Rockler Disc Sander Angle Jig Instructions

Rockler Disc Sander Angle Jig Instructions
Disc Sander Angle
Jig Instructions
Congratulations on the purchase of your new Disc Sander Angle Jig! It allows you to sand precise angles on the end of your workpiece and to
sand perfectly round circles. For safe and effective operation of the jig, please read the instructions fully before starting.
GENERAL SAFETY WARNINGS
This tool is designed for specific applications as defined in the instructions and should not be modified and/or used
for any other applications. Before using the Disc Sander Angle Jig read, understand and follow all instructions and
safety information provided. KEEP THESE INSTRUCTIONS.
> For any tool that is used in conjunction with this
product always read, understand and follow the
instructions and safety warnings for that tool.
> Remain alert and use good judgment when using
this tool. Do not use this tool if you are in any way
impaired by medications, alcohol, drugs or fatigue.
> Before using this product, review and verify that all
tools used with it are in proper working order as
defined by the tool’s owner’s manual.
> Dress appropriately and remove all jewelry, secure
loose clothing and tie up long hair before using
this tool.
> All safety equipment must be installed and working
properly as defined by the tool’s owner’s manual.
> It is the sole responsibility of the purchaser of this tool
to ensure that any third party reads and agrees to all
the safety precautions outlined in this manual prior
to using the tool.
> Do not use this product until you have read the
provided instructions and warnings and are confident
you understand them.
> Always wear safety glasses in compliance with ANSI
safety standards and hearing protection and follow all
standard shop safety practices including:
• Keep your work area well lit and clean.
• Use dust collection tools and dust face masks to
reduce exposure to dust.
• Use accessory safety equipment such as
feather boards, push sticks, and push blocks
whenever appropriate.
• Do not use power tools in explosive
environments, e.g. in the presence of flammable
liquids, fumes or dust.
• Keep children and bystanders away while operating
your tools.
• Maintain proper footing at all times and do
not overreach.
• Do not force the tool.
• Unplug all power tools before making any
adjustments or changing accessories.
> Maintain these instructions and warnings as long as
you own the tool. Keep in a place where they will be
readily available for reference.
> The user assumes all risk for the proper use of
this tool and for ensuring product suitability for
intended application.
>
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.
SPECIFIC SAFETY WARNINGS
> The bolt of the expandable miter bar must be
tightened to secure the jig before turning on
the disc sander.
> When sanding with the jig fence as a support, the
fence must be secured by tightening all knobs.
2
> Always keep your fingers away from the sanding disc.
> All sanding must be done on the downward-moving
quadrant of the disc.
4
5
4
16
15
6
4
3
9
9
9
6
9
2
14
8
14
11
1
10
13
18
12
LIST
PARTS
1
2
3
4
5
6
7
8
9
Angle Jig Base
Aluminum Fence
Adjustable MDF Fence Face
1" Round Knob
1" Round Knob with Post
3/4" x 5/16-18 T-Bolt
11⁄2" x 5/16-18 T-Bolt
T-Track
#6 x 3/8" Screw
7
17
Quantity
1
1
1
3
1
2
1
1
4
10 Expandable Miter Bar
11 Expandable Miter Bar Bolt
12 Miter Bar 3/4" Screw
13 Miter Bar
14 1/4-20 x 1" Machine Screw
15 Circle Stop
16 Circle Sanding Point
17 T-Nut
18 Nylon Sleeve
Quantity
1
1
1
1
2
1
1
1
1
3
Fig. 1
Jig Setup
1.Install the fence assembly on the Angle Jig Base (1).
Do NOT install the T-track (8) in the Angle Jig
Base (1) at this time.
2.Disc sanders come in different sizes, therefore, you
will need to trim the front of the Angle Jig Base (1)
to fit your disc sander. To do this, unplug your sander
and position the jig next to the sander, square to the
disc, so the miter bar on the underside of the Angle Jig
Base (1) aligns with the miter slot in the sander’s table.
The front of the Angle Jig Base (1) should extend
beyond the edge of the disc. Make sure that the fence
assembly will be able to pivot along the full range
without contacting the disc. Fig. 1.
Note: The jig comes with the Miter Bar (13) and
Expandable Miter Bar (10) already installed on the
4
Angle Jig Base (1). If the Angle Jig Base (1) does not
extend past the edge of the disc, remove the Miter
Bar (13) and Expandable Miter Bar (10) and reinstall
them, using the rear set of mounting holes.
3.Mark the location of the disc’s edge on the side
of the Angle Jig Base (1).
4.Move the jig to a work surface and remove the fence
assembly, the Miter Bar (13) and the Expandable
Miter Bar (10).
5.Measure 1/16" back from the mark you made in Step 3
and mark across the face of the Angle Jig Base (1). This
will be your cut line. Fig. 2.
Note: No more then 3" should be removed from
Fig. 2
the Angle Jig Base (1) to allow the arm to have full
range motion.
6.Using a table saw or circular saw with a straightedge
guide, trim the front of the Angle Jig Base (1) to the
cut line. Fig. 3.
7.Reinstall the Miter Bar (13), Expandable Miter Bar (10)
and fence assembly on the jig.
8.Attach the T-track (8) in the slot in the Angle Jig
Base (1). To do this, align one end of the T-track (8)
with the back edge of the Angle Jig Base (1), mark
and drill 1/16" diameter stopped pilot holes and
secure with the included #6 x 3/8" screws (9).
Fig. 3
5
Fence Calibration
1.Install the jig on the disc sander so the Miter Bar (13)
and Expanding Miter Bar (10) are in the miter slot on
the sander. Use a Phillips-head screwdriver to tighten
the Expandable Miter Bar Bolt (11).
2.Loosen the fence assembly and use a combination or
try square to position the fence 90˚ to the sanding disc.
Tighten the knobs to lock the fence assembly in
position. Fig. 4.
3.Use a Phillips-head screwdriver to loosen the screws
securing the Hairline Indicator. Adjust the Hairline
Indicator until its line is on the 0˚ line on the scale,
then tighten the screws to secure. Fig. 5.
Jig Use
Sanding Angles
The Circle Sanding Point (16) should not be inserted in the
T-track (8) during angle sanding operations.
1.Set the fence assembly to the desired angle and tighten
the knobs to lock it in position.
Fig. 4
Fig. 5
6
2.Install the jig on the disc sander so the Miter Bar (13)
and Expanding Miter Bar (13) are in the miter slot on
the sander. Position the jig so that your workpiece will
be roughly centered on the quadrant of the disc that
is rotating downward. (If your disc sander spins
Fig. 6
counterclockwise, this would be the left side of the
disc.) Tighten the Expandable Miter Bar (10) to
secure, and check to be sure the jig won’t shift.
CAUTION IT IS IMPORTANT TO POSITION
THE WORKPIECE ON THE CORRECT SIDE OF THE
DISC TO AVOID THE DANGER OF THE SPINNING
DISC CATCHING AND LIFTING OR PROPELLING
THE WORKPIECE.
3.Keeping your workpiece against the fence assembly and
tight to the jig, turn the sander on and carefully advance
the workpiece until it makes contact with the abrasive
disc. Fig. 6.
CAUTION KEEP YOUR HANDS AWAY FROM
THE DISC WHILE IT’S IN MOTION.
4.Sand the workpiece until the desired angle is achieved.
Sanding Circles
1.If necessary, remove the fence assembly from the jig.
2.Install the jig on the disc sander so the Miter Bar (13)
and Expanding Miter Bar (10) are in the miter slot
on the sander. Position the jig so that the T-track (8) is
roughly centered on the section of the disc that is
rotating downward. Tighten the Expandable Miter
Bar (10) to secure.
3.Slide the Circle Stop (15) into the T-track (8), followed
by the Circle Sanding Point (16). The Circle Stop (15)
must be between the sanding disc and the Circle
Sanding Point (16).
Fig. 7
4.Position the Circle Sanding Point (16) so the tip is set
back from the sanding disc a distance equal to the
desired finished radius of the circular workpiece
to be sanded.
5.Holding the Circle Sanding Point (16) in position,
slide the Circle Stop (15) up against it and use a 2mm
hex wrench (not included) to tighten it in place.
Double-check the setting to be sure the point is
the correct distance from the disc. Fig. 7.
6.Drill a 1/8" diameter x 1/8" deep stopped hole centered
on the underside of the workpiece. This will register
the workpiece on the Circle Sanding Point (16).
Note: It is best to cut off excess material to the desired
circle diameter
7.Position the workpiece on the jig, with the center hole
on the Circle Sanding Point (16). Turn on the sander
and advance the workpiece into the sanding disc,
holding it down and turning it slowly. Continue to
advance and spin the workpiece until the Circle Sanding
Point (16) contacts the Circle Stop (15). At this point,
your workpiece should be at its final size. Fig. 8.
Check Rockler.com for updates. If you have further questions, please
contact our Technical Support Department at 1-800-260-9663
or support@rockler.com
Fig. 8
7
54963
Rev 08/16
Distributed by Rockler Companies, Inc.
©2016 Rockler Woodworking and Hardware
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