ROCKLER 68393 4-in-1 Cutting Board Handle Routing Template Instructions

ROCKLER 68393 4-in-1 Cutting Board Handle Routing Template

GENERAL SAFETY WARNINGS

This product is designed only for specific applications as defined in the instructions and should not be modified or used for any manner not described in these instructions. Use only recommended accessories. Before using the 4-in-1 Cutting Board Handle Routing Template: READ, UNDERSTAND and FOLLOW ALL INSTRUCTIONS AND SAFETY WARNINGS. KEEP THESE INSTRUCTIONS READILY AVAILABLE FOR FUTURE REFERENCE.

• Always confirm that you are using the most recent version of the Instructions and safety warnings for your product (see the Instructions link on the product page at Rockler.com).

• Before using another tool with this product, always read, understand and follow the instructions and safety warnings in the owner’s manual for that tool. If you do not have the owner’s manual, obtain one from the tool’s manufacturer before using it with this product.

• Before using any chemical with this product, always read, understand and follow all safety warnings
  and guidelines in the manufacturer’s Safety Data Sheet (SDS; formerly called “MSDS”), especially regarding:

  • How to safely use the chemical, including potential hazards and recommended first aid measures;
  • Personal safety equipment required to safely use the chemical (e.g. gloves, eye protection, mask/respirator, etc.);
  • Proper and safe handling, storage and disposal of the chemical.

• Before using this product, review and verify that all tools to be used with it have safety equipment installed and are in proper working order as defined by the tool’s owner’s manual.

• Do not use this product until you have read and are confident you understand:

  • Product Specific Safety Warnings (p. 3);
  • Assembly (pp. 4 – 5);
  • Setup for Cutting (p. 6);
  • Cutting (pp. 7 – 8).

•  The user assumes all risk and responsibility for the proper and safe use of this product and for ensuring product suitability for the intended application.

• It is the sole responsibility of the purchaser of this product to ensure that anyone you allow to use this product reads and complies with all instructions and safety precautions outlined in this manual prior to use.

• Follow all standard shop safety practices, including:

  • Keep children and bystanders away from the tool operating area;
  • Do NOT use power tools in explosive environments, or in the presence of flammable liquids, fumes or dust;
  • TURN OFF AND UNPLUG all power tools BEFORE making any adjustments or changing accessories;
  • Remain alert and use good judgment. Do not use this product if you are in any way impaired by medications, alcohol, drugs or fatigue;
  • Keep your work area well lit and clean;
  • Dress appropriately. Secure loose clothing, remove all jewelry and tie up long hair before using this product;
  • ALWAYS wear safety glasses, hearing protection and respiratory protection that complies with NIOSH/OSHA/ANSI safety standards;
  • Use dust collection tools and dust face masks to reduce exposure to dust;
  • Use safety equipment such as featherboards, push sticks and push blocks, etc., when appropriate;
  • Maintain proper footing at all times and do not overreach;
  • Do NOT force woodworking tools.

• These warnings and instructions do NOT represent the total of all information available regarding tool safety, use and technique. Always seek out opportunities to learn more and improve your skills and knowledge.

WARNING: Drilling, sawing, sanding or machining wood products can expose you to wood dust, a substance known to the State of California to cause cancer. Avoid inhaling wood dust or use a dust mask or other safeguards for personal protection. For more information go to www.P65Warnings.ca.gov/wood.

Danger indicates a hazardous situation that, if not avoided, will result in death or serious injury.
Warning indicates a hazardous situation that, if not avoided, could result in death or serious injury.
Caution indicates a hazardous situation that, if not avoided, may result in minor or moderate injury or property damage.
Notice indicates important or helpful information and/or user tips.

PRODUCT-SPECIFIC SAFETY WARNINGS

• To avoid serious injury, keep hands and fingers away from spinning router bit. Maintain awareness of the bit at all times.

WARNING

• In addition to these instructions, be sure to read, understand and follow the user’s manual that came with your router, including all safe-operating instructions.
• Use only with a plunge router that can accept a standard guide bushing.
• Unplug your router before installing or adjusting the router bit or guide bushing.
• Make sure the workpiece will not shift during the routing process. Elevate the workpiece on Bench Cookie Work Grippers (46902, sold separately) or secure it to a sacrificial board with double-sided tape or 2-Sided Stick-It Dots (61868, sold separately).
• When it’s not possible to clamp the template to the workpiece, you MUST secure the template to the workpiece with double-sided tape or 2-Sided Stick-It Dots (61868, sold separately).

CAUTION

• Do NOT attempt to cut the full depth in a single pass. Cut no more than 1/4″ deep in each pass. Make multiple passes to achieve final depth.
• Use of dust collection is strongly recommended. When routing holes, remove router from template between passes and vacuum residual dust from holes to ensure guide bushing can maintain contact with template. Dust buildup could prevent router from cutting uniform handle holes.

NOTICE

• To achieve the 1″, 11⁄4″ or 11⁄2″ spacing from the edge of your workpiece to the routed handle opening, you must use a 3/8″ diameter router bit. Spiral up-cut bits are strongly recommended. Using a smaller-diameter router bit will increase the spacing from the edge of the workpiece.

Prepare the Router

WARNING

• Use only with a plunge router that can accept the included standard 11⁄4″ guide bushing.
• Unplug your router before installing or adjusting the router bit or guide bushing.

1. Check the baseplate on your plunge router to make sure that it is centered on the router base. If it isn’t, adjust it by loosening the screws that hold the baseplate to the base and shifting the plate. Some routers come with an accessory to center the baseplate. If yours didn’t, Rockler carries a Router Baseplate Centering Guide for both 1/4″ and 1/2″ collets (89238 and 80548, sold separately).
2. Install the included guide bushing and locking ring on the baseplate.
3. With the router unplugged, securely install a 3/8″ diameter straight or spiral up-cut router bit.

Set Up the Template on the Workpiece
The template has nine clusters of three holes along the edges. These clusters are positioned near the shape openings, and they accept the included registration pins to provide consistent spacing from the edge of the workpiece. When the recommended 3/8″ diameter router bit is used and the registration pins are installed in the innermost holes, the routed handle opening will be 1″ from the edge(s) of the workpiece. When the registration pins are installed in the middle holes, the spacing from the edge(s) will be 11⁄4″. And when the registration pins are installed in the outermost holes, the routed handle opening will be 11⁄2″ from the edge(s). Fig. 1.

1. Determine where you want the handle opening to go on your workpiece. If referenced off of a corner or an edge, determine which set of registration pin holes you want to use to achieve the desired spacing.

2. Place the registration pins in the holes for the desired spacing. If the handle opening will be in a corner of your workpiece, use all four pins (two per edge). If referencing off of one edge of the workpiece – to center the handle opening, for example – use two pins.
   WARNING: Make sure the workpiece will not shift during the routing process. Elevate the workpiece on Bench Cookie Work Grippers (46902, sold separately) or secure it to a sacrificial board with double-sided tape or 2-Sided Stick-It Dots (61868, sold separately). When it’s not possible to clamp the template to the workpiece, you MUST secure the template to the workpiece with double-sided tape or 2-Sided Stick-It Dots (61868, sold separately).

3. Place the template on the workpiece, with the registration pins against the edges, and secure the template in place. Use clamps, so long as you can move the router along the cutting path unimpeded. If that’s not possible, use double-sided tape or 2-Sided Stick-It Dots (61868, sold separately). Fig. 2. If centering the routed handle opening, draw a centerline on your workpiece and line up the template to that line. Use double-sided tape or 2-Sided Stick-It Dots (61868, sold separately) to fully secure the template to the workpiece. Fig. 3.

4. Check the template and workpiece to ensure that neither will shift during routing.

Rout the Handle Opening

1. With the plunge router turned off and the bit fully retracted, position the router on the template so the guide bushing is in the desired opening, up against the edge nearest you. Set the cutting depth to no more than 1/4″; most plunge routers include stop mechanisms that allow you to set several cutting depths.
2. Turn on the router and carefully plunge the bit into the workpiece no more than 1/4″ deep for the first pass, locking the depth at this setting.
3. Keeping the guide bushing tight against the edge of the template opening, move the router in a clockwise direction until you’ve routed the full outline of the handle. Then move the router back and forth to cut the interior of the handle opening. Fig. 4.
4. Once the opening has been fully routed with that depth setting, retract the bit and turn off the router. Allow the bit to come to a stop and remove the router from the template.
5. Blow or vacuum out any dust or chips left in the opening.
6. Adjust the depth setting on your router to cut an additional 1/4″.
7. Place the router back on the template and repeat Steps 1-6 until you have routed all the way through your workpiece.
8. Remove the template. If desired, chuck a bearing-guided round-over bit in your router to soften the edges of the opening for more comfortable handling.

Check Rockler.com for updates. If you have further questions, please contact our Technical Support Department at 1-800-260-9663 or support@rockler.com

Distributed by Rockler Companies, Inc. 4365 Willow Dr. Medina, MN 55340 68393 Rev 07/22
1-800-279-4441
www.rockler.com

References

• Woodworking Tools, Hardware, DIY Project Supplies & Plans - Rockler
• P65Warnings.ca.gov/wood
• Woodworking Tools, Hardware, DIY Project Supplies & Plans - Rockler

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