Woodstock REBEL W2000 User's Manual
Contents
1. ROUTER TABLE ITEM W2000 OPERATING MANUAL WOODSTOCK INTERNATIONAL WOODWORKING TOOLS AND ACCESSORIES P O Box 2309 Bellingham WA 98227 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 REVISED FEBRUARY 2004 111 lt lt VIII TABLE OF CONTENTS INTRODUCTION 2 A SAFETY INSTRUCTIONS FOR ALL TOOLS cccscsssessssssesssesssecsusssesssecsuessecsseesuessesssecsueeseaneeen 2 ADDITIONAL SAFETY RULES FOR THE REBEL 20 3 C COMMENTARY 4 OINI 7 0 lt A IN E 5 PIECE 5 ASSEMBLY sccccccsscsssecsesssecsuesscssecsuecsscsuecsuecsucssecsucesucsuscsussucsuessuessusasecsusssucssessuessnessessucssuessesaueeseeeseeee 6 10 6 SAFETY GUARD 8 D MITER GAUGE o c esceccescscccvecscecsecssessccsscccvsssecsuscsnssucceuscsecsucesssesessuecsasssessucssarssnssstesarssessatesarsaeesasere 9 E ELECTRICAL SWITCH OPTIONAL 9 F MOUNTING THE ROUTER 9 G WIRING THE ROUTER 10 ADJUSTMENTS 11 A ROUTER TABLE INSERT 11 FENCE ADJUSTMENT ccccsccssscsssssecssecsucssecsseceusssvcsuccsuessucsusesucssucsuessuecsucsuessucssucsaeesucsanceneeaucenees 12 SAFETY GUARD 13 D MITER 04008 14 OPERAT2. Inverted Fixture with workpiece Do not use rough wood composites such as oriented strand board or a plywood with inner voids for a pat tern edge The jig or fixture should also be stable com fortable to use and designed with safety in mind Secure your workpiece with blocks screws or wedges If using screws make sure they don t protrude through the finish face of your workpiece 18 W2000 Rebel The workpiece should rest flat on the surface of the table and must not chatter inside the jig There are a number of shaper handbooks available that describe many types of jigs fixtures hold downs and patterns that are used in the cabinetmaking industry These same books apply to router shaping as well When using any fixture always test it to ensure that it func tions as it was intended before turning your router on To freehand shape proceed as follows Step 1 Remove the two part fence assembly from The Rebel Step 2 Place the starting pin in the router insert or clamp a starting block to the table surface Figures 25 and 26 Figure 25 Using the starting pin Note safety guard has been raised to demonstrate pin positioning Figure 26 Using a starting block Step 3 Insert a desired router bit with support bear ing into your router and securely tighten the router collet See your router owner s manual for correct procedure ANOTE It may be necessary to lift the router insert with rout
3. deeper until reaching the desired depth Step 3 Position the infeed fence for the correct depth of cut Please refer to the Fence Adjustment Section Step 4 Select a sample piece of wood for testing Make sure the sample you choose 15 at least 12 long As with your finish piece the test piece must be processed using all safety mea sures and safety devices After you have com pleted your test cut re adjust the router bit height the fences the hold downs or other safety devises if necessary Please refer to the appropriate sections in this manual F Miter Gauge Work The miter gauge is used to control narrow workpieces when shaping or routing end grain such as door rails tenons and profiling edges To use the miter gauge Step 1 Position the miter gauge in the miter slot Always feed against the direction of router bit rotation Adjust the miter gauge angle if nec essary See Miter Gauge Adjustment on Page 15 Step 2 Since the miter gauge supports the work through the entire cut slide the outfeed fence out of the way Failure to do so may cause a dangerous kick back situation The infeed fence in conjunction with a wood block may be used as a workpiece positioning guide when using the miter gauge Step 3 Determine the depth of cut and position the workpiece against the miter gauge Firmly hold the workpiece against the miter gauge body and slide the miter gauge and workpiece past the router bit Fi
4. should be worn Wear a hat or other protective head wear if your hair is long NEVER STAND OR LEAN ON TOOL USE SAFETY GLASSES AND EAR PRO TECTION Also use a DUST MASK if the cut ting operation is dusty A WARNING 18 NEVER LEAVE THE TOOL RUNNING DO NOT OVERREACH Keep proper footing and balance at all times MAINTAIN TOOLS IN TOP CONDITION Keep tools sharp and clean for best and safest performance Follow instructions for lubricating and changing accessories DISCONNECT TOOLS FROM POWER before servicing and when changing accessories such as blades bits and cutters AVOID ACCIDENTAL STARTING Make sure the switch is in the OFF position before plugging in the cord CHECK DAMAGED PARTS Do not operate the machine until you are certain it 1s in perfect running condition UNATTENDED TURN POWER OFF Do not leave the tool until it comes to a full stop DO NOT OPERATE THE TOOL IF USING DRUGS ALCOHOL OR MEDICATION DO NOT WORK IN HASTE or operate machine if you are mentally or physically fatigued IF THERE IS SOMETHING YOU DO NOT KNOW OR UNDERSTAND DO NOT OPER ATE MACHINE Ask for help first Confusion is dangerous BAD HABITS ARE DANGEROUS Review all safety procedures often B Additional Safety Rules For The Rebel The following are important safety considerations when using The Rebel 4 WARNING Always feed against the rotation of the cutter For
5. system consists of a clear plastic guard and arm which have been assembled at the fac tory There is also a height adjustment bar mounting bracket with lock knob and bolt and washer The clear plastic guard has been designed to fit over the router bit during operation and can be connected to a 3 flex hose for dust collection purposes Step 1 Mount the safety guard mounting bracket to the back of The Rebel table with the two 4 28 x 1 socket head cap screws provided Figure 6 Figure 6 Mounting safety guard bracket Step 2 Insert the height adjustment bar into the mounting bracket so the threaded hole is fac ing up Tighten the lock knob to secure the height adjustment bar Step 3 Slide the c 18 x 34 hex head bolt through the 3416 flat washer and loosely thread into the hole on top of the height adjustment bar Step 4 Slide the slotted end of the safety guard arm under the washer and tighten the hex head bolt Figure 7 8 W2000 Rebel Figure 7 Safety guard installed D Miter Gauge The miter gauge has been pre assembled at the factory except for the handle The handle greatly aids in miter gauge control To assemble the handle Thread the handle into the hole located on top of the miter gauge body and tighten down Figure 8 Figure 8 Attaching the miter gauge handle E Electrical Switch optional Although the power switch on your router can be turned on and off each time you
6. IONS ccccsssccssssecssessuessecsseconssscsusssucssecsusssucesessueesucsuscsusssucsueesucssessuessucssecsuessnesaeessesanesseeaneesees 15 SITE PLANNING cccssccssecsecssecssecsucssecesecouessecsseceusescsuecsuecsecsusssucssecsusssuesssssessuessecsusesuesaneaseeaneesees 15 B WORKING HEIGHT 15 16 GENERAL OPERATIONS cccccssssssecssecsuessecssecsusssessuecsueesecsusesucssecsuessucssucssessuessessusesuesaneanecaneesees 16 STRAIGHT EDGE SHAPING cccccscssscsssssecssecsscssecsuecsucccvessscsscssucsusesacssecssessecssecsacesecerecsaeenecenees 17 F MITER GAUGE WORK 17 G FREEHAND WORK cccccsscsssessesssecsucssecssecsucsseceusssucssecsuecsusesecssecsucsucessecsusssessuecsussusestesanseseeaneesees 18 H USING STOP AAA A A A n E EE EEEE EEEE A ran 20 MAINTENANCE 00 cscccscesssessecsuecsucssecsueesecssecsusssvcesecsussssessecsuesucsuscsusssucssessuessusssessuessucsueesuessuseseeaneesees 21 PARTS BREAKDOWN o oo ccscssssssesssesssessesssecsuecsucesvcsucssvessecsuscsucssecsusssucsuessuessucsuessuessussueestesaneeseeaneesees 22 PARTS 1197 2 23 WARRANTY AND RETURNS 24 Always wear eye protection Always feed against the rotation of the cutter Use overhead guard when 16006 16 not in place I Introduction A WARNING For Your Own Safety Read Instructions Before Using The Rebel Keep fingers away from rotating cut
7. Please note that the safety guard is not intended to be used as a hold down All hold downs and other safety devices must be used correctly so they will work as intended Figure 19 Safety guard adjusted properly W2000 Rebel 13 D Miter Gauge In order to make straight predictable miter cuts the Step 6 Adjust the 90 miter gauge stop bolt so it rests miter gauge must be properly adjusted There are 3 against the pin Re tighten the jam nut Be adjustable stops built into the miter gauge two at 45 careful not to alter the position of the stop and one at 90 that are engaged by pushing 10 the stop bolt pin These stops make it easier to make changes in the miter gauge angle Step 7 Re check the squareness of the miter gauge to the miter slot using your square If it is not To adjust the miter gauge stops square repeat steps 1 6 Step 1 Insert the miter gauge into its slot and adjust Repeat steps 1 7 for the two 45 miter gauge stop bolts the blade angle to 90 Pull out the miter gauge stop pin Step 2 Place an accurate square against the miter 3 gauge bar and the face of the miter gauge Step 3 If there is a gap between the miter gauge bar and the square loosen the miter gauge lock knob and move the face of the miter gauge into the square until the gap is eliminated Re tighten the lock knob Step 4 Push 10 the miter gauge stop pin Stop bolt Jam nut Step 5 Loosen the ja
8. Rebel 3 C Commentary Woodstock International Inc 15 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 1t s been hammered out in someone s garage Instead you will find an inherent ruggedness which denotes strength and dura bility The Rebel represents countless hours of research development and hands on testing by skilled woodworkers The effort that went into the develop ment 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 rugged ness and durability Woodstock is committed to offering top quality products and supporting them through customer ser vice and technical documentation The manual you now have represents our latest effort to produce the best d
9. able height above the floor ranges between 32 and 36 depending on your personal preference The Rebel is 17 tall so the stand should be between 15 and 19 tall Minimum stand width and depth are 26 and 20 respectively The width and depth can of course be increased to suit your needs The stand should be strong enough and have the sta bility to support the anticipated weight of material and the hold down pressure of the operator Please follow all safety procedures when constructing a new or adapting an existing stand or bench top We also cau tion against temporary support surfaces such as a thin piece of plywood on top of a couple of saw horses While this is certainly quick we do recommend that if you use plywood and saw horses make sure that the top is strong and stable enough and will not flex or shift under load A WARNING Do not operate The Rebel in a position that will compromise comfort and safety Serious personal injury may occur Adjust the foot pads to compensate for any irregular stand surface It is very important that The Rebel is stable and supported by all four legs If machining long or unstable stock we recommend removing the feet and securing The Rebel directly to the table surface It may be necessary to shim under the legs to compen sate for an irregular stand surface before permanently securing The Rebel Mount The Rebel to the work surface with screws lag bolts or clamps
10. and understand all safety procedures about woodworking relating to your particular operation There are plenty of informa tion sources available from public TV books and video s to the high school shop instructor or wood working club in your area Do not jump right in and attempt to perform something beyond your capabili ties Instead start by making simple projects to gain the experience necessary to do more complex tasks No matter what your skill level always practice good safe ty procedures and follow the recommendations listed in this manual E Straight Edge Shaping Straight edge shaping requires the use of the fence assembly Although many edge shaping router bits have a guide bearing the fence should still be used to provide maximum support and safety during the rout ing operation Please review the Fence Adjustment Section on Page 13 Remember use a sample piece of wood and make a test cut For straight edge shaping proceed as follows Step 1 Select the appropriate router bit and mount it securely into the router collet Follow the router manufacturer s recommended proce dure Step 2 Adjust the router and router bit height in rela tion to your workpiece Lock the router height adjustment mechanism into position Again follow the manufacturer s recom mended procedure ANOTE If removing a lot of material it is best to run your stock through in multiple passes each time setting the router to cut
11. anu al If everything is secure including router collet and all loose tools and bits are put away you can now test the optional switch Plug the 110V plug from The Rebel switch into the wall outlet Turn the safety lock switch on and the router should start up If using The Rebel without the optional switch observe all safety procedures plug your router power cord into an outlet and switch the router on Some routers have a simple toggle switch while others have a trigger switch with locking device for hands free operation If your router has a spring loaded locking devise depress the trigger depress the locking devise and then release the trigger To turn the router off sim ply depress the router switch to release the locking device Please refer to the instruction manual supplied with your router for more information regarding your particular switch ACAUTION Always wear safety glasses and follow all safety procedures If using an extension cord it must be rated Hard Service Grade S or better Conductor size must be 12 AWG or larger and the cord must contain a grounding wire and plug pin Repair or replace the extension cord if damaged III Adjustments A Router Table Insert Located in the four corners of the insert ledge on the table are four holes These holes are threaded to accept the 10 32 x 54 setscrews provided Figure 14 The setscrews are turned in or out from underneath to a
12. chaser from the date of purchase This warranty does not apply to defects due directly or indirectly to misuse abuse negligence accidents repairs or alterations or lack of maintenance This is Woodstock s sole written warranty and any and all warranties that may be implied by law including any merchantability or fitness for any particular purpose are hereby limited to the duration of this writ ten warranty We do not warrant or represent that the merchandise complies with the provisions of any law or acts In no event shall Woodstock s liability under this warranty exceed the purchase price paid for the product and any legal actions brought against Woodstock shall be tried in the State of Washington County of Whatcom 24 W2000 Rebel We shall in no event be liable for death injuries to per sons or property or for incidental contingent special or consequential damages arising from the use of our products To take advantage of this warranty the product or part must be returned to the original place of purchase Proof of purchase must accompany the merchandise Woodstock reserves the right to change specifications at any time since we constantly strive to achieve better quality equipment We make every effort to ensure that our products meet high quality and durability standards and we hope you never need to use this warranty
13. d fence To adjust the two fences simply take a good quality machined straightedge and place it against the infeed fence Adjust the outfeed fence up to the straightedge and lock in position Figure 18 Figure 18 Fence alignment Please take the time to adjust your fence correctly You will avoid frustration and the chance of ruining your workpiece Remember to always use a sample and make a test cut before using a finish piece Always double check yourself and make sure that the lock knobs are securely tightened so the fence will not move during the routing process C Safety Guard The safety guard s primary purpose 16 to keep your fin gers away from the router bit The secondary function is to serve as a dust pickup Always use the safety guard Adjust the safety guard as follows Step 1 Loosen the 5 hex bolt Center the safety guard over the router collet and re tighten the hex bolt Step 2 Loosen the lock knob and lower the safety guard as close to the workpiece as possible without restricting stock movement Figure 19 After the guard has been positioned securely tighten the lock knob on the back of The Rebel table Step 3 A dust collector or shop type vacuum can be connected to the top of the safety guard Use a 3 flex hose and secure with a hose clamp Figure 19 When connecting a dust collection unit make sure that the hose and other dust pickup devices do not hamper your move ment or stock feeding
14. djust router table insert flush with the table Figure 14 Leveling setscrew and jam nut AI SE kural ON A To adjust the router table insert Step 1 Use a good quality straightedge and place it on the table surface so it rests above one cor ner of the router table insert Figure 15 Step 2 Loosen the jam nut and turn the leveling setscrew in or out so that the router table insert just touches the straightedge Step 3 Repeat this procedure for the other three comers Step 4 Re check each corner and make fine adjust ments if necessary Once the insert is level tighten down all four jam nuts Figure 15 Checking insert for flushness W2000 Rebel 11 B Fence Adjustment The Rebel uses a two piece fence adjusting system Each fence can be independently controlled This sys tem has the advantage of allowing the two fences to be offset from one another In certain applications such as edge jointing this offset is necessary to safely and precisely machine your workpiece In other instances where the outfeed bearing surface is the same as the infeed bearing surface the two fences must be perfect ly aligned in the same plane The split fence arrange ment gives you the flexibility to do both To move the fence simply loosen the two fence lock handles and slide the fence either forward or backward and lock in position Depending on the size of the router bit and the amount of material to be re
15. er out of The Rebel to safely and efficiently install or remove router bits Step 4 Set the depth of cut by raising or lowering the router in its mounting base Refer to your router owner s manual Step 5 Follow all safety procedures and turn the router on Firmly support the workpiece against the starting pin or starting block AND THEN gently swing the work into the router bit Step 6 Step 7 Figure 27 Work is supported by the guide bearing Once the workpiece or fixture is contacting the guide bearing on the router bit move the workpiece or fixture away from the starting pin or starting block and continue feeding against the guide bearing Figure 27 It is important that you feed the work smoothly and evenly in order to reduce tear out and burning In some cases it may be desirable to start and end the cut in waste portions of the workpiece in order to avoid these types of problems As you approach the end of a squared off cut control the workpiece or fixture so that the corner of the workpiece or fixture does not ride around the guide bearing Slide the work piece smoothly past the guide bearing A CAUTION There is a tremendous cutting force on the work piece Fixtures must be stable solid and designed for safety Please follow all recommended safety procedures W2000 Rebel 19 H Using Stop Blocks If a particular application requires that you precisely and consistently start and or
16. gure 23 When shaping end grain the router bit will tend to tear out the wood as the bit clears the workpiece To prevent tear out use a back up piece of wood posi tioned between the workpiece and the miter gauge You may also fasten a wood face piece against the miter gauge body with screws through the two slots Ensure that the face piece 19 long enough to support the end of the workpiece but not so long that it won t slide past the router bit Figure 23 Using the miter gauge W2000 Rebel 17 G Freehand Work The Rebel is ideally suited to performing freehand work Freehand shaping enables you to profile the edge of curved or irregular shaped wood In order to free hand shape on The Rebel The fence must be removed a starting pin or starting block and a router bit with a guide bearing must be used In many cases it 15 advantageous to use a jig or fixture during freehand shaping When properly designed a jig or fixture will Keep the workpiece firmly in posi tion speed production runs provide a guide for pattern work and provide greater safety for the operator When freehand shaping we recommend the use of a jig or fixture whenever possible When making a jig or fixture use a material that 1s dimensionally stable and is easy to fasten such as a good quality plywood or MDF If the fixture will incorporate a pattern use a material that will smoothly follow the guide bearing Figure 24 Figure 24
17. his 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 DO NOT use it until you have resolved any questions you might have D Unpacking 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 identifi cation 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 futu
18. hot of some type of protec tive coating Many types of machine table coatings are available on the market today These will keep the table surface in prime condition and reduces friction when feeding material Periodically check all bolts and fasteners to make sure that they are tight Periodically check the router insert and ensure that it is flush to The Rebel table Ensure that the router is firmly mounted to the router insert Inspect the router especially the collet Ensure that the collet tightens securely around the router bit W2000 Rebel 21 VI Parts Breakdown 20 ae 227 46 497 SEE ye 22 W2000 Rebel VII Parts List Ref Description Ref Description 2 PHILLIPS HD SCREW 10 24 X 3 4 2 3 PANEL PUSH HANDLE LOCK KNOB 5 CAP SCREW 1 4 28 X 5 3 FLAT WASHER 7 FIBER WASHER g FOOT 9 FINE C ________ 10 FLAT WASHER 10 SCALE GUIDE STUD FLAT HEAD SCREW 1 4 20 X 1 4 STOP PIN 14 STOP BLOCK MITER BAR HEX NUT 10 32 BRACKET FLAT HEAD SCREW 1 1 28 X 3 2 SMALL INSERT PHILLIPS HD SCREW 6 32 X LARGE INSERT STARTING PIN CAP SCREW 2 28 X 1 MITER BODY W2000 Rebel 23 VIII Warranty and Returns Woodstock International Inc Woodstock warrants this product against defects in workmanship and mate rials under normal use and service for a period of one year This warranty extends to the original pur
19. igure 11 Removing sub base from router W2000 Rebel 9 Step 2 Center the sub base on the table insert and mark the screw mounting locations on the table insert Figure 12 To find the center of the table insert position the sub base on the table insert so the distance from edge to edge on the right and left side are the same and the distance from edge to edge on the top and bottom are the same Figure 12 Marking insert for drilling Step 3 Drill and counter sink the screw holes 10 the table insert Fasten the router base to the router table insert using the screws from the router sub base Figure 13 Counter sink Figure 13 Drill and counter sink insert 10 W2000 Rebel A CAUTION Your existing sub base mounting screws may be too short to safely secure your router to the table insert Ensure that your mounting screws are suffi ciently long enough to safely hold your router inverted position If necessary purchase longer mounting screws of the same thread size to secure your router to the table insert Step 4 Make sure all router mounting screws fas tened securely and slip the router with the router table insert into The Rebel table G Wiring the Router If using the optional safety switch make sure it is in the off position You can now plug your router into the cord connected to the back of the switch Turn the router switch on Refer to the router instruction m
20. m nut on the stop bolt Figure 20 Miter gauge 14 W2000 A Site Planning Although The Rebel is completely portable and can be set up and used just about anywhere we would like to discuss some basic considerations When choosing a location for The Rebel ensure that there is adequate room for maneuverability and safety Give yourself enough room for the longest piece that you anticipate shaping Keep the area clean and open so that you can access The Rebel from all four sides This not only gives you plenty of elbow room but 1 makes adjusting and using The Rebel that much safer and easier If you plan to process long stock we suggest that you pick up a couple of roller stands to support the infeed and outfeed end of the workpiece during machining Finally when choosing a location make sure that you have adequate lighting so that you can clearly see what you are doing When transporting The Rebel to the job site take measures to protect it from damage Do not stack other equipment or lumber on top of the table Secure The Rebel so it will not bounce around and cause nicks dents and or casting cracks Once at the job site observe the same considerations as you would for sta tionary use Always give yourself plenty of room B Working Height The Rebel was designed to be used with a fabricated stand to raise the height to a comfortable distance above the floor The recommended working t
21. most routers and bits the direction of feed is from right to left as you face The 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 Use quality material Wood that is cupped warped bent or split will not machine proper ly and can present many safety hazards Do not shape or rout material that contains loose or unsound knots 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 16 held securely in the collet 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 15 a greater ten dency for kick back Hold the workpiece firm ly using clamps jigs or fixtures and feed even ly Wear ANSI approved safety equipment such as eye face ear and respiratory protection Use sharp router bits The old adage is true A sharp tool is a safe tool Plan your work Figure your steps out before you start cutting Do not shape material that is too small to be safely processed without a jig or fixture to hold the piece Make sure that all fasteners used in assembly have not vibrated loose A starting pin or starting block must be used when shaping irregular workpieces W2000
22. moved adjust the infeed fence The infeed fence is the right hand fence as you are facing the front of The Rebel Slide the infeed fence to the back or to the front depending upon the desired depth of cut Use a good quality rule to measure the distance between the miter gauge slot and the maximum arc of the router bit Transfer this measurement less the desired depth of cut to both ends of the infeed fence You can also gauge the infeed fence by placing a sam ple piece of wood against the fence and sliding it up to the router bit Figure 16 Figure 16 Gauge position of infeed fence with a sample piece of wood 12 W2000 Rebel For applications where the entire edge of the work piece 1s being shaped the outfeed fence must be offset by the same amount of material that you are removing Use a sample piece at least 12 long as a test piece Read and follow all safety procedures covered in this manual before cutting a sample A WARNING Do not make fence adjustments while the router is running Adjust your infeed fence accordingly Feed the sample far enough so that the end of the workpiece extends well beyond the cutter and overlaps with the outfeed fence Figure 17 With the uncut end still supported by the infeed fence adjust the outfeed fence so that it sup ports the other end of the workpiece After the outfeed fence contacts the workpiece and is securely locked in position begin again with you
23. ocumentation possible If you have any criti cisms 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 con tact your Woodstock distributor or call Woodstock International at 1 800 840 8420 between 8am and 5pm Pacific Standard Time Monday through Friday 4 W2000 Rebel 4A WARNING To operate this or any tool safely and efficiently it is essential to become as familiar with its charac teristics as possible Take as much time as neces sary 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 The specifications drawings and photographs illus trated 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 t
24. place it For expediency replacements can be obtained from your local hardware store Figure 1 Rebel parts ready for assembly W2000 Rebel 5 Assembly 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 Z 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 light ed area to reduce eye strain during assembly Figure 2 Mounting legs and side panels to the work A Stand ing table The stand is made up of four legs two side pieces and a front piece and back piece All similar parts are inter changeable with one another Step 1 Turn the working table up side down and loosely bolt on all four legs using the 4 28 x socket head cap screws provided Step 2 Mount the short and long side panels between the legs using the 1 4 28 4 socket head screws provided Figure 2 Step 3 Use Allen wrench
25. r test piece and make a full length sample cut If your workpiece catches on the edge of the outfeed fence then the fence must be set back slightly for the workpiece to clear On the other hand if everything clears but your are getting snipe on the end of your workpiece then the edge of the outfeed fence needs to be brought forward Figure 17 Gap indicates amount fence should be adjusted Both fences must also be perfectly parallel with each other Check each fence with a precision rule against the miter slot Add the offset amount if any and mea sure the outfeed fence at both ends If each end of the infeed and outfeed measurements are the same then the two fences are parallel For applications where an adequate bearing surface remains after edge shaping the fences must be in a straight line in relation to one another One of the eas iest ways to do this is to remove the existing wood fac ings and put on a one piece unit Make sure the piece you use is rigid enough so it does not flex as you push your workpiece along We recommend using hard wood plywood for stability and strength Of course most species of solid hardwoods are just as suitable birch maple etc For some applications it may be necessary to notch the bottom of the auxiliary wood fence so it will clear the router bit If you would rather use the fence as 15 then you must adjust the outfeed fence so it lies in the same plane as the infee
26. re 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 16 not a occurrence it is possible that or more of the parts could have been missed during the machining and deburring process E Piece Inventory 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 1 Working Table 4 Legs 4 Rubber Feet 2 Short Side Panels 2 Long Side Panels 2 Aluminum Fences 1 Plastic Insert Assembly 1 Starting Pin 1 Safety Guard 1 Safety Guard Bracket 1 Safety Guard Rod 1 Lock Knob 2 Wood Facings 1 Miter Gauge 4 Fence Lock Handles 1 Miter Gauge Handle 4 T Nuts Bagged 1 Bolt Bag Arm Contents of the bolt bag Size 1 4 28 x 5 8 1 4 28 x 1 10 32 x 3 4 10 32 1 4 20 Flat Washers ig Flat Head Screws 4 20 x 1 4 Hex Bolt ie 18 x Wrench ag gt fe Description Cap Screws Setscrews Hex Nuts He hL HB B 2 In the event that any non propriety parts are missing e g a bolt or nut etc we would be glad to re
27. stop multiple workpieces at the same place it may be beneficial to use stop blocks Stop blocks are positioned so that when the end of the workpiece contacts the stop block travel is restricted Figure 28 For example if cutting mortises with a router they must be precise in length so that the tenons will fit properly In some instances it may be desirable to precisely start and or stop while doing edge work such as chamfering Stop blocks can be sim ple scraps of wood that clamp to the fence or table or they can be adjustable after market stop blocks that attach to the top of the fence To use stop blocks deter mine their position and secure to the fence or table The amount of offset between the stop block and router bit 15 dependent upon the distance between the end of the cut and the end of the workpiece Test your setup with a scrap piece of wood and adjust if necessary Once the stop blocks are properly adjusted it is a sim ple matter to produce consistent multiple cuts 20 W2000 Rebel Figure 28 Stop block in position Because there are no moving parts maintenance 15 vir tually eliminated However we do make the following 4 WARN ING recommendations Any maintenance performed on The Rebel should be only done after the router has been turned off and the cutter has come to a complete stop and the plug pulled from the outlet Failure to do so may result in serious personal injury Give the table a s
28. ters Do not use awkward hand positions 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 A WARNING KNOW YOUR POWER TOOL Read the owner s manual carefully Learn the tool s applications and limitations as well as its par ticular hazards KEEP ALL GUARDS IN PLACE and in working order 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 ground ing prong 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 KEEP WORK AREA CLEAN Cluttered areas and benches invite accidents AVOID DANGEROUS ENVIRONMENTS Do not use power tools in damp or wet loca tions or expose them to rain Keep your work area well lighted 2 W2000 Rebel 7 KEEP CHILDREN AND VISITORS AWAY All children and visitors should be kept a safe distance away from your work area MAKE WORKSHOP CHILD PROOF with padlocks master switches or by removing starter keys DO NOT FORCE TOOL Tools work better and more safely when they are allowed to work at their own speed WEAR PROPER APPAREL Do not wear loose clothing gloves neckties or jewelry that might get caught in moving parts Non slip footwear
29. to assist in starting and tighten all cap screws down Step 4 Attach the feet to the legs Figure 3 Figure 3 Attaching the feet to the legs Step 5 Turn the stand assembly over and move on to the next section 6 W2000 Rebel B 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 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 Figure 4 Attaching the 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 18 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 start ing the router Figure 5 Attaching the wood facing W2000 Rebel 7 C Safety Guard The safety guard
30. use The Rebel the optional switch Item Number W2001 offers greater convenience and safety The optional switch is avail able through your retailer The switch assembly consists of a guarded rocker type switch with removable key three prong 110 volt female cord and three prong 110 volt male power cord Step 1 Mount the electrical switch in the nght front leg opening To mount the switch feed the male and female cords through the leg open ing and snap the switch plate into place Figure 9 Figure 9 Installing the switch Step 2 The two grounding terminals must be attached to the Rebel frame Remove any convenient socket head cap screw attaching the leg to the tabletop Overlap the two ring terminals connected to the end of the two grounding green wires Insert the socket head cap screw through the ring terminals and re fasten to the tabletop Figure 10 A WARNING The Rebel must be electrically grounded when using the optional switch Failure to attach the grounding terminal to the Rebel frame may result in serious personal injury Grounding Ring Terminals Figure 10 Attaching the grounding ring terminals F Mounting the Router Attaching your router to The Rebel is very easy When using your router in The Rebel you must follow all safety recommendations by the router man ufacturer Step 1 Remove the existing router sub base that is attached to your router base Figure 11 F
31. whichever is easier W2000 Rebel 15 C Safety Before you use your Rebel Please review the general safety rules for all power tools listed in the beginning of this manual A WARNING Please observe all safety rules specified in your router owners manual Make sure you fully under stand your capabilities and that you have a complete understanding of your router and the inherent haz ards associated with it You must follow all safety procedures and perform each operation in the safest way possible Failure to do so may result In serious personal injury There are many after market hold down devises avail able that increase the safety factor when processing material These hold down devises include spring loaded pressure wheels and feather boards Figure 21 and 22 Figure 21 Pressure rollers 16 W2000 Figure 22 Feather board A WARNING When adjusting the fence replacing router bits or performing any maintenance or inspection always turn the router off make sure it has come to a com plete stop and pull the plug from the outlet BEFORE performing such duties Serious personal injury may occur D General Operations The general operating procedures are just that gener al in nature They are not the final word on perform ing any one of the many functions that are possible with The Rebel If you are a beginning woodworker gather as much information as you can
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