Woodpeckers MORTISE match Precision Tool Owner’s Manual

MORTISEmatch™
OWNER’S MANUAL

MORTISE match Precision Tool

HARDWARE BAG

*NOTE: “Festool” & “Domino” are registered trademarks of Festool and are not associated with Woodpeckers, LLC.

https://www.woodpeck.com/mortisematch.html

If you think you’re missing anything, email us at mailroom@woodpeck.com.

You can also call us at 800-752-0725 from 9:00 a.m. to 4:00 p.m. EST Monday – Friday.

ASSEMBLY

I. ASSEMBLE & ALIGN BASE TO TABLE
AT THIS POINT YOU WILL NEED:

• 1 (1) Table

• 2 (1) Base

• 7 (1) Carriage Stop Screw & Nylon Washer

• 3 (1) Carriage

• 4 (2) Lock Knob (Red)

• 11 (1)Allen Driver 1/8″

• HARDWARE BAG
  (4) Phillips Flat Head Screw 1/4″-20 x 5/8″
  (4) Hex Screw #10-32 x 3/8″

• 10 (2) Spring, 3.5″

Phillips Screwdriver (Not Included)

1. Remove the Carriage Stop Screw & Nylon Washer 7 Figure 1.

2. Loosen the Lock Knobs 4 and remove the Carriage 3 from the Base 2. Figure 2.

3. Slide the Base out from the Table 1

4. Install (4) #10-32 x 3/8″ Hex Screws into counter-sunk holes in the recess for the Base. Screw them in until they are just below the surface.
   These will be used to level the Base in Step 6. Figure 3.

5. Slide the Base back into position on the Table. Install (4) Phillips Flat Head Screws 1/4″-20 x 5/8″ through the Base and start the screws into the threaded holes in the Table. DO NOT tighten at this time. Figure 4.

6. Using the Allen Driver, reach in through the openings in the Base to the Hex Screws. Rotate the Hex Screws counterclockwise for the Plate to move up to match the Table height evenly. Use a straight edge across the Base and the Table to assist in matching the surface heights. Figure 5.

7. Once the two surfaces are even, tighten the (4) Phillips Flat Head Screws M4″-20 x 5/8″. Figure 6.

8. Place one Spring 10 into each post on the Base. Figure 6.

II. ATTACHING YOUR DOMINO JOINER
AT THIS POINT YOU WILL NEED:

• 3 (1) Carriage
• 4 (2) Lock Knob
• 7 (1) Carriage Stop Screw & Nylon Washer
• HARDWARE BAG
  (2) Phillips Flat Head Screw, 5mm x 12mm

NOTE: Removing the weight of the Domino motor will make installation easier. Remove the motor from your Domino base as if you were changing bits (see Festool instructions ifyou’re unfamiliar).

1. Flip the Carriage 3 over and attach it to the bottom of your Domino base, using the (2) 5mm x 12mm Phillips Flat Head Screws. Figure 7.
   IMPORTANT NOTE: Confirm that the front edge of the Domino base and the front edge of the Carriage align with each other. Figure 7A.

2. Confirm that the springs are in place in the posts of the Base. Place the Carriage/Domino base assembly onto the posts. Push the assembly down as low as it will go and secure the (2) Lock Knobs 4 Figure 8.

3. Re-install the Carriage Stop Screw & Nylon Washer 7. Figure 8.

III. INSTALLING THE DP TRACKS
AT THIS POINTYOU WILL NEED:

• 5 (1) Left, Dual Purpose Track (“Woodpeckers”)
• 6 (1) Right, Dual Purpose Track (“MortiseMatch”
• HARDWARE BAG
  ( 8) Phillips Flat Head Screw 1/4″-20 x 1″
  ( 8) Oval Nuts 7/16″ Wide, 1/4″-20 Thread

1. Align the Table 1 on your workbench so the Carriage is off the workbench and easily accessible from underneath. Secure the Table 1 to your workbench with a clamp.
   NOTE: The MortiseMatch will not be stable hanging off the edge of the table without a clamp.

2. Insert (4) Phillips Flat Head Screws 1/4″-20 x 1″ up through the bottom of the right side of the Table 1. Start an Oval Nut onto each screw. Figure 9.

3. Slide the Right, Dual Purpose Track (with the “Mortise Match” engraving) 5 into position on the Base 1 over the installed Oval Nuts. Figure 9A.

4. epeat Steps 1 & 2 for the Left Dual Purpose Track.

5. Using a straight edge, align the Left DP Track, Right DP Track and the Carriage/Domino. Then tighten all (8) Phillips Flat Head Screws from under the Table. Figure 10.

IV. ADJUSTABLE PROTRACTOR
AT THIS POINTYOU WILL NEED :

• 8 (1) Adjustable Protractor Assembly
• 11 (1)Allen Driver 1/8″
• HARDWARE BAG
  9 (1) Red Knob

The Adjustable Protractor will support your material at any angle between 90° and 45°. Do not “set” the angle with the Adjustable Protractor. Always cut your material accurately, align it to the front edge of the Domino, clamp the material in place and then  position the Adjustable Protractor flush against the edge of the material. At that point, the Adjustable Protractor provides a reference for additional workpieces to be positioned the same way. Once the first sides of all joints are cut, the Offset Gauge is used to mirror the Adjustable Protractor to the other side of the Mortise Match to cut the second side of each joint. Figures 11 & 11-A.

USING THE MORTISEMATCH

I. HOW TO USE THE MORTISEMATCH
The Domino Joinery Machine has an array of built-in and bolt-on accessories for alignment. They’re very good at their intended purpose, but none of them address the issue of small (narrow) workpieces, particularly narrow workpieces joined at a mitered angle. That is what MortiseMatch is designed to accomplish. A side benefit of the MortiseMatch design is that for somewhat larger frame construction, the stationary machine approach can improve accuracy and speed up repetitive processes.
By carefully keeping the “show” faces of your construction against the Table and using the mirroring feature of the Adjustable Protractor, you will be able to create joints with perfectly matching faces and ends.
IMPORTANT NOTE: Careful stock preparation is imperative. The MortiseMatch will help you cut the mortises in alignment to each other, but if the material is not cut square (or at the correct miter angle), it won’t make the joint “better”. Be sure your cuts are square (or at the right angle) and true in both directions.

• The typical MortiseMatch procedure has 5 steps:
  1. Adjust the Carriage to position the mortise in the thickness of the stock.
  2. Adjust the Adjustable Protractor to support the stock and set the lateral position of the mortise in the joint.
  3. Cut one mortise of each mating pair of mortises.
  4. Index the Offset Gauge and flip the Adjustable Protractor to the opposite side of the Table.
  5. Cut all the remaining mortises.

Let’s look at each step in detail…

II. VERTICAL ADJUSTMENT OF THE MORTISE
It isn’t critical that the mortise be in the exact center of the material.
What is critical is keeping the outside face of joining pieces always down against the table. That said, in general, the mortise should be approximately centered.

1. Here’s the fastest way to get really close:
   1. Measure the thickness of your material
   2. Convert measurement to mm (inch measurement x 25.4).
   3. Divide the mm measurement in half.
   4. Set the Domino Fence to that measurement using the scale built into the Domino (refer to your Domino manual) then pivot the Domino fence so it is parallel with the material stock thickness.
   5. Release the Lock Knobs 4 and allow the Carriage 3 to rise to its upper limit.
   6. Place a piece of your stock on the table, under the Domino fence.
   7. Press down on the Carriage until the Domino fence contacts the stock. Figure 12.
   8. Lock the Carriage.
   9. Pivot the Domino fence up and secure it. Figure 12-A.

The Mortise should now be approximately centered on your stock.
NOTE: The Carriage adjusts to locate the center of the mortise anywhere between 6mm and 27mm, which means you can locate a mortise in the center of your stock from a 1/2″ thick to over 2″ thick.

III. LATERAL ADJUSTMENT OF THE MORTISE
Typically, you will want the mortise centered on your stock.
However, miter joints will often need to be adjusted toward the inside of the joint to avoid the mortise blowing out on the outside edge.

1. Prepare your stock and cut to final width and length.
2. Determine the best location for the center of your mortise and mark it on your stock.
3. Align the end of your stock to the Domino and the center mark on your material to the centerline of the Domino.
4. Clamp the material to the Table 1 using a track clamp (not included).
5. Align the Adjustable Protractor 8 to the edge of your material and the Fence 5 & 6 of the MortiseMatch. Lock the Adjustable Protractor down to the Table and lock the Angle Lock Knob.

IV. CUTTING THE FIRST MORTISE OF EACH SET
Miter joints are easier to keep track of than butt joints. On mitered joints you just cut one end of all the sides. Butt joints require you to cut opposing corners of ends and sides at the first setting.

1. Place a mark on the back side of each of your workpieces.
2. Position the workpiece against the Adjustable Protractor 8 and the Fence 5 & 6.
3. Clamp the material to the Table 1 using a track clamp (not included).
4. Cut the mortise.
5. Repeat for all workpieces.
6. Butt joints will have two opposing ends and two opposing edges cut on the first setting.

V. MIRRORING THE ADJUSTABLE PROTRACTOR
Here’s the magic. You’re going to flip the Adjustable Protractor to the other side of the Table and index it to the cutter so that the mortises align in the mating pieces perfectly.

1. Loosen the screws that lock the Offset Gauge on the Adjustable Protractor 8.
2. Slide the Offset Gauge toward the Domino until in contacts the stop latch (see Domino manual… also know as the “flipper”) and lock the Offset Gauge in place.
3. Remove the Red Knob 9 that holds the Adjustable Protractor to the Table.
4. Flip the Adjustable Protractor over and place it on the other side.
5. Set it against the Fence and slide it forward until the Offset Gauge contacts the stop latch on that side.

Now the Adjustable Protractor is positioned the same distance from the center of the mortise.

https://www.woodpeck.com/mortisematch.html

Scan the QR code above to watch the video or visit woodpeck.com under the video tab towards the bottom of the product page.

VI. CUTTiNG THE SECOND MORTISE OF EACH SET
Almost done. Just be sure you see the backside mark and mortise in the opposite end of each workpiece.

VII. MORTISEMATCH SPECIFICATIONS

• Phenolic Table Dimensions: 16″ x 23″ x 3/4″
• Minimum Material Width: 1″ (24.4mm)
• Maximum Width (Single Centered Mortise): 3-1/4″ (82mm)
• Lowest Mortise Position: 1/4″ (6mm) to center of mortise.
• Highest Mortise Position: 1 -3/16″ (30mm) to center of mortise.
• Fits both the Domino XL DF-700 and the DF-500.

NOTE: If you need to use the Domino in hand-held mode during a project where you’re using it in the MortiseMatch, it is not necessary to remove it from the Carriage.
Just remove the Carriage Stop, unlock the Lock Knobs and lift the Domino with the Carriage  off the Base. It will be fully functional as you’re used to using it.

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WARNING! To reduce the risk of injury keep hands away from moving parts. Refer to your Domino tool manual for proper setup and use.
WARNING! To reduce the risk of injury, wear safety goggles or glasses with side shields, ear protection & a dust mask.
WARNING!
This product can expose you to chemicals, including chromium, which is known to the State of California to cause cancer and birth defects or other reproductive harm.
For more information go to www.P65Warnings.ca.gov

Woodpeckers, LLC Strongsville, Ohio
woodpeck.com
© 2022 Woodpeckers, LLC
REV081022

References

• Woodworking Tools Designed and Made in USA | Woodpeckers
• P65Warnings.ca.gov

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