ROCKLER 55819 Compact Router Ellipse or Circle Jig Instructions

: June 4, 2024
: ROCKLER

Table of Contents

ROCKLER 55819 Compact Router Ellipse or Circle Jig
Compact Router Ellipse/Circle Jig Instructions
GENERAL SAFETY WARNINGS
PRODUCT-SPECIFIC SAFETY WARNINGS
Jig and Workpiece Setup
ROUTER MOUNTING HOLE KEY
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

ROCKLER 55819 Compact Router Ellipse or Circle Jig

Compact Router Ellipse/Circle Jig Instructions

ROCKLER-55819-Compact-Router-Ellipse-or-Circle-Jig-
fig-1

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 Compact Router Ellipse/Circle Jig: 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 he 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);
- Jig and Workpiece Setup (pp. 4 – 5);
- Routing an Ellipse (pp. 5 – 6);
- Routing a Circle (pp. 6 – 7).
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 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

DANGER

To avoid serious injury, keep hands and fingers away from spinning router bit. Always maintain awareness of the bit.

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 the Compact Router Ellipse and Circle Jig ONLY with a compact router equipped with a plunge base. Do NOT use with fixed-base routers.
Unplug your router before installing or adjusting the
router bit or jig.
Always place a sacrificial panel that’s at least as big as your workpiece underneath the workpiece to prevent damage to your work surface.
Make sure that your workpiece is secured to the sacrificial panel with double-sided tape and that the sacrificial panel is secured to your work surface with double-sided tape. Using double-sided tape will provide full access to the top surface of the workpiece while helping prevent it from shifting during routing.
If you are cutting both inside and outside edges to create a frame, make sure that the center island, the frame area itself and any outside waste areas of your workpiece are securely attached to the sacrificial panel with double-sided tape. Failure to do this could allow unsecured parts of the workpiece to shift, which could result in personal injury or damage to your project.
Do NOT attempt to make the full depth of cut in one pass. Make several passes, increasing the depth of cut with each pass.
Maximum material thickness (for through routing) is 1/2″.

Jig and Workpiece Setup

WARNING

Use the Compact Router Ellipse and Circle Jig ONLY with a compact router equipped with a plunge base. Do NOT use with fixed-base routers.
Unplug your router before installing or adjusting the router bit or jig.
Always place a sacrificial panel that’s at least as big as your workpiece underneath the workpiece to prevent damage to your work surface.
Make sure that your workpiece is secured to the sacrificial panel with double-sided tape and that the sacrificial panel is secured to your work surface with double-sided tape. Using double-sided tape will provide full access to the top surface of the workpiece while helping prevent it from shifting during routing.
If you are cutting both inside and outside edges to create a frame, make sure that the center island, the frame area itself and any outside waste areas of your workpiece are securely attached to the sacrificial panel with double-sided tape. Failure to do this could allow unsecured parts of the workpiece to shift, which could result in personal injury or damage to your project.
Maximum material thickness (for through routing) is 1/2″.

NOTE

We recommend using a 1/4″ diameter spiral up-cut bit (82652, sold separately).

ROUTER MOUNTING HOLE KEY

Attach your compact plunge router to the Jig Arm (1) with the included 10mm Pan-Head Machine Screws (8) and install the router bit.
Set up your workpiece by attaching it with double-sided tape to a sacrificial panel attached to a solid, stable surface.

Routing an Ellipse

Mark the center point on your workpiece. Lay out the major (long) and minor (short) axes of your ellipse so that they’re perpendicular and intersect at the center point. The major axis can be a maximum of 24″ long and a minimum of 11″. The minor axis can be a maximum of 19″ long and a minimum of 6″. (The maximum difference in length between the major and minor axes is 5″.) Fig. 1.
Use the scribe lines machined into the Jig Base (2) to center it on the intersection of the major and minor axes. Secure the Jig Base to the workpiece with the included #6 Wood Screws (7). Fig. 2.
Insert a Dovetailed Key (3) into each channel in the Jig Base (2). Slide the one that moves along the minor axis to the center of the Jig Base. (We will refer to this key as
“Dovetail Key A.”)
Loosen the two Locking Pivots on the Jig Arm (1) and position them so they mount on the pins in the Dovetailed Keys (3). Fig. 3. The Locking Pivot closest to the router MUST be mounted on “Dovetail Key B,” which travels along the major axis.
Rotate the Jig Arm (1) so it’s aligned with the major axis, and adjust it in or out until the bit is positioned as desired to make the cut. Tighten the Locking Pivot on Dovetail Key A. Fig. 4.
Rotate the Jig Arm (1) so it’s aligned with the minor axis, and adjust it in or out until the bit is positioned as desired to make the cut. Tighten the Locking Pivot on Dovetail Key B. Fig. 5. Note that the maximum distance between Locking Pivots A and B is 21⁄2″.
WARNING
Do NOT attempt to make the full depth of cut in one pass. Make several passes, increasing the depth of cut with each pass.
With the router off, practice rotating the Jig Arm (1) through the full range of your eventual cut. You want to ensure that the dovetail keys will move smoothly, as well as verify the ellipse pattern. Then make the series of cuts to achieve the desired final depth.

Routing a Circle

Mark the center point on your workpiece and lay out the perpendicular axes.
Use the scribe lines machined into the Jig Base (2) to center it on the intersection of the axes. Secure the Jig Base (2) to the workpiece with the included #6 Wood Screws (7).
Remove one of the Locking Pivots from the Jig Arm (1) and one of the Dovetail Keys (3) from the Jig Base (2).
Make sure the remaining Dovetail Key (3) is in the channel that has the two holes near the center. Align the holes in the Dovetail Key (3) with the holes in the Jig Base (2) and secure with two of the included #6 Wood Screws (7). Fig. 6.
Loosen the Locking Pivot on the Jig Arm (1) and position it so it mounts on the pin in the Dovetailed Key (3).
Adjust the Jig Arm (1) in or out until the bit is positioned as desired to cut the desired diameter. Tighten the Locking Pivot.
WARNING
Do NOT attempt to make the full depth of cut in one pass. Make several passes, increasing the depth of cut with each pass.
With the router off, rotate the Jig Arm (1) through the full range of the eventual cut. You want to ensure that the Jig Arm will move smoothly, as well as verify the circle pattern. Then make the series of cuts to achieve the desired final depth.