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Cutting tenons – Sears 26462_0 User Manual

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Cutting Tenons

1. Make certain that the adjustable fence is locked

in position with its face flush with the front face of the
fence.
2. Mount the push block assembly on the fence, as
described in the section PUSH BLOCK ASSEMBLY
TO THE ROUTER TABLE UNITIZED FENCE.
3. Install the proper table top insert into the table top
hole.
4. Mark line "A" and "B" on the edge of the work piece
closest to the end to be cut. Line "A" is the FULL

DEPTH OF CUT (total amount of material you want to
remove) and line "B" is the FULL DESIRED HEIGHT
OF THE TENON. See Figure 33.

5. Position the work piece between the clamp plate
and the push block so that its side is held flush against
the face of the fence. The end to be cut is resting on
the edge of the router table insert hole, and the surface

marked with lines "A" and "B" is facing the router bit.
Clamp the work piece in this position by snugly tighten­
ing the wing nut on the clamp rod, making sure that
the clamp plate stays oriented on the work piece as
shown in Figure 33. MAKE SURE THE ROUTER IS

UNPLUGGED WHEN POSITIONING AND CLAMP­
ING THE WORK PIECE AND MAKING ADJUST­
MENTS.

FIGURE 33

NOTE

Tighten the wing nut just enough to

clamp the work piece in position. OVERTIGHTENING
the wing nut could cause binding in the sliding motion
of the push block, which in turn could result in varia­
tions and/or steps in the finished tenon surface when
cut.

6. Slide work piece up next to the router bit and adjust
the fence and the router, as described in the section,
ADJUSTING DEPTH AND HEIGHT OF CUT. The
outer most cutting edge of the bit should be aligned
with line "A", and the top cutting edge of the bit should
be aligned with line "B". Tightly secure the fence and
the router.
7. Slide the push block with the work piece clamped,
back away from the bit.
8. Turn router "ON" using the switch. Holding the push

block and work piece against the fence WITH BOTH
HANDS AND FINGERS A SAFE DISTANCE AWAY
FROM THE SPINNING BIT, feed the work piece
across the bit, making a full depth of cut in one pass.
(DO NOT STOP FEEDING THE WORK PIECE UNTIL
IT HAS COMPLETELY PASSED ACROSS THE

ROUTER BIT) (Ref. Figure 34)

NOTE

work piece and slide the push block back to the previ­
ous starting position.

10. Position and clamp the work piece in the same
manner as described in step 5. (Make sure the wing
nut is tightened just enough to clamp the work piece in
position, and the end to be cut is resting flat on the top
of the router table.) Repeat steps 7, 8, and 9. See
Figure 35.

11, To cut ends of the tenon, position and clamp the

work piece in the same manner as described in step 5
with the work piece oriented as shown in Figure 36.

Repeat steps 7, 8, and 9. Follow these same steps for
cutting the opposite side.

FIGURE 35

Clamp and test cut a scrap piece of

wood to check your adjustments before making your
finished cut.

9. Turn router "OFF" using the switch. Unciamp the

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