each screw. Flip the base over and mount the 16" Double Track/Angle Guide to the oval nuts. Position them so the taller/ wider end is flush and square to a long edge of the base. Check that they're parallel to each other and tighten the screws. See fig. 9.

3 ASSEMBLY - ATTACH SACRIFICIAL PLATE TO BASE Make sure the base is on a flat solid support when per- forming these operations. Cut a sacrificial plate out of 3/4" thick flat sheet stock such as MDF or particle board. The plate should measure at least 8" wide (or up to 24" - the width of the base) by the length between the Angle Guides. Position the plate flush with the front edge of the base at the narrow end of the Angle Guides. Drill and countersink the plate for flat head wood screws (not included) and place the screws at least 2-3" back from the front edge of the base so the router bit will not strike them. Use addi- 10 Work tional screws as needed to fasten the plate tight to the base. This sacrificial plate will need to be replaced periodically. See fig. 10 & 11.

MOUNT WORK TO THE BASE Make sure the base is on a flat solid support when per- forming these operations. The thickness capacity of the Scarfing Jig depends on the Sacriﬁ cial Angle Guide selected. Thickness capacity for the 8-1 Angle Plate Guide is 2-3/8", 10-1 Angle Guide is 1-7/8" and the 12-1 Angle Guide is 1-5/8". Base It is necessary to mount the work to the sacrificial plate, and then to each other. The work pieces must be stair stepped when attaching them. We recommend you use flat head wood screws to hold the work securely, but you may also be able to use double stick tape or other holding methods. See fig. 10 & 11. The amount of stair step will vary depending on the thickness of the work and the ratio of the Angle Guides, but the first work piece should always be attached 1" back from the front edge of the base/plate. See fig. 10 & 11. To figure the amount of stair step, multiply the thickness of the work (6mm, 1/4", 12mm, 1/2", etc.) by the ratio of the Angle Guide. For example, using 12mm stock with the 8-1 ratio Angle Guide, the formula would be: 12mm x 8 = 96mm stair step. Attach each work piece separately. Make sure you place the screws at least one inch back from the area of the stair step so the router bit can't strike them. See fig. 10 & 11. Long parts will require extra support along the length of the part to keep it on a flat and even plane. This could be as simple as 2 x 4's placed under the part at even intervals.

11 Screws need to be positioned so they don't interfere with the eventual cut line of the bit.

4 PREPARE TO CUT SCARF JOINT Make sure the base is on a flat solid support when per- 12 forming these operations. Install a 3/8" spacer (BUSH050), a washer (WB002) and a ratchet handle (5860) on six of the 3/4" bolts (HB020). These are the Stops. Slide the bolt head of two of the Stops into the T-slot of each 32" Double Track on each Angle Guide, position them at each end of each track and tighten. The front Stops (at the narrow ends of the Angle Guides) control the forward position and angle of the Sled Assembly. The rear Stops prevent you from running the Sled Assembly off the 32" Double Tracks. See fig. 12. Stops - x6 Install the bolt head of the remaining two Stops in the top T-slot of the front Ultra Track of the Sled Assembly. These Stops control the left-to-right range of the Router Sled. They should be adjusted to prevent the router bit from cutting into the Angle Guides or the 12" Double Tracks. See fig. 12. 13 Set the 12" Double Tracks of the Sled Assembly on the 32" Double Tracks of the Angle Guides. Position the Sled Assembly so the overhanging ends of the 12" Double Tracks are at the front and against the Stops on the 32" Double Tracks. Adjust one 12" Double Track so there is a 1/32" to 1/16" gap between the inside of it and vertical face of the Angle Guide, with the opposite 12" Double Track snug against the opposite Angle Guide. See fig. 12 & 13. If your Scarfing Sled included a Brace (model 3430 or Gap of 1/32" 3440 only), install 1/2" screws (5770B) through the holes in to 1/16" the brace and start an oval nut (5760B - flat side first) on the ends of the screws. Slide the oval nuts of the Brace in the lower outside T-slot of either the front or rear Ultra Track of the Track Sled. Center it side-to-side on the Ultra Track and tighten the screws. See fig. 14. 14

Attach brace (if included) to front or rear Ultra Track of the Track Sled.

5 PREPARE TO CUT SCARF JOINT Make sure the base is on a flat solid support when per- 15 forming these operations. Install the necessary bit (we recommend a bit with at least a 2-1/2" overall length) in your router and attach the router to the Router Sled. Set the Router Sled so it rides on the Ultra Tracks of the Track Sled, making sure the ribs of the Glides are fully engaged in the slots of the Ultra Tracks. Set the Stops on the Ultra Track to control the side-to-side movement of the Router Sled and prevent it from striking the Angle Guides or the Double Tracks. Adjust the bit so it nearly touches the corner of the work at Bit position at both ends of one end by adjusting the position of the Track Sled on the Angle work should be the same. Guides and lowering the bit. Slide the Router Sled across the length of the Track Sled, noting the position of the bit in relation to the corner of the work. See fig. 15. By adjusting the position of just one of the front Stops 16 on one of the 32" Double Tracks, you can skew the Track Sled slightly until this position is the same at both ends of the work. Temporarily clamp the 12" Double Tracks of the Track Sled to the 32" Double Tracks of the Angle Guides. Loosen each front Stop and slide them away from the ends of the 12" Double Tracks 1/4" to 3/8" (use a spacer so this margin stays exactly the same at both ends), tighten the front and rear Stops firmly and remove the clamps. See fig. 15. Cut spacers out of some 1/4" thick stock. The spacers should be narrower than the width of the bit you're using and at least 1-1/4" long so they're easy to grasp. With the Track Sled resting against the front Stops, you'll make your first side-to- side pass with the router. For each subsequent pass you'll slide the Track Sled back on the 32" Double Tracks, insert a spacer in the T-slot of the 32" Double Track between each the end of the 17 12" Double Tracks and the front Stops, then let the Track Sled rest against the spacers. Make the next side-to-side pass with the router, install another pair of stops and repeat. See fig. 16 & 17. Spacer CUT SCARF JOINT Make sure the base is on a flat solid support when per- forming these operations. Starting with the Track Sled resting against the front Stops, set the routers depth of cut to 1/8" or less. As you finish each side-to-side pass, add spacers between the front Stops and Track Sled to move the Track Sled back for the next pass. When using the Router Sled, don't place excessive side pressure on the Track Sled and always maintain a slight downward pressure on the Router Sled. Never try to reach beyond a comfortable and safe distance. To guide the Router Sled from side-to-side you can 18 use either the handles on the Router Sled or the handles on your router, whichever you are more comfortable with. It's always better to take several light cuts instead of a one or two heavy cuts. Leave just enough material to make a light final cut. Whether you move the Router Sled from left-to-right or right-to-left will depend on what side of the bit the majority of the work is on. Always work against the rotation of the bit - never climb cut! Always take appropriate safety precautions! See fig. 18.