No. 870 - General Tools And Instruments
Contents
1. shown on 2 stock L 1 2 JOINT B VA MAX LENGTH YA MAX LENGTH 7 1 4 MIN LENGTH 1 4 MIN LENGTH MORTISE TENON 13 CUSTOMER SUPPORT Please visit our website at www generaltools com woodworking to obtain additional woodworking Information instructional videos and product manual http www generaltools com Products E Z Pro Mortise and Tenon Jig__870 aspx WARRANTY INFORMATION The No 870 Mortise amp Tenon Jig Kit from General Tools amp Instruments is warranted to the original purchaser to be free from defects in material and workmanship for a period of one year Subject to certain restrictions General will repair or replace this product if after examination it is determined by General to be defective in material or workmanship 14 GENERAL Specialty Tools amp Instruments GENERAL TOOLS amp INSTRUMENTS 80 White Street New York NY 10013 3567 PHONE 212 431 6100 FAX 212 431 6499 TOLL FREE 800 697 8665 e mail sales generaltools com www generaltools com 870 User s Manual Specifications subject to change without notice 2011 GENERAL TOOLS amp INSTRUMENTS NOTICE WE ARE NOT RESPONSIBLE FOR TYPOGRAPHICAL ERRORS MAN 870 3 22 112. with the inner wall of the jig Fig 11 and the stock will be at its nominal center in the templates e When adjusting the Centering Wall and to maintain parallel alignment always make sure the bar is correctly seated on the jib body with its serrated matching surface 4B Fig 11 in the jig Tips to assure an accurate joint alignment particularly if you are making a face frame or similar matching surface type joint always keep the matching faces to the same side of the jig 3 Positioning the Stock Using the Positioning Bars When in the deployed position Fig 12 the Positioning Bars serve two basic purposes 1 They position the stock at the correct depth below the underside of the template for routing 2 They align the stock so it is squared at 90 degrees to the jig longitudinally Fig The Positioning Bars Fig 12 and 13 are stored along the inside edge of the underside of the jig s top when routing 1 To extend the bars use the Positioning Bar handles 6A located under the outside top edge 2 After you fully deploy the Positioning Bars you re ready to place the stock in the jig Insert the stock gently up against the deployed Positioning Bars Fig 14 and tighten the Thumb Screws 5 just enough so the stock is held loosely by the Face Clamps 7 Center the stock longitudinally using the jig s centering marks 1A on the jig Fig 15 Before tightening the Face Clamps be sure the s
3. GENERAL E Z Aro MORTISE amp TENON JIG No 870 USER S MANUAL U S PATENTS APPLIED FOR PLEASE READ THESE INSTRUCTIONS FULLY BEFORE USING THIS JIG www generaltools com woodworking CONTENTS I UIFOdUIGUDOPII Z oeseeae bens wilian awakusqa qpawaqauqulkaasaaekaqaaqg qaqaq auqa 3 Capacity and Specifications 3 What s in the Jig Kit 3 Anatomy of the Jig 58 4 Anatomy of the Quick Change Router Base Bushing Assembly 4 Preparing the Router i 5 6 Safety Overview eee 5 Installing the Quick Change Guide Sleeve 5 Centering the Base Plate and the Quick Change Guide System 5 Setting the Cutting Depth 6 Mounting the Jig cekace case conan se weeen sen pee as 6 Operating Instructions 00 02 eee eee 7 12 1 Marking Joint Centers and Location 7 2 Centering the Stock 7 3 Positioning the Stock using the Positioning Bars 8 4 Setting the Joint Length 9 Length of Mortise amp Tenon Chart 9 5 Setting the Depth of the Router Bit 10 6 Routing the Tenon 11 7 Routing the Mortise 12 Routing Other Size Mortise a
4. M amp T Joint 3 1 8 depending on bit used What s in the M amp T Jig Kit 1 The fully assembled jig 2 Quick Change Router Base Bushing Assembly consists of e One Quick Change 1 3 16 guide sleeve and locking nut e One 1 4 guide bushing 1 1 4 OD e One 1 4 shank centering pin e One flat soanner wrench for guide sleeve locking nut adjustment e One 3 8 guide bushing e One 1 2 guide bushing 3 One 1 4 straight upcut spiral carbide router bit It is highly recommended that you familiarize yourself with the nomenclature in Fig 1 and Fig 2 on p 4 before proceeding ANATOMY OF THE E Z PRO MORTISE amp TENON JIG Fig 1 JIG ASSEMBLY IN PROFILE JIG ASSEMBLY MORTISE SECTION TENON SECTION 1 Jig Assembly 5 Face Clamp Thumb Screws 1A Centering Marks 6 Positioning Bars 1B Centering Notches 6A Positioning Bars deployed 1C Template Positioning Indicators 6B Positioning Bars retracted for storage 2 Mortise Section Templates and cutting 2B Template Position Rule 7 Face Clamps 3 Tenon Section Templates 8 Mounting Flange 4 Centering Wall 4A Markings 4B Serrations 4C Thumb Screws ANATOMY OF THE QUICK CHANGE ROUTER BASE BUSHING ASSEMBLY R3 Fig 2 a 5 8 O D 88 R1 Lock Nut Flat Spanner Wrench R2 1 3 16 Router Base Guide Sleeve R6 7 8 O D Router Guide Bushing 83 1 1 8 O D Router Guide Bushing for for the 3 8 Tenon the 1 4 Ten
5. R2 R1 a 1 1 8 Router Guide Bushing for 1 4 joints R3 a 1 4 Upcut Spiral Router Bit and a Centering Pin R4 These parts will permit you to make 1 4 mortises and tenons suitable for 3 4 thick board Fig 24 The kit also includes the Guide Bushings you will need to make mortises and tenons of 1 2 R7 or 3 8 R6 Page 4 however you will need to make a separate purchase of the corresponding upcut spiral bits Please see sizing chart on Page 10 e To make a 3 8 tenon you ll need a 3 8 Upcut Spiral Bit and the 7 8 Guide Bushing R6 e To make the matching 3 8 mortise change to the 1 1 8 Guide Sleeve R 3 Fig 25 e To make a 1 2 tenon you ll need a 1 2 Upcut Spiral Bit and the 5 8 Guide Bushing R7 e To make the matching 1 2 mortise change to the 1 1 8 Guide Sleeve R 3 Fig 26 NOTE Guide bushings can be changed without removing router bit Fig 24 Ve 9 1 p DU opcupe A OD GUIDE BUSHING R 3 BUSHING R 3 1 4 JOINT 7 shown on R 1 stock 27 MAX LENGTH 2 MAX LENGTH Ff Ff fA MIN LENGTH As MIN LENGTH MORTISE TENON Fig 25 oily 4 22 BIT gt OD GUIDE 27 BIT 61 1 BUSHING R 3 3 8 JOINT ES lt shown on 1 1 4 stock 3 MAX LENGTH 1 MIN LENGTH 3 MAX LENGTH 1 MIN LENGTH MORTISE TENON Fig 26 g 1 y 9 8 OD GUIDE BIT OD GUIDE BUSHING R 3 BUSHING R 7
6. ee also Setting the Cutting Depth on page 6 To set the plunge depth of the router Fig 18 and subsequently the cutting depth of the bit remember to add 1 2 to the desired depth of the joint Therefore if you re setting the joint depth to be 1 then your measurement would be a total of 1 1 2 from the face of the base plate to the tip of the bit DEPTH OF JOINT FROM THE FACE OF THE BASE PLATE TO THE TIP OF THE CUTTING BIT 1 2 EQUALS THE DEPTH OF THE JOINT PLUS 1 2 Fig 18 10 6 Routing the Tenon When routing the tenon make sure the Guide Bushing R 3 only rides against the outer edges of the tenon template 3 Fig 19 at all times 1 Start the cut by putting the guide bushing into the end of the template 2 With the guide bushing in the end of the template and the router base squarely on the jig surface turn the router on 3 Plunge the router to a workable depth and guide the router bit clockwise through the cutting process making sure to keep the Guide Bushing tight to the outer edge at all times NOTE You can make successive plunges to any depth while moving the Guide Bushing clockwise around the tenon template always riding against the edge to make the cleanest joint possible We recommend making successive shallow plunges and cutting sweeps to avoid over stressing the cutting bit Fig 19 amp 20 Caution before retracting the router bit from the cut be sure
7. nd Tenons 13 Customer Support 624 6406 8 58 ge bees ee 8 89 8 9 ee ose eacke oe 14 Warranty Information 3 353 353 5 ees 14 NOIS annsna r ee ok oe eee 15 Sample Mortise amp Tenon Joint INTRODUCTION Thank you for purchasing General Tools amp Instruments E Z Pro Combination Mortise amp Tenon Jig M amp T Jig the woodworking industry s first integrated jig capable of making matching mortise and tenon joints of professional quality right out of the box The jig makes creating Mortise amp Tenon joints the sturdiest of all wood joints for furniture cabinets and frames an easy simple and fast process The Mortise amp Tenon Kit comes with a fully assembled jig and includes a 1 4 straight up cut router bit and 1 4 guide bushing Also included are the guide bushings for cutting 3 8 and 1 2 joints You will need to supply your own 3 8 and 1 2 upcut router bits The M amp T Jig has a one piece heat treated high grade aluminum body with its adjusting bolts up cut fasteners and bit made of steel to SAE specifications The unit s adjustable positioning bars and router bushing assembly are also made of solid steel Capacity and Specifications Accommodates stock from 1 2 to 1 2 thick and any length Mortise and Tenon thickness 1 4 3 8 and 1 2 Minimum length M amp T Joint 1 1 8 depending on bit used Maximum Length
8. on as well as for all R7 5 8 O D Router Guide Bushing mortises for the 1 2 Tenon R4 Centering Pin R8 1 4 Upcut Routing Bit PREPARING THE ROUTER SAFETY OVERVIEW 1 KNOW YOUR ROUTER Read the owner s manual that came with your router before you use it Understand the machine s applications and limitations as well as the specific potential hazards Inherent in its use Before using the router check that none of its moving parts is broken loose or misaligned NOTE General Tools amp Instruments is not responsible for router misuse or the disregard of standard safety precautions associated with using a router Installing the Quick Change guide sleeve The EeZ Pro M amp T Jig is designed to be used with plunge routers with base plates with a 1 3 16 center hole and a 1 3 8 counter bore This is to accommodate the included Quick Change guide sleeve and bushing If your router base cannot mate with the guide sleeve you can purchase a Universal Router Plate with the appropriate center hole dimensions to attach to or replace your current router base With the proper base plate installed 1 Insert the Guide Sleeve R 2 into the Base BASE PLATE WITH Plate 1 3 16 CENTER HOLE AND A 2 secure the Lock Nut R 1 firmly with 1 3 8 COUNTER the flat Soanner Wrench Provided 3 Screw the 1 1 8 Router Guide Bushing R 3 into the center of the guide sleeve and hand tighten Fig 3 Centering the Ba
9. or secured to a mounting board which can then be clamped to a bench Fig 8B WORK BENCH Fig 8A OPERATING INSTRUCTIONS 1 Marking Joint Centers and Location Mark the stock with center marks at the positions for the tenon and the mortise These marks will be needed to center the tenon section and the longitudinal position of the mortise on the stock If you have correctly set the centering wall for the thickness of the stock the stock will automatically be centered for stock thickness when clamped in the jig Tip if there is a variation in the thickness of the stock used you may adjust for this by use of appropriate shims or by readjusting the centering bar CENTER POSITION OF THE MORTISE CENTER POSITION OF THE TENON s t Fig 9 MORTISE SECTION TENON SECTION 2 Centering the Stock e Centering the stock in the jig is accomplished by adjusting the centering wall 4 Fig 10 for the thickness of the stock e The jig will handle stock with a thickness between 1 2 and 1 1 2 e Using the lumber industry s nomenclature these two thicknesses designated as 2 quarter 1 2 and 6 quarter 1 1 2 indicating the number of 1 4 increments of thickness e The markings are on the tenon end of the Centering Wall 4A Use these quarter units to adjust for the thickness of your stock in quarters For example if you are using 3 4 three quarter stock align the number 3
10. se Plate and the Quick Change Guide System 1 With your router upside down plunge the base and lock it 2 Insert the 1 4 Centering Pin R 4 in the router chuck and tighten it securely 3 Loosen the mounting screws of the base plate just enough to allow a little movement Fig 4 4 Carefully release the plunge lock and gently guide the plunge base to extension on the cone section of the centering pin Fig 5 this allows the loosened base plate to move on its screw holes to a perfect centering position 5 Tighten the base plate screws securely e Once you have completed this centering operation remove the centering pin from the router and replace it with the router bit Setting the Cutting Depth e Set the depth of your plunge router for the desired depth of your mortise and tenon e When the stock is correctly mounted in the jig its top edge will be 1 2 below the top working surface of the jig Fig 7a e Accordingly add 1 2 to the desired depth of the mortise and tenon when setting the plunge depth of the router Fig 7b DEPTH OF JOINT FROM THE FACE a THE BASE PLATE TO THE ER w TIP 0F THE CUTTING BIT EQUALS THE Fig 7B POSITIONING ARM DEPTH OF THE ROUTER IN THE FULLY SHOWN DEPLOYED JOINT PLUS 1 2 PLUNGED POSITION MOUNTING THE JIG The M amp T Jig can be mounted directly on the edge of a bench using the integral mounting flange 9 Fig 8A
11. st position and approximates a 1 joint These are actually fractional inch markings and refer to the amount of template closure For example if you set the templates to 1 2 it means that you re reducing the approx 3 long joint by a 1 2 on each side Therefore your joint size will be approx 2 Or if you set the template to 3 4 you ll be taking 3 4 from each side of the joint resulting in a joint length of approx 1 1 2 Please note the chart below indicates the exact length of each joint for each marking on the template and for each bit size Make the same ruler settings to both templates on the mortise side as well as to both sides of the tenon side to have a centered and matching mortise and tenon Fig 18 For exact joint lengths for each size bit please refer to the sizing chart below Length of Mortise and Tenon Chart Template Position Markings 4 578 258 288 ave 1778 1 5 8 138 1 18 75 38 s 238 242 lama 2 rsa 1 2 ima 1 42 sve 278 28 8 5238 216 1 778 158 158 11 18 The jig itself has two Centering Marks 1A Fig 17 on its top surface that which indicate the longitudinal center of the templates There are also Centering Notches 1B on the deployed Positioning Bars 6 they indicate the center of the template s width To keep the joint centered longitudinally always make the same template position setting to all templates Fig 17 5 Set the Depth of the Router Bit S
12. to turn the router off Tip depending on the actual thickness of your stock you may at times get a fence or flash around the edge of your tenon Fig 21 Be sure to cut file or sand it off cleanly to ensure a tight fit 1 4 UP CUT BIT SHOWN Fig 19 R 3 GUIDE BUSHING Fig 21 11 Fig 22 7 Routing the Mortise Tip when routing the mortise it is advisable to increase the depth of cut slightly more than that of the tenon to allow space for glue to be put on the tenon before inserting it into the mortise The Guide Bushing R 3 fits the Mortise Template 2 Fig 22 exactly to prevent it from wandering out of line It will be used for all mortises regardless of size Fig 23 1 Before turning on the router place the guide bushing in the end of the mortise template and Slide it through the template to be sure it moves freely Fig 23 2 With the guide bushing in the end of the template and the router base squarely on the jig surface turn the router on 3 Plunge the router and guide the router bit through the cutting process NOTE We recommend cutting the mortise in successive overlapping plunges to depth and then repeatedly move the bit back and forth to clean up the mortise slot The method you use is up to your experience on how to obtain the best cut 12 ROUTING OTHER SIZE MORTISE AND TENONS The EeZ Pro Mortise and Tenon Jig Kit includes the guide sleeve with Locking Nut
13. tock is flat and square against the Positioning Bars but not too tight and correctly centered 4 Tighten the Face Clamps enough to secure the stock from moving 5 Using their handles return the Positioning Bars to their storage position Fig15 IN USE POSITION STORED FOR ROUTING 4 Setting the Joint Length The M amp T jig has two working sections the mortise section and the tenon section Fig 16 NE 11 i gt pide 2 202022 CED MORTISE MORTISE SECTION TENON SECTION Each section is equipped with left and right Adjustable Sliding Templates 2 Fig 16 that are used to set the length of the cut There are 0 1 2 and 1 marks alongside each template s edge 2B When you set the size of the opening make sure that ALL of the templates indicate the same measurement this assures that the cut will be centered Fig 16 To adjust the templates for the desired joint length loosen the Lock Screws on the right and left template and slide them to the desired equal position as indicated with the Template Positioning Rules 2B and re tighten the screws When the 0 on the template positioning rule 2B is aligned with the Template Position Indicator 1C on the jig surface the template is open to its longest position and approximates a 3 long joint Fig 16 When the 1 is aligned with the template position indicator 1C the template is closed to its shorte
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