Grizzly G1023SLW User manual

A router guard kit is included with your machine to
reduce the risk of accidental cutter contact during
operation. The router guard is also designed to be
connected to a dust collector to help collect dust
and chips during operation.
The router guard is intended to be used with a
shop-made fence and must be used when mak-
ing cuts that leave part of the router bit exposed
to the operator.
Inventory & Assembly
The inventory is shown in Figure 1 and the parts
breakdown and assembly lines are shown in
Figure 2.
ROUTER GUARD KIT
FOR G1023SLW
INSTRUCTION SHEET
Figure 1. Router guard inventory.
If you need help with the router guard, call our
Tech Support at: [phone].
COPYRIGHT © APRIL, 2006 BY GRIZZLY INDUSTRIAL, INC.
WARNING: NO PORTION OF THIS DOCUMENT MAY BE REPRODUCED IN ANY SHAPE
OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.
#TR8217 PRINTED IN TAIWAN
Overtightening the fasteners that secure the
plastic guard to the bracket may crack or
break the plastic guard, rendering it unsafe
for use.
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Figure 2. Parts breakdown.
REF PART # DESCRIPTION QTY
1 PS25 PHLP HD SCR 8-32 X 5/8 2
2 PWN02 WING NUT 1/4-20 2
3 PHTEK11 WOOD SCREW #8 X 3/4 2
4 P1023SLW620-4 HORIZONTAL BRACKET 1
5 P1023SLW620-5 VERTICAL BRACKET 1
6 PCB18 CARRIAGE BOLT 1/4-20 X 1/2 2
7 P1023SLW620-7 GUARD 1
8 PW08 FLAT WASHER #8 6
9 P1023SLW620-9 LOCK WASHER #8 2
10 PN14 HEX NUT 8-32 2
11 P1023SLW620-11 PHLP HD SCR 10-24 X 2-1/2 4
12 PW06 FLAT WASHER 1/4 2

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Figure 5. Center point marked on support
board.
2. Move the table saw fence next to the opening
on the router table extension wing and mark
the center point of the table hole opening on
the right-hand side of the table saw fence
face (Figure 4).
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Figure 4. Table hole center point marked on
fence face.
Fence Setup
The fence setup requires making a support board
and two fence pieces. The support board aids in
mounting and remounting the fence pieces.
The fence pieces must be moved in or out to
minimize router bit clearance for maximum safety
and support.
Often, more than one fence will be necessary to
safely accommodate various sized router bits.
To set up a fence:
1. Make a support board with a piece of 11⁄2"
stock, approximately 28" long, cut to 21⁄2" tall
and square up on all sides (Figure 3).
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Figure 3. Support board dimensions.
3. Mark the center point of the length of the sup-
port board (Figure 5).
4. Remove the fence face from the right-hand
side of the fence by unscrewing the six
mounting screws.
Note: Be careful not to disturb any shim tape
on the metal body of the fence. This has been
carefully installed at the factory to ensure
that the fence face remains straight when
installed.
5. Rest the fence face and the support board
on the table saw table, align the center point
marks, and clamp the two pieces together.
6. Use the table saw fence face as a template
to transfer the screw hole positions on your
fence board (Figure 6). (Use a center punch
or long nail to mark the holes.)
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Figure 6. Fence and board lined up and
clamped to transfer screw hole positions.

7. Unclamp the support board and fence face,
and drill holes through the support board
where marked with a 3⁄16" drill bit.
8. Countersink the holes in the face of the sup-
port board approximately 1⁄4" deep with a 3⁄8"
drill bit, as shown in Figure 7.
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Figure 7. Steps for drilling and countersinking
screw holes into support board.
Figure 8. Reattaching fence face.
9. Reattach the fence face at both ends, as
shown in Figure 8.
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Figure 10. Determining fence thickness from
router bit dimensions.
11. Make a 28" long fence that is 23⁄4" tall.
The fence thickness is determined by the
largest size router bit you will use. A 11⁄2"
thick fence works well for most router bits.
Ultimately, the fence must be thick enough
to accommodate the portion of the router bit
behind the front fence surface. To determine
this, subtract the cutting depth from the router
bit diameter, then add 1⁄4" (see Figure 10).
Make sure you properly square up all sides of
your fence. (If you regularly experience snipe
from squaring your boards with your planer
and jointer, make the fence 4" longer and cut
off the end with the snipe after squaring the
board up.)
10. Attach the support board to the fence with the
long Phillips screws included with the kit, as
shown in Figure 9.
Figure 9. Attaching support board.

13. Face plane approximately 1⁄16" off of the
fence board that will be the infeed fence. The
amount of material removed in this step will
control your depth of cut.
Removing more than 1⁄16" from the infeed
fence may greatly increase the risk of injury
when routing.
— If you are using a router bit that will remove
the entire face of the workpiece, as illus-
trated in Figure 12, continue with Step
13.
12. Cut your fence in half. One side will be the
infeed fence and the other side will be the
outfeed fence.
— If you are using a router bit that will not
remove the entire face of your workpiece,
as illustrated in Figure 11, then skip ahead
to Step 14.
Figure 11. Typical routing operation for partial
face removal of workpiece.
Figure 12. Typical routing operation for full face
removal of workpiece.
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Figure 13. Positioning fences around router bit.
14. Mount your router with the installed router bit
on the table saw extension wing as it will be
positioned for regular routing operations.
15. Mount the table saw fence to the left of the
router bit and move the fence so the support
board is next to the router bit.
Attaching the fence faces incorrectly during
the next step may increase the risk of kick-
back or other serious personal injury during
routing operations.
16. Position the infeed and outfeed fences as
close as possible to the maximum diameter
of the router bit, but not farther than 1/8" (see
Figure 13).
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Figure 14. Minimum clearance fence setup.
For maximum safety and support, consider
using a minimum clearance design for your
fences. Minimum clearance fences are cut
around the shape of the router bit to minimize
clearance between the router bit and the
fence, as shown in Figure 14.

18. Center the guard over the table opening and
attach the guard assembly to the top of the
fence boards with the two provided wood
screws, as shown in Figure 16.
19. Adjust the guard horizontally (if necessary)
by using the horizontal bracket slots and
wood screws.
20. Adjust the height of the guard 1⁄8" higher than
the workpiece height by using the vertical
bracket slots and carriage bolt/wing nuts.
21. Connect the top of the guard to your dust col-
lection system with a 3" adapter.
Figure 16. Attaching router guard.
17. Clamp, predrill with a countersinking bit, and
attach the fence pieces with at least two
wood screws per side, as shown in Figure
15. (Only use wood screws that are long
enough to thread into the support board, but
not too long that they enter the plastic fence
face.)
Note: If you followed Step 13, be sure to
install the modified board on the infeed side.
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Figure 15. Attaching fence boards.
If you change router bits, the fence pieces
must be adjusted in/out so there is not more
than 1⁄8" clearance between the router bit
and the fences.