ROCKLER WOODWORKING AND HARDWARE 52149 Rail Coping Sled Instructions

ROCKLER WOODWORKING AND HARDWARE 52149 Rail Coping Sled

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 Rail Coping Sled:

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);
  • Exploded View (p. 5);
  • Tapering Setup (pp. 6-7);
  • Tapering Operation (pp. 8-9);
  • Straight-line Ripping (pp. 10-11).
• 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 feather boards, 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.
• The notice indicates important or helpful information and/or user tips.

PRODUCT-SPECIFIC SAFETY WARNINGS

DANGER

• To avoid serious injury, keep your hands and fingers out of the path of the spinning router bit. Maintain awareness of router bit and safe hand position at all times.
• Turn off and unplug your router before setting up or using your Rail Coping Sled, changing the router bit, or adjusting the cutter height.

PARTS LIST

3
7| Front Handle| 1|  | 17| Cap Nut| 4
8| Rear Handle| 1|  | 18| 13⁄4″ Mounting Screws| 4
9| 1″ Round Knob| 2|  | 19| #8 x 13⁄4″ Wood Screws| 2
10| 4-Star Knob| 1|  | 20| Abrasive Strip| 1

Assembly

Assemble the parts as shown. Do not fully tighten the 1″ Round Knobs (9) that secure the Fence Guide (1), the Front and Rear Handles (7 and 8) or the Mounting Screws (18) that attach the Fixed Fence (3) and Lever Clamp (5) to the Sled Base (2). You will tighten these during calibration. Do not attach the Sacrificial Piece (6) until all setup and calibration steps are completed.

Setup and Use

THESE WARNINGS PERTAIN TO ALL REMAINING STEPS:

DANGER

• To avoid serious injury, keep your hands, and fingers out of the path of the spinning router bit. Maintain awareness of router bit and safe hand position at all times.
• Turn off and unplug your router before setting up or using your Rail Coping Sled, changing the router bit, or adjusting the cutter height.

1. Position the assembled Rail Coping Sled so that the clear Fence Guide (1) is tight against the fence of the router table. Make sure the 1″ Round Knobs (9) on the Fence Guide are loose.

2. Keeping the Fence Guide (1) against the fence, adjust the Sled Base (2) until it is precisely 3/4″ away from the fence along its entire length. Take measurements at both ends of the Sled Base to confirm that it is parallel to the router table fence. Fully tighten the 1″ Round Knobs (9), then measure again to confirm that nothing shifted. Fig. 1.

3. With the Fence Guide (1) still tight against the router table fence, use a combination or engineer’s square to set the sled’s Fixed Fence (3) at precisely 90°. Tighten the Rear Handle (8) to lock the Fixed Fence in place, then flip the Sled Base (2) and tighten the Mounting Screws (18). If needed, use a 5/16″ or 8mm wrench to hold the Cap Nuts (17) while tightening. Fig. 2. NOTICE
   To make precise setup faster and easier when using rail and stile bit sets on 3/4″ stock, we offer dedicated setup jigs (Fig. 3 – Setup Jig Method) that have the rail and stile profiles machined into the edges. Go to www.rockler.com for details.

4. To set the bit height, place a test piece of your rail stock on the Sled Base (2), slide it next to the bit and adjust the bit until it’s at about the proper height. Tighten the bit. Fig. 3 – Wooden Block Method.

5. Align the router table fence flush with the bit’s bearing and secure it in place.

6. Position the test stock for routing by pressing it up against the Fixed Fence (3) and the router table fence.

7. Slide the Adjustable Fence (4) tight against the stock and tighten the 4-Star Knob (10). Fig. 4 – Arrow 1.

8. Use the knob on the Lever Clamp (5) to adjust the clamp foot so it will apply sufficient pressure, then engage the clamp to fully secure the stock. Fig. 4 – Arrow 2.

9. Make a test cut. Fine-tune the bit height and repeat test cuts until the joint is flush.

10. Return the sled to the router table, with the Fence Guide (1) up against the fence. Place the Sacrificial Piece (6), square corners down, on the Sled Base (2) up against the Fixed Fence (3) and slide it toward the router table fence until it makes contact. Secure it by driving #8 x 13⁄4″ Screws (19) through the predrilled holes in the back edge of the Fixed Fence. Use a combination or engineer’s square to verify that it’s square to the router table fence. Fig. 5.

11. Clamp your project stock in the sled, up against the Sacrificial Piece (6), and make your cuts, moving the sled from right to left on the router table. Fig. 6.

Check Rockler.com for updates. If you have further questions, please contact our Technical Support Department at 1-800-260-9663 or [email protected].

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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