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BEFORE BEGINNING

 

Identify and verify that you have all the parts 

listed. Read the instructions at least once, familiarizing 

yourself with the parts before beginning. You'll 

need a #3 Phillips screwdriver for assembly.  

ASSEMBLY

 

Attach the 12" One Track 

(4212)

 to the Mounting 

Plate 

(8615A)

 using two 3/4" screws 

(5771B)

 and two 

Offset Oval Nuts 

(5765B)

.  Set the assembly on edge so 

the edge of the One Track and the edge of the Mounting 

Plate are even with each other, then center the One Track 

on the Mounting Plate and tighten the screws. 

See fig. 1  

 

Insert two 1" Screws 

(5772B)

 thru the front 

mounting holes in the Toggle Clamp 

(6305)

, insert the 

non-threaded holes in the Clamp Pad 

(6305B)

 over the 

ends of the screws, then tighten the screws in the two 

threaded holes in the Mounting Plate. 

See fig. 2 

 

 Set the 35mm Cup Routing Plate 

(8615B)

, with its 

recessed slots facing up, in the recessed area on the Mounting 

Plate.  Set an Oval Nut 

(5760B - raised side up)

 in each 

slotted recess in the Cup Routing Plate. Install a 1/8" Spacer 

(BUSH001)

 on each of two 1" Screws 

(5772B)

 and insert the 

screws thru the holes in the Mounting Plate on either side of 

the Toggle Clamp, in to the oval nuts and tighten. 

See fig. 3

 

Install a 1/4" Spacer 

(BUSH002)

 on two of the 1/2" 

Screws 

(5770B)

.  Start an Offset Oval Nut 

(5765B) 

on 

the end of each screw and insert one in each end of the 

One Track so there’s one on each side of the Mounting 

Plate.  Turn the offset portion of the oval nut towards 

the Mounting Plate when you install it. 

See fig. 4

 

1

2

3

1

4

The edge of the slot 

nearest the center of the 

Cup Routing Plate is the 

center line of the jig.

5771B

5765B

4412

8615A

8615B

5760B

5772B

5772B

BUSH001

5770B, BUSH002 & 5765B

6305

6305B

Summary of Contents for 8615

Page 1: ...ption Qty 5772B 1 Screw 4 Part Description Qty 5770B 1 2 Screw 2 Part Description Qty 5765B Offset Oval Nut 4 Part Description Qty BUSH002 1 4 Spacer 2 8615 Hinge Routing Jig Please Read Carefully Part Description Qty 5771B 3 4 Screw 2 Part Description Qty HB030 1 Bolt 1 Part Description Qty WB002 Washer 3 Part Description Qty BUSH001 1 8 Spacer 2 Part Description Qty NUT250 Cap Nut 2 Part Descrip...

Page 2: ...aded holes in the Mounting Plate See fig 2 Set the 35mm Cup Routing Plate 8615B with its recessed slots facing up in the recessed area on the Mounting Plate Set an Oval Nut 5760B raised side up in each slotted recess in the Cup Routing Plate Install a 1 8 Spacer BUSH001 on each of two 1 Screws 5772B and insert the screws thru the holes in the Mounting Plate on either side of the Toggle Clamp in to...

Page 3: ...jig and can be used to reference the jig to an index mark on the work See fig 3 Measure from the Cap Nut on the Stop to the center of the Cup Routing Plate and adjust the Stop to the distance needed up to 4 1 4 or 108mm max Use the Screw 1 4 Spacer between the Mounting Plate and the Stop as a stop for the Stop By adjusting this stop on each side of the jig you can move the Stop from one side of th...

Page 4: ...th of the bit taking into account the thickness of the jig Plunge the router bit slowly into the approximate center of the hinge cup opening in the Cup Routing Plate moving in a small clockwise circle as you plunge to cut a relief opening Move towards an edge of the hinge cup opening then move clockwise following the edge of the hinge cup opening until the hinge cup has been cut See fig 9 Before m...

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