Kval Commander, Instruction Manual

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You can now set the Off Feed Stop to the location you just calculated by loosening the socket
head bolt and sliding the stop so that its left edge indicates what you calculated on the tape.
Hinge Size:
Determine the hinge size by the turret mounted on the right side of the router, and spacer pins
for door and jamb backsets. Turn air pressure off at the router with the slide valve so you are
able to move the router easily. Don’t forget to turn it back on again before you machine doors.
Adjust hinge width by rotating the stop turret. Two stop turrets are provided for this location:
on for ¼” radius bits, and one for 5/8” radius bits. On each turret, the longest bolt gives a 3 ½”
hinge, the middle bolt is for 4” and the shortest is for 4 ½”. The Flat side of the turret exposes a
stop pin hole used for odd sized hinges, we can provide four position turrets if you determine a
need for them (like alternative pre-hanging setup.) Change this pin when the radius of the
hinge router changes.
Hinge Backset Door:
If you are using a ½” bit, the length of this pin will be the same as the backset that you desire.
Add 3/8” to the pin length for 1 ¼” router bits… in other words use a 5/8” pin for a ¼” backset.
Some machines are set up to cut completely through the stile. In this case all backset pins are
5/16” longer and no pin is used to cut through the bottom skin.
Hinge Backset Jamb:
Space stop pins limit the cutter travel up into the jamb. Notice that this pin contacts a bolt
mounted to the chip out assembly. The chipout block is spring loaded up to the contact the
jamb edge during the jamb routing sequence. The cutter is indexed off the edge of the jamb, to
compensate for bowed jambs. Select the proper pin from the pin chart for the distance that you
want to cut into the jamb.
NOTE:
If you machine jambs wider than 7 ½” turn the cylinders around so that they clamp
down on the jamb. Bowed jambs still machine correctly although hinge mounting will take a
bit more effort.
Exterior Doors:
When you wish to machine exterior doors you will probably need to change hinge sizes as
explained earlier. Two other adjustments are also necessary.
To minimize pocket tear out; the hinge router should cut less than half the bit diameter on its
first horizontal past in to the jamb; and then into the door. To make this happen you need to
adjust the routers tilt in height by adjusting the cylinder stack.
The stack needs to be raised 3/8” for exterior doors and lowered the same amount to go back to
1 3/8” doors. To adjust’ turn off the hinge section’s slide valve; loosen the black ratchet handle
that clamps the lower cylinder stack bracket in place and then turn the 4 prong black knob. The
roll pin indicator in the slot will be stationary while the slot and scale (reference door thickness)
will go up or down.