ROCKLER 53687 Rock Steady Folding Top Extension Kit Instructions

Create with Confidence™
Rock-Steady Folding Top Extension Kit Instructions
Effective June 2022
Instructions

53687 Rock Steady Folding Top Extension Kit

Review full instructions prior to use for important safety information.
Always check Rockler.com to confirm that you are using the most recent version of instructions for your product.

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 Rock-Steady Folding Top Extension Kit: 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);
• Parts List (p. 4);
• Configure Brackets for Your Application (p. 5);
• Attaching Brackets to Shop Stand (p. 5);
• Attaching Brackets to Wooden Workbench (pp. 6 – 7);
• About the Extension Tabletop (p. 7);
• Attach Legs to Extension Tabletop (p. 7);
• Mount the Extension Tabletop to the Tabletop Bracket (pp. 7 – 9);
• Folding the Tabletop for Storage (p. 9);
• Shop Drawings – Leg Mounting Hole Template (p. 11).

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

PRODUCT SPECIFIC SAFETY WARNINGS

WARNING

The Rock-Steady Folding Top Extension Kit is NOT designed for – nor should it be used for – wall mounting.

The maximum weight capacity per pair of brackets and legs depends on the material used for your tabletop. Under no circumstances should the load on the table exceed 250 lbs., including the weight of the tabletop.
To avoid pinching or crushing your fingers, always keep your hands clear of the leg folding mechanism and the bracket hinge mechanisms.
Before using tabletop, both Adjustable Leg Assemblies (10) must be deployed and locked.
Do NOT sit or stand on tabletop or allow children to climb or play on or under the tabletop; keep pets away.
Ensure table feet are positioned flat; do NOT use on sloped or uneven ground.
To avoid tipping, do NOT overload table; make sure load is centered on table surface.
If the Rock-Steady Folding Top Extension Kit is installed on a worktable with casters, the casters must be locked before using the extension table
Maximum workbench leg thickness (if mounting to a wooden bench or table): 11⁄2″
Extension top minimum thickness: 3/4″ for plywood or solid wood 11⁄8″ for MDF
Do NOT use with a particleboard top
Maximum tabletop thickness: 1½”

CAUTION

Make sure to fully tighten all fasteners.

Do NOT attempt to lift more than you are physically able.
Get help if necessary. Use proper lifting techniques.

PARTS LIST

Fig. 1

Configure Brackets for Your Application
The Tabletop Brackets (1) and Stand/Bench Brackets (2) come assembled in a configuration for mounting to Rock-Steady Shop Stands and the Rock-Steady Router Table Stand or to wooden workbenches. They also can be reconfigured to mount to Rockler’s legacy shop stands.
To reconfigure each bracket/hinge assembly for Rockler’s legacy shop stands:

1. Use one 4mm hex wrench (not included) in each M6 Flange Bolt (5) to loosen and remove at least one of the bolts. If you don’t use a hex wrench in each bolt, the Barrel Bushing (4) will spin as you try to loosen the bolts.

2. Slide out the Barrel Bushing (4). The Plastic Bushings (3) hould remain in the Tabletop Bracket (1); if they come out, reinstall them before reassembling the brackets.

3. Rotate the Stand/Bench Bracket (2) 180° so that the diagonally spaced square holes are at the top.

4. Align the holes in the arms of the Tabletop Bracket (3) with the top connection holes in the Stand/Bench Bracket (2), making sure that the Plastic Bushings (3) are in the
   correct position.

5. Slide the Barrel Bushing (4) back into position, joining the brackets.

6. Reinstall and tighten the M6 Flange Bolts (5)

Attaching Brackets to Shop Stand

1. On the face of the Shop Stand where you want to install the table extension, remove the two carriage bolts, washers and nuts attaching the leg to the top stretcher in the left corner.
   Keep track of the washers and nuts; you will reuse them to attach the bracket/hinge assemblies.

2. Make sure that your bracket/hinge assemblies are configured to match your model of shop stand. If they’re not, refer to the Configure Brackets for Your Application section above to reconfigure them.

3. Align the square holes in the Stand/Bench Bracket (2) with the holes in the stand where you just removed the carriage bolts, washers and nuts.

4. Use two of the 5/16″-18 Carriage Bolts (6) included in the Folding Top Extension Kit, as well as the nuts and washers you removed in Step 1, to connect the bracket/hinge
   assembly to the stand (and the leg to the stretcher). The carriage bolts included in this kit have a longer square section next to the head so they can register in the square holes of both the bracket and the leg of the stand.

5. Repeat Steps 1-4 to install the other bracket/hinge assembly on the right corner.

Attaching Brackets to Wooden Workbench

1. Make sure that your bracket/hinge assemblies are configured so that the straight vertical set of square holes on the Stand/Bench Brackets (2) is at the top. If they’re not,
   refer to the Configure Brackets for Your Application section above to reconfigure them. This will position the two rounded slot holes at the top.

2. Determine whether you need to mount the bracket/hinge assemblies on the legs of the workbench or the underside of the top. If the top overhangs the face of the leg to
   which the brackets would be attached by 31⁄2″ or more, the bracket/hinge assemblies must be mounted to the underside of the benchtop.

NOTICE
If mounting to the legs of your wooden workbench:
A. Position a bracket/hinge assembly in the desired location on each leg, with the top edge of the Stand/Bench Bracket (2) 1/16″ below the underside of the top.
B. Holding the bracket/hinge assembly in position, use a combination or try square to make sure that it is square to the leg and make a mark at the center of each of the two rounded slots in the Stand/Bench Bracket (2).
In addition to the slots, the Stand/Bench Brackets (2) have a round hole for installing a third M6 x 50mm Flathead Bolt (7) once the extension top is installed and leveled with the top of your workbench. You will mark and drill the hole and install the bolt after you have fine-tuned the position of your extension top later in the process.
C. Drill 1/4″ diameter holes all the way through each leg at the marked locations. Take care to drill the holes as straight as possible. If necessary, use a drill press or drill guide, such as the Portable Drill Guide (52885, sold separately).
D. Chuck a countersink in your drill to ease the edges of the holes you just made so that the heads of the M6 x 50mm Flathead Bolts (7) will sit flush to the surface. The holes
need to be countersunk only in the leg face opposite where the bracket/hinge assemblies will be attached.
E. Repeat process for the other bracket/hinge assembly on the other leg.
F. Attach each bracket/hinge assembly to the workbench leg with two M6 x 50mm Flathead Bolts (7), two Flat Washers (8) and two M6 Nylon Insert Locknuts (9).

If mounting to the underside of the top of your wooden workbench:
A. Determine where along the edge of your benchtop you want to mount the bracket/hinge assemblies and mark the locations on the underside of the benchtop.
B. At these locations, measure in 5/8″ from the edge of the benchtop and mark lines parallel to the edge of the table.
These lines will be used to help locate the holes for mounting the Stand/Bench Bracket (2) to the benchtop.
C. At these locations, use a combination or try square to hold each bracket/hinge assembly in position on the underside of the benchtop, with the end of the Stand/Bench Bracket (2) flush and perfectly square to the edge. Make a mark at the center of each of the two rounded slots in the Stand/Bench Bracket, as well as the centered circular hole.
D. Working from the underside of the benchtop, drill 1/4″ diameter holes all the way through at the marked locations.
Take care to drill the holes as straight as possible. If necessary, use a drill press or drill guide, such as the Portable Drill Guide (52885, sold separately).
E. Chuck a countersink in your drill to ease the edges of the holes on the top of the benchtop so that the heads of the M6 x 50mm Flathead Bolts (7) will sit flush to the surface.
F. Attach each bracket/hinge assembly to the workbench leg with three M6 x 50mm Flathead Bolts (7), three Flat Washers (8) and three M6 Nylon Insert Locknuts (9).

About the Extension Tabletop
You will need to build a top to serve as your extension table. In all cases, the thickness of the extension top MUST match the thickness of the stand’s or bench’s tabletop for the added surface to be flush.
The length and width of the table depend on the depth and height of the stand or bench. Keep in mind that the Adjustable Leg Assemblies (10) need 26″ along one dimension to be able to retract and fold up.

Attach Legs to Extension Tabletop

1. Place your tabletop topside down on a smooth work surface.
2. Determine how you need to orient the legs so that they will fit within the area of the extension tabletop when retracted and folded up for storage. Note that if they will fold toward each other, their mounting positions must be offset so that they both can fold flat. Again, one dimension of the tabletop must be at least 26″ to allow the Adjustable Leg Assemblies (10) to retract and fold up within the area of the top.
3. Use the template in the Shop Drawing (p. 11) to mark the locations of holes you need to drill to attach the Adjustable Leg Assemblies (10) to the tabletop. Note that the template includes guides for creating a 1″ setback from the tabletop edges. Keep in mind that if the Adjustable Leg Assemblies will fold toward each other, their mounting positions must be offset.
4. With the top still topside down, drill 1/4″ diameter holes all the way through the top at the marked locations. Place a sacrificial backer piece under the drilling locations to minimize blowout and take care to drill the holes as straight as possible. If necessary, use a drill press or drill guide, such as the Portable Drill Guide (52885, sold separately).
5. Flip the tabletop right side up. Chuck a countersink into your drill to ease the edges of the holes you just made so that the heads of the M6 x 50mm Flathead Bolts (7) used to mount the Adjustable Leg Assemblies (10) to the tabletop will sit flush to the surface.
6. Double-check that you’ve oriented the Adjustable Leg Assemblies (10) correctly; then attach each Leg Assembly to the tabletop with four M6 x 50mm Flathead Bolts (7), four Flat Washers (8) and four M6 Nylon Insert Locknuts (9).

Mount the Extension Tabletop to the Tabletop Bracket

1. Measure the distance from the surface of your shop stand top or benchtop to the floor. Then subtract the thickness of your tabletop from that number.
2. Unfold the Adjustable Leg Assemblies (10) until they lock in the open position. On each Leg Assembly, press the blue paddle nearest the bottom and pull on the leveler foot to extend the leg. (The slots allow you to extend the leg in 1″ increments.) Measure the distance from the bottom of the leveler foot to the underside of the tabletop, and keep adjusting the Adjustable Leg until the length is approximately equal to the final number from Step 1. Do this for both Leg Assemblies. (You might want to mark the slot setting for future reference.)
3. Locate or cut two straight pieces of 3/4″ thick scrap wood that are at least 2″ wide and 1′ long. Place these two pieces on the top of your shop stand or workbench, toward the sides, so that they extend over the edge where you will mount the extension table. Clamp these pieces securely in place with bar clamps.
4. Position your extension table with legs deployed where you will want it against the shop stand or workbench. Make sure the extension tabletop is under the scrap pieces you clamped in Step 3, and leave a gap of at least 1/16″ between the edge of your extension tabletop and the edge of the top of your shop stand or workbench; this will allow the extension tabletop to be lowered without binding. Clamp the extension tabletop securely to the scrap boards. Fig. 1.
5. Working from under the extension tabletop – and being careful not to shift anything – carefully mark the six screw hole locations (three on each bracket) for attaching the tabletop to the Tabletop Brackets (1).
6. Unclamp the extension tabletop and set it topside down on a work surface where you will be able to work on it more easily. Drill 1/4″ diameter holes all the way through the top at the marked locations. Place a sacrificial backer piece under the drilling locations to minimize blowout and take care to drill the holes as straight as possible. If necessary, use a drill press or drill guide, such as the Portable Drill Guide (52885, sold separately).
7. Flip the tabletop so you can access the top face. Chuck a countersink into your drill to ease the edges of the holes you just made so that the heads of the M6 x 50mm Flathead Bolts (7) used to mount the Tabletop Bracket (1) to the tabletop will sit flush to the surface.
8. Carefully reposition the extension tabletop back against the shop stand or workbench and clamp it to the scrap wood supports.
9. Align the holes in the extension tabletop with the holes in the Tabletop Brackets (1) and attach with three M6 x 50mm Flathead Bolts (7), three Flat Washers (8) and three M6 Nylon Insert Locknuts (9) at each mounting location.
10.  Place a level across the workbench or shop stand top and the extension top to check whether they are flush.
    If they’re not and the hinge/bracket assemblies are mounted to a shop stand, adjust the Stand/Bench Brackets (2) and/or the leveler feet on the Adjustable Leg Assemblies (10) until the tops are flush.
    If they’re not and the hinge/bracket assemblies are mounted to the legs of a wooden workbench, adjust the Stand/Bench Brackets (2) and/or the leveler feet on the Adjustable Leg Assemblies (10) until the tops are flush. Once the tops are flush, use the centered hole on the Stand/Bench Brackets as a guide to drill 1/4″ mounting
    holes through the workbench legs. Then countersink the hole on the leg face opposite the bracket and finalize the position of the Stand/Bench Brackets with an M6 x 50mm Flathead Bolt (7), Flat Washer (8) and M6 Nylon Insert Locknut (9) at each mounting location.

Folding the Tabletop for Storage

1. Remove everything from the extension table.
2. Supporting the extension tabletop with one hand, press and hold the lower paddle on one of the Adjustable Leg Assemblies (10) and lift up on the leveler to fully retract the bottom section of the leg. Release the paddle to lock the leg in the retracted position. Fig. 2.
3. Continuing to hold the tabletop, press the upper paddle on the same Adjustable Leg Assembly (10) and rotate it upward until it locks in the closed position. Fig. 3.
4. Supporting the extension tabletop with one hand, press and hold the lower paddle on the other Adjustable Leg Assembly (10) and lift up on the leveler to fully retract the bottom section of the leg. Release the paddle to lock the leg in the retracted position. Fig. 3.
5. Continuing to hold the tabletop, press the upper paddle on the second Adjustable Leg Assembly (10) and rotate it upward until it locks in the closed position. Fig. 3.
6. Carefully allow the tabletop to fold down. Fig. 4.
7. To raise the table, follow the same process in reverse.
   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

Shop Drawings Leg Mounting Hole Template

53687
Rev 06/22
Distributed by Rockler Companies, Inc.
4365 Willow Dr. Medina, MN 55340
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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