Overhead router and sledge pin jig

Interwood OFC overhead router, serial no 19470 (1970)

Preparation

1. Put on ear defenders and safety glasses

2. Check that the machine isolation switch is on

Tool set up

3. Depress cutter head raise/lower pedal to raise the cutter head and use the black handle on the side of the cutter head to lock it up

4. Insert the first machine spanner into the machine

5. Use the other spanner to loosen and remove the cutter tool assembly, i.e. cutter, collet and outer collar

6. Remove old cutter and replace in holder

7. Remove collet from outer collar

8. Insert new cutter with appropriate collet into the outer collar

9. Insert new cutter tool assembly into the machine and fasten with the two spanners

10. Remove the spanners and replace in holder

Pin set up

11. Select a pin of the same width as the cutter

12. Insert pin in sleeve below table so that it sits at the same level as the table and fasten in place

Fix workpiece in jig

13. Position workpiece in jig

14. Ensure that the workpiece is fast against fixed edges

15. Position adjustable edges to hold workpiece fast and screw them down so that the workpiece cannot move

Position pin, workpiece and cutter

16. Press pedal to raise cutter head and lock it up

17. Turn handle to raise pin

18. Position jig and workpiece near to cutter head and lower table by unlocking the table rise/fall mechanism, using the wheel below the table and locking the rise/fall mechanism again so that the jig and workpiece fit underneath the guard

19. Position the jig over pin where you want to start cutting

20. Release cutter head clamp and release pedal gently to lower the cutter head. Adjust the cutter position so that it is just above the workpiece when the cutter head raise/lower pedal is completely released: unlock the wooden height stop, turn the nurled metal adjuster so that the threaded rod stops the cutter head at the desired depth

21. Raise the cutter head, clamp up and adjust the height of the cutter lower to the cutting depth required. The cutting depth should be no more than the diameter of the cutter, less for harder woods or if the cutter is blunt (although the cutter should not be blunt).