Shop fox D4902 Owner's Manual
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Shop fox D4902 Owner's Manual

Tenoning jig
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MODEL D4902
TENONING JIG
OWNER'S MANUAL
(FOR MODELS MANUFACTURED SINCE 11/18)
Phone: (360) 734-3482 • Online Technical Support: techsupport@woodstockint.com
COPYRIGHT © MARCH, 2019 BY WOODSTOCK INTERNATIONAL, INC.
WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT
THE WRITTEN APPROVAL OF WOODSTOCK INTERNATIONAL, INC.
#20286KB  Printed in Taiwan

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  • Page 1   MODEL D4902 TENONING JIG OWNER'S MANUAL (FOR MODELS MANUFACTURED SINCE 11/18) Phone: (360) 734-3482 • Online Technical Support: techsupport@woodstockint.com COPYRIGHT © MARCH, 2019 BY WOODSTOCK INTERNATIONAL, INC. WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF WOODSTOCK INTERNATIONAL, INC. #20286KB  Printed in Taiwan...
  • Page 2 This manual provides critical safety instructions on the proper setup, operation, maintenance, and service of this machine/tool. Save this document, refer to it often, and use it to instruct other operators. Failure to read, understand and follow the instructions in this manual may result in fire or serious personal injury—including amputation, electrocution, or death.

  • Page 3: Table Of Contents

    Contents INTRODUCTION......................2 Woodstock Technical Support ..................2 Functional Overview ....................2 Identification ......................3 Table Saw Requirements ..................... 3 SAFETY........................4 Standard Machinery Safety Instructions ................4 Additional Safety for Tenoning Jigs ................6 SETUP........................7 Unpacking ......................7 Inventory ....................... 7 Needed for Setup .....................

  • Page 4: Introduction

    Model D4902 (For Machines Mfd. Since 11/18) INTRODUCTION Woodstock.Technical.Support This machine has been specially designed to provide many years of trouble-free service. Close attention to detail, ruggedly built parts and a rigid quality control program assure safe and reliable operation.

  • Page 5: Identification

    Plate Plate Knob Table.Saw.Requirements The D4902 Tenoning Jig is designed to work with most table saws. Use the table saw requirements listed below to verify that your table saw will work with the tenoning jig. Table Saw Miter Slot ....Standard ⁄...

  • Page 6: Safety

    Model D4902 (For Machines Mfd. Since 11/18) SAFETY SAFETY For.Your.Own.Safety, Read.Manual.Before.Operating.Machine The. purpose. of. safety. symbols. is. to. attract. your. attention. to. possible. hazardous. conditions.. This. manual.uses.a.series.of.symbols.and.signal.words.intended.to.convey.the.level.of.importance.of.the. safety.messages..The.progression.of.symbols.is.described.below..Remember.that.safety.messages.by. themselves. do. not. eliminate. danger. and. are. not. a. substitute. for. proper. accident. prevention. mea- sures—this.responsibility.is.ultimately.up.to.the.operator!
  • Page 7 Model D4902 (For Machines Mfd. Since 11/18) WEARING.PROPER.APPAREL..Do not wear FORCING.MACHINERY..Do not force machine. It clothing, apparel, or jewelry that can become will do the job safer and better at the rate for entangled in moving parts. Always tie back which it was designed.

  • Page 8: Additional Safety For Tenoning Jigs

    Model D4902 (For Machines Mfd. Since 11/18) Additional.Safety.for.Tenoning.Jigs Serious.cuts,.amputation,.or.death.can.occur.from.contact.with.rotating.saw.blade.during. operation..Workpieces,.broken.blades,.or.flying.particles.thrown.by.blade.can.blind.or.strike. operators.or.bystanders.with.deadly.force..To.reduce.the.risk.of.these.hazards,.operator.and. bystanders.MUST.completely.heed.the.hazards.and.warnings.below. OWNER’S MANUALS. Read and understand this JIG CONTROL. ALWAYS use two hands to firmly manual and the manual for your table saw hold both tenoning jig handles when cutting.

  • Page 9: Setup

    Model D4902 (For Machines Mfd. Since 11/18) SETUP Unpacking This machine has been carefully packaged for safe transportation. If you notice the machine has been damaged during shipping, please contact your authorized Shop Fox dealer immediately. Inventory The following is a list of items shipped with your machine.

  • Page 10: Cleaning Machine

    Model D4902 (For Machines Mfd. Since 11/18) Cleaning.Machine To prevent corrosion during shipment and storage of your machine, the factory has coated the bare metal surfaces of your machine with a heavy-duty rust prevention compound. Gasoline.and.petroleum. products.have.low.flash. If you are unprepared or impatient, this compound can points.and.can.explode.

  • Page 11: Preparing Table Saw

    Model D4902 (For Machines Mfd. Since 11/18) Preparing.Table.Saw The Model D4902 Tenoning Jig is designed to work with a table saw that has a ⁄ " x ⁄ " miter T-slot on the left side of the blade. To help ensure safe and accurate tenons, Always.

  • Page 12: Assembly

    Model D4902 (For Machines Mfd. Since 11/18) Assembly To assemble tenoning jig, do these steps: Side Support 1. Attach clamp brace to back of side support using (1) M10-1.5 x 20 cap screw with 10mm lock washer, and (1) M10-1.5 x 25 cap screw with 10mm lock washer, as shown in Figure 2.

  • Page 13: Re-Mounting Guide Bar

    Model D4902 (For Machines Mfd. Since 11/18) Re-Mounting.Guide.Bar The guide bar can be mounted to the slide plate in two positions (see Figure 5), depending on the distance between the left-hand miter slot of the table and the Slide blade. The jig ships with the guide bar mounted in the Plate outward position.
  • Page 14 Model D4902 (For Machines Mfd. Since 11/18) 3. Loosen set screw on micro-adjust assembly, then remove micro-adjust assembly from rod (see Figure 7). Set Screw Inward 4. Remove (2) pre-installed M6-1 x 20 button head cap Mounting screws that secure guide bar to base plate, then...

  • Page 15: Adjusting Guide Bar

    Model D4902 (For Machines Mfd. Since 11/18) Adjusting.Guide.Bar In this procedure you will adjust the guide bar so that it slides back and forth in the table saw miter slot without side-to-side play or tilt that could cause the workpiece to DO.

  • Page 16: Adjusting Side Support

    Model D4902 (For Machines Mfd. Since 11/18) Adjusting.Side.Support In this procedure, you will adjust the side support perpendicular to the saw table. Then you will set the 90° positive stop so the support can be quickly returned to DO. NOT. remove. the. T-slot. washers.

  • Page 17: Adjusting Back Support

    Model D4902 (For Machines Mfd. Since 11/18) Adjusting.Back.Support In this procedure you will adjust the back support perpendicular to the saw table, then set the 90° positive stop so the back support can be returned to the perpendicular position after an angle cut.

  • Page 18: Adjusting Blade Clearance

    Model D4902 (For Machines Mfd. Since 11/18) Adjusting.Blade.Clearance In this procedure you will adjust the side support to be parallel with the saw blade and ⁄ " away from it. Then you will set the safety stop set screw (see Figure 14) so You.
  • Page 19 Model D4902 (For Machines Mfd. Since 11/18) 7. Use micro-adjust knob to move side support against saw blade (see Figure 16). Side Guide Bar Micro- Support Access Hole Adjust Note: If tenoning jig side support will not reach Knob the blade, you may need to re-mount guide bar...

  • Page 20: Operations

    Model D4902 (For Machines Mfd. Since 11/18) OPERATIONS Operation.Overview The Model D4902 will perform many types of operations that are beyond the scope of this manual. Many of these operations can be dangerous or deadly if performed incorrectly. The instructions in this section are written with the...

  • Page 21: Cutting Basic Tenons

    Model D4902 (For Machines Mfd. Since 11/18) Cutting.Basic.Tenons This tenoning jig is designed to make tenon cheek cuts only. Generally, cheek cuts are made before the structural and cosmetic shoulder cuts, which are then made without ALWAYS.make.sure.table.saw.is.turned. using the jig (see Figure 17).
  • Page 22 Model D4902 (For Machines Mfd. Since 11/18) 3. Plane a piece of wood approximately ⁄ " thick to match base plate of tenoning jig, then clamp it to front of table and even with right side of base plate, as shown in Figure 19.
  • Page 23 Model D4902 (For Machines Mfd. Since 11/18) 5. Cut a backing board approximately 5" wide by 9" tall out of a piece of ⁄ " plywood, then mount it to jig side support using either wood screws through back of support or recessed cap screws and hex nuts through front of backing board (see Figures 22–23).
  • Page 24 Model D4902 (For Machines Mfd. Since 11/18) Cutting.Tenon.Cheeks 1. DISCONNECT TABLE SAW FROM POWER! ALWAYS. move. workpiece. completely. 2. Make sure all tenoning jig lock levers are tightened, through. blade. to. reduce. risk. of. and workpiece is properly mounted and securely kickback..
  • Page 25 Model D4902 (For Machines Mfd. Since 11/18) 9. Turn saw OFF, disconnect it from power, then wait for blade to come to a complete stop. 10. Loosen clamp shoe, remove workpiece, then move tenoning jig back to front of table.
  • Page 26 Model D4902 (For Machines Mfd. Since 11/18) Cutting.Tenon.Shoulders The final set of cuts will remove the waste pieces from the previous cuts to produce the shoulders and complete ALWAYS. use. a. cross-cut. saw. blade. the tenon. when.making.the.tenon.shoulder.cuts.. Otherwise,. the. blade. can. aggressively.

  • Page 27: Accessories

    8420 or at sales@woodstockint.com. The Shop Fox.W1671.Heavy.Duty.Mortising.Machine is the ideal shopmate for the D4902 Tenoning Jig. The W1671 features a heavy- duty fence and hold down to eliminate unwanted wood movement and "sticking chisels," ensuring accurate and fast operation. The unique swiveling base allows easy off-the-bench operations and opens new possibilities for custom mortises.
  • Page 28 Model D4902 (For Machines Mfd. Since 11/18) The Shop Fox.D4031.Mortising.Attachment.Kit.For.Drill.Presses comes in a durable molded carrying case and includes a cast-iron chisel holder and fence, hold down assembly, quill alignment pin, four chisels ( ⁄ ", ⁄ ", ⁄ ", ⁄...

  • Page 29: Maintenance

    • Lubricate the tenoning jig pivot points. Cleaning.&.Protecting Cleaning the Model D4902 is relatively easy. Vacuum excess wood chips and sawdust, and wipe off the remaining dust with a dry cloth. If any resin has built up, use a resin dissolving cleaner to remove it.

  • Page 30: Parts

    Model D4902 (For Machines Mfd. Since 11/18) PARTS Main 44 45 -28-...
  • Page 31 Model D4902 (For Machines Mfd. Since 11/18) Main.Parts.List REF PART # DESCRIPTION REF PART # DESCRIPTION XD4902001 LOCK HANDLE 68L, M8-1.25 XD4902037 LOCK WASHER 10MM XD4902002 FLAT WASHER 5/16 XD4902038 CLAMP BRACE XD4902003 SET SCREW M8-1.25 X 55 XD4902039 WARNING LABEL...
  • Page 32 -30-...
  • Page 33 Model D4902 (For Machines Mfd. Since 11/18)
  • Page 34 Fold along dotted lIne place stamp Here Woodstock international inc. p.o. box 2309 bellingham, Wa 98227-2309 Fold along dotted lIne tape along edges--please do not staple...

  • Page 35: Warranty

    Woodstock International, Inc. will repair, replace, or arrange for a dealer refund, at its expense and option, the Shop Fox machine or machine part proven to be defective for its designed and intended use, provided that the original owner returns the product prepaid to an authorized warranty or repair facility as designated by our Bellingham, Washington office with proof of their purchase of the product within two years, and provides Woodstock International, Inc.

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