ROCKLER 54931 Steel Router Table Cabinet Instruction Manual

ROCKLER 54931 Steel Router Table Cabinet Instruction Manual

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 Steel Router Table Cabinet: 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);
  • Assemble the Bottom Section of the Cabinet (pp. 3 – 7);
  • Assemble the Dust Bucket (pp. 8 – 10);
  • Mount the Dust Bucket (pp. 10 – 11);
  • Installing Safety Power Tool Switch Bracket (pp. 11 – 13);
  • Attaching the Cabinet Top and Doors (pp. 13 – 14);
  • Attaching a Router Tabletop (pp 14 – 15).
• 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 any 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

WARNING Always lock the caster wheels before turning on the router or or using the Steel Router Table Cabinet.

CAUTION The Steel Router Table Cabinet is assembled with Phillips-head self-tapping screws. Tighten the screws until they “bite” and are fully installed. Do NOT overtighten, or you risk stripping the mounting holes and reducing the screws’ effectiveness.

PARTS LIST

1. Cabinet Bottom 1
2. Caster 4
3. M8 Caster Bolt 16
4. M8 Caster Nut 16
5. Washer 16
6. Front Rail 1

Assemble the Bottom Section of the Cabinet

1. Attach the four Casters (2) to the Cabinet Bottom (1) with four M8 Caster Bolts (3), four Washers (5) and M8 Caster Nuts (4). Fully tighten. Fig. 1.

2. Lock down the casters and then attach one of the Front Rails (6) to the front edge of the Cabinet Bottom (1) with three M4 x 3/8″ Pan-Head Self-Tapping Screws (S1). You can tell the front edge of the Cabinet Bottom from the back by noting the number of small mounting holes in the corners; the front corners have three small holes, while the back corners have only two. Fig. 1.
   
   
   PARTS LIST
   7 Rear Corner Bracket 2
   8 Left Front Corner Bracket 1
   9 Left Side Panel 1
   10 Right Front Corner Bracket 1
   11 Right Side Panel 1
   12 Left Drawer Slide Bracket 2
   13 Right Drawer Slide Bracket

3. Fit the Left Front Corner Bracket (8) and one of the Rear Corner Brackets (7) onto the outside edges of the Left Side Panel (9) and attach each with five M4 x 3/8″ Pan-Head Self-Tapping Screws (S1). Figs. 2 and 3.

4. Fit the Right Front Corner Bracket (10) and one of the Rear Corner Brackets (7) onto the outside edges of the Right Side Panel (11) and attach each with five M4 x 3/8″ Pan-Head Self-Tapping Screws (S1). Figs. 2 and 3.
   
   

5. Fit the two Left Drawer Slide Brackets (12) between the Left Front Corner Bracket (8) and Rear Corner Bracket (7) and up against the Left Side Panel (9). Align the top Left Drawer Slide Bracket with the top set of large mounting holes in the Left Side Panel assembly; position the other Left Drawer Slide Bracket at the desired height underneath. Attach each to the Left Side Panel assembly with two M6 x 1/2″ Pan-Head Self-Tapping Screws (S2) driven from the outside of the assembly and one M4 x 3/8″ Flat-Head Self-Tapping Screw (S3) driven through the inner face of the Left Front Corner Bracket and into the shorter tab at the front of the Drawer Slide Bracket. **Figs. 4 and 5.

NOTICE

**Because they support the Middle Shelf (18), the top set of Drawer Slide Brackets (12 and 13) MUST be installed in the top set of large mounting holes in the Side Panel assemblies. When attaching drawer slides to the Drawer Slide Brackets (12 and 13), use three M4 x 3/8″ Flat-Head Self-Tapping Screw (S3) for each slide.

6. Fit the two Right Drawer Slide Brackets (13) between the Right Front Corner Bracket (10) and Rear Corner Bracket (7) and up against the Right Side Panel (11). Align the top Right Drawer Slide Bracket with the top set of large mounting holes in the Right Side Panel assembly; position the other Right Drawer Slide Bracket at the desired height underneath. Attach each to the Right Side Panel assembly with two M6 x 1/2″ Pan-Head Self-Tapping Screws (S2) driven from the outside of the assembly and one M4 x 3/8″ Flat-Head Self-Tapping Screw (S3) driven through the inner face of the Right Front Corner Bracket and into the shorter tab at the front of the Drawer Slide Bracket. Figs. 4 and 5.
   PARTS LIST
   6  Front Rail 1
   14  Back Panel 1
   15  Middle Shelf

7. Attach the Back Panel (14) to the Cabinet Bottom (1) with three M4 x 3/8″ Pan-Head Self-Tapping Screws (S1) driven up through the Cabinet Bottom and into the bottom flange (with the angled ends) on the Back Panel. Fig. 6.

8. Fit the Left and Right Side Panel Assemblies in place on the Cabinet Bottom (1), with the Back Panel (14) in between. Attach each Side Panel Assembly to the Cabinet Bottom with three M4 x 3/8″ Pan-Head Self-Tapping Screws (S1) driven up through the Cabinet Bottom and into the bottom flanges of the Left and Right Side Panels (10 and 12) and one M4 x 3/8″ Pan-Head Self-Tapping Screw into each of the Left and Right Front Corner Brackets (9 and 11). Fig. 7.

9. Attach the Left and Right Side Panel assemblies to the Back Panel (14) with three M4 x 3/8″ Pan-Head Self-Tapping Screws (S1) driven into the three smaller mounting holes in each of the Rear Corner Brackets (8). Then drive two M6 x 1/2″ Pan-Head Self-Tapping Screws (S2) into the larger mounting holes in each of the Rear Corner Brackets aligned with the holes in the rear flanges of the Left and Right Drawer Slide Brackets (12 and 13). Fig. 8.

10. Attach the bottom Front Rail (6) to the tabs at the bottom of the Left and Right Front Corner Brackets (9 and 11) with two M4 x 3/8″ Flat-Head Self-Tapping Screws (S3) on each side. Make sure to use flat-head screws. Fig. 9.

11. Fit the Middle Shelf (15) onto the top Left and Right Drawer Slide Brackets (12 and 13), making sure to position it so that the long edge with the holes is at the back of the Cabinet. Attach the Middle Shelf to the Left and Right Drawer Slide Brackets with three M4 x 3/8″ Pan-Head Self-Tapping Screws (S1) into each. Attach the Middle Shelf to the Back Panel (14) with two M4 x 3/8″ Pan-Head Self-Tapping Screws (S1) driven into the middle two holes along the back. Do not drive screws into the two outer holes. Fig. 10.

PARTS LIST

16. Dust Bucket Left Side Panel 1
17. Dust Bucket Right Side Panel 1
18. Dust Bucket Bottom Bracket 2
19. Dust Bucket Side Vent 1
20. Dust Bucket Front Panel 1
21. Dust Bucket Top Bracket 2
22. Dust Bucket Dual Port 1
23. Dust Bucket Dual Port Gasket 1
24. Dust Bucket Cord Retainer Wing Nut 1
25. Dust Bucket Cord Retainer Bolt 1
26. Dust Bucket Rear Panel 1

Assemble the Dust Bucket

1. Attach one Dust Bucket Bottom Bracket (18) to the inside face of the Dust Bucket Left Side Panel (16) with four M4 x 3/8″ Pan-Head Self-Tapping Screws (S1) and the other Bottom Bracket to the inside face of the Dust Bucket Right Side Panel (17) with two M4 x 3/8″ Pan-Head Self-Tapping Screws in the two outer holes. (Two other screws will be installed in the next step.) Fig. 11.

2. Attach the Dust Bucket Side Vent (19) to the outside face of the Dust Bucket Right Side Panel (17) with six M4 x 3/8″ Pan-Head Self-Tapping Screws (S1). Fig. 11.

3. Mount the Dust Bucket Top Brackets (21) to the outside faces of the Dust Bucket Left and Right Side Panels (16 and 17) with two M4 x 3/8″ Pan-Head Self-Tapping Screws (S1). Fig. 11.

4. Position the Dust Bucket Left and Right Side Panels (16 and 17) inside the side flanges of the Dust Bucket Front Panel (20) and attach them with four M4 x 3/8″ Pan-Head Self-Tapping Screws (6) on each side. Fig. 12.

5. Starting from the inside face of the Dust Bucket Rear Panel (26), fit the Dust Bucket Cord Retainer Bolt (25) through the hole next to the rotating cord retainer and thread on the Dust Bucket Cord Retainer Wing Nut (24). Fig. 13.

6. Position the Dust Bucket Dual Port Gasket (23) and Dual Port (22) against the Dust Bucket Rear Panel (26), align the mounting holes on each. Attach with six M4 x 3/8″ Pan-Head Self-Tapping Screws (S1). Fig. 13.
   
   
   

7. Position the Dust Bucket Rear Panel assembly against the rear edges of the Dust Bucket Left and Right Side Panels (16 and 17), making sure that the flanges of the Rear Panel (26) overlap the Side Panels. Fig. 14.

8. Position the Left and Right Rear Louver Panels (27 and 28) so that their mounting holes are aligned with the mounting holes in the Dust Bucket Left and Right Side Panels (16 and 17) and Dust Bucket Rear Panel (26). Secure the parts together with four M4 x 3/8″ Pan-Head Self-Tapping Screws (S1) on each side. Fig. 15.

Mount the Dust Bucket

1. Lower the Dust Bucket assembly into the Cabinet, aligning the mounting holes in the Dust Bucket Bottom Brackets (18) and Left and Right Rear Louver Panels (27 and 28) with the mounting holes in the Middle Shelf (15). Secure with three M4 x 3/8″ Pan-Head Self-Tapping Screws (S1) through each Bottom Bracket and two M4 x 3/8″ Pan-Head Self-Tapping Screws through the bottom flanges of the two Louver Panels and into the Middle Shelf. Fig 16.
   

2. Secure the Left and Right Rear Louver Panels (27 and 28) to the Rear Corner Brackets (8) with two M4 x 3/8″ Pan-Head Self-Tapping Screws (S1) on each side. Fig. 17.

Installing Safety Power Tool Switch Bracket

The Steel Router Table Cabinet includes a Switch Bracket (29) and an opening for mounting the optional Safety Power Tool Switch (20915, sold separately). The bracket can’t be installed with a router tabletop on the Cabinet, and it’s easiest to install before the Cabinet Top (31) is added. Otherwise, you’ll need to remove the tabletop and loosen the right side of the Cabinet Top to fit it in.

1. Attach the Safety Power Tool Switch to the outside face of the Switch Bracket (29).

2. Carefully pry one of the arms of the “Stop” paddle to disconnect it, and remove the paddle from the Safety Power Tool Switch. (Use very controlled pressure; otherwise, the paddle arm could break. Also remember to reattach it once the installation is complete.)

3. Fit the Switch Bracket (29) and attached Safety Power Tool Switch into the Cabinet so that the Switch face extends through the opening in the side.

4. Align the mounting holes in the bottom flange of the Switch Bracket (29) with the holes in the Middle Shelf (15). Attach with two M4 x 3/8″ Pan-Head Self-Tapping Screws (S1) up through the Middle Shelf. (You will secure the Switch Bracket at the top s you attach the Cabinet Top (31) later. Fig. 18.
   
   
   
   
   

5. Feed the power cord from the Safety Power Tool Switch through the cord retainer in the Right Rear Louver Panel (28). (The cord from the router will run through the same cord retainer to plug into the switch.)

Attaching the Cabinet Top and Doors

1. Attach the top Front Rail (6) to the tabs at the top of the Left and Right Front Corner Brackets (9 and 11) with two M4 x 3/8″ Flat-Head Self-Tapping Screws (S3) on each side. Make sure to use flat-head screws. Fig. 19.
2. Position the flexible Anti-Vibration Pad (30) on top of the assembled Dust Bucket, aligning the mounting holes, and then position the Cabinet Top (31) on top of that. Be careful not to shift the pad’s position, and make sure that the long edge of the Cabinet Top that has the screw hole near the center is at the front of the Cabinet. Drive four M4 x 3/8″ Flat-Head Self-Tapping Screws (S3) to secure the Cabinet Top and Anti-Vibration Pad to the Dust Bucket. Fig. 20.
3. Attach the Cabinet Top (31) to the tope flange of the Switch Bracket (29) and the rest of the Cabinet assembly by driving M4 x 3/8″ Flat-Head Self-Tapping Screws (S3) at the locations shown in Fig. 21.
4. To install the Left and Right Doors (32 and 33), open the top and bottom hinges on each and hold the door up to the Cabinet, aligning the mounting holes in the hinges with the mounting holes on the Front Corner Brackets. Secure the Doors to the Cabinet with two M4 x 3/8″ Pan-Head Self-Tapping Screws (S1) in each hinge. Fig. 22.

Attaching a Router Tabletop

1. The Cabinet Top (31) has four predrilled mounting holes, circled in black in Fig. 23, that are spaced specifically to fit ProMax Cast Iron Router Tabletop (63481, sold separately) and Pro Phenolic Router Tabletop (49428, sold separately). Please note that, if you are installing the Pro Phenolic Router Tabletop on the Steel Router Table Cabinet, you will need to add spacer strips between the table and the Cabinet Top to provide clearance for the carriage bolts used to secure the router table fence to the Pro Phenolic table.
   The two extra mounting holes, circled in white in Fig. 23, allow installation of additional screws if installing the HPL Router Tabletop (46924, sold separately) or another tabletop with a bottom face into which screws can be driven. 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

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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