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SETTINGS AND ADJUSTMENTS
SPECIFICS:
The extended range router carriage and related setup is capable of machining all materials as the stan
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dard butt router along with the ability to process extra thick exterior jambs and T-shaped mullions with
or without weather-stripping applied. When configured for the thicker jambs and mullions the router
will accommodate flat or single rabbeted jambs from 1-5/8 to 2-3/4” thick and mullions with 1-1/8” to
2-1/4” center thickness and a 1/2” thick stop on both sides. All other dimensions for jambs and doors are
equivalent to the standard capabilities on the Magnum. Change over time from setup for standard jambs
to thicker jambs requires less than 5 minutes.
GENERAL USE:
The extended range router operates in a similar fashion as the standard Magnum butt router with a few
variations. The lower indexing pins, 13-597, position the router to perform operations on square edged
doors and standard thickness jambs, up to 1-1/2”. To mortise beveled edge doors, raise the rear of the
router carriage one position higher and lock it into position with the lower indexing pins. All operations
performed in these two configurations are referenced in the standard operating procedures section of the
operator’s manual.
PROCEDURE FOR PROCESSING EXTRA THICK JAMBS AND MULLIONS:
Configuring the router for thicker jambs as described above requires a few procedures to be followed that
vary from the standard router as follows:
1.
Raise the rear of the carriage to the top most position and engage the upper indexing pins.
2.
Replace the standard index dog, 6809-006, with the extended index dog provided in boxed parts, 6805-
090. The extended stop dog must be installed with the sloped surface towards the operator similar to the
manner that the standard dog was installed.
3.
To operate the router in this configuration the width index must be manually adjusted approximately 1-
1/8” below the door width after sizing the door. This is to ensure that the face of the jamb and the edge of
the door are flush with one another as the reference point has changed to extend the router’s capabilities.
Note:
When processing doors and jambs with the router set-up in this configuration, the router will process
square edge doors only. The width index adjustment may also cause interference with the main bar on
some raised molding doors. In such cases, the door and jamb will need to be processed in separate opera
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tions. When machining the jamb, substitute a door without raised molding to provide clamping of the
router carriage.
When processing T-shaped mullions, the six Jamb Lifter Spacers, 6805-088, that are provided in boxed
parts, will need to be installed on the Jamb Lifters, 6805-116, as a rest for the center portion of the mul
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lion. To install these components, orient the Spacers so that the thumb screw is on the right and the center
opening is facing down. Insert the Spacers down onto the Jamb Lifters and slide them forward until they
are resting firmly against the lip of the Jamb Lifters then tighten the thumb screw to secure.
3-19 BUTT ROUTER FOR EXTERIOR JAMBS AND MULLIONS
