66
ROUTER TABLE OPERATION
R9
PLUS
Joinery System User Guide
Making The Beam
Chapter 1
A
B
C
A
B
D
B
C
A
E
A
B
C
C
A
B
1-1
The beam assembly consists of the main beam
, the
sacrificial backer board
and the clamping surface
. The
clamping surface and sacrificial board are made from commonly
available
5
⁄
8
"[15mm] MDF (optional
3
⁄
4
"[19mm]). Hardwood or
softwood may also be used.
1-3
Cut a piece of MDF 30" long and 2
1
⁄
8
" wide [762mm
x 54mm]. This will be your clamping surface
. Then cut
your sacrificial boards 1
1
⁄
2
" x 30"[35mm x 762mm]. You may
want to cut a number of extra sacrificial boards now to use as
replacements
.
1-5
This procedure is critical to the accuracy of the jig.
Before attaching the MDF boards to the beam, use each pin plate
as a drill guide. First, mark a line 4
1
⁄
2
"[114mm] in from the end
of the beam and square it across
. Next, stack the clamping
surface
, sacrificial board
and beam
near the edge of the
workbench and clamp in place
.
1-2
Start with a straight, flat and square 30"[762mm] length
of wood, 1
1
⁄
2
" x 3
1
⁄
2
" x 30"[35mm x 89mm x 762mm].
1-4
Lay out the mounting screw holes
and clamp holes
as
per the drawing on pages 38-39. Drill and countersink the screw
holes on the clamping surface. Drill the
5
⁄
16
"[8mm] holes
in
the sacrificial board. This piece can be reversed and flipped four
times to use up all four surfaces.
1-6
Clamp a pin plate with its wide straight side flush to the
flat bench surface
and its side edge on the line
. Using
the 2 small holes
in the pin plate as a drill guide, drill two
3
⁄
32
"[2,5mm] pilot holes 1"[25,4mm] deep.
Important: Please use these step-by-step instructions in conjunction with the technical drawing on pages 38-39 of the Appendix.