JessEm MAST-R-FENCE III User manual

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MAST-R-FENCE III
Owners Manual
Model #04400
61 Forest Plain Road
Oro-Medonte, Ontario, Canada
L3V 0R4
Toll Free: 1-800-436-6799
Local: 705-726-8233
Fax: [phone]
Email: [email protected]
Web: www.jessem.com

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JESSEM TOOL COMPANY - LIMITED WARRANTY WARRANTY LIMITATIONS
MESSAGE TO OUR CUSTOMERS
CONTINUOUS PRODUCT IMPROVEMENT POLICY
All JessEm products are warranted to be free from
defects in material and workmanship. JessEm will
repair or replace any product which upon inspection,
proves to be defective for a period of (1) year from
dated receipt and proof of purchase from an autho-
rized JessEm Distributor. All warranty claims should
be made direct to JessEm Tool Company.
This warranty does not cover:
• Repairs or alterations made or attempted by anyone
other than JessEm Tool Company or an authorized
JessEm service professional.
• Normal wear and tear.
• Abuse, misuse or neglect.
Contact JessEm for a warranty claim return autho-
rization and instructions to proceed. The consumer
is responsible for shipping costs to return product to
JessEm Tool Company. We will repair or replace the
product at our discretion and JessEm Tool will return
shipment to you at no charge.
• Improper care or maintenance.
• Continued use after partial failure.
• Products that have been modied in any way.
• Products used with improper accessories
Thank you for choosing the Mast-R-Fence III router table fence Model: #04400 from JessEm Tool Company.
We appreciate your support and hope that our product serves you well. This product is designed to provide
many years of reliable service, provided it is used as intended and taken care of.
IMPORTANT
Read and understand the contents of
this manual before assembly or
operation of this product
This user manual will assist you in assembly and general operation of this product. It is not our intent to
teach you about woodworking. It is assumed that you are an experienced woodworker with the basic skills
and experience necessary to use this product safely. If after reading the following instructions, you are un-
sure or uncomfortable about safely using this product, we urge you to seek additional information through
widely available woodworking books or classes.
As part of our Continuous Product Improvement Policy, JessEm products are always advancing in design,
quality and function. Therefore, there may be differences between what is shown in our catalogs, on our
website, on retail displays and what is sold at time of purchase. We reserve the right to make positive
changes to our products at our discretion to ensure you, the customer, have the very best product.
State of California: WARNING
Cancer and Reproductive Harm.
www.P65Warnings.ca.gov
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IMPORTANT SAFETY PRECAUTIONS
ROUTER AND ROUTER FENCE
SAFETY PRECAUTIONS
Always make sure the fence on your router table is
locked rmly into position before each use.
Never force the bit or overload the router beyond
the expectations of the tool.
Be sure that at least 3/4 of the shank length is in-
serted securely in the router collet.
Never bottom out the bit in the collet. Allow 1/16”
clearance between shank and bottom of collet.
Always rout in two or more passes when large
amounts of stock must be removed.
Use reduced RPM speeds for large diameter bits.
Before operating any machinery or power tool,
read and understand all safety instructions in
theowner’s manual that came with the router.
If you do not have a manual, contact the manufac-
turer and obtain one before using any power tool.
Always wear eye protection in compliance with ANSI
safety standards when operating any power tool.
Always use proper guards and safety devices when
operating power tools and machinery.
Carefully check router bits before each use.
Do not use if damage or defect is suspected.
Do not exceed the recommended RPM for any
router bit.
Do not wear loose clothing or jewelry that may catch
on tools or equipment.
Unplug the tool or machine when mounting or mak-
ing any adjustments to mechanical performance.
A) Personal Safety
i) Stay alert, watch what you are doing and use common sense
when operating a tool. Do not use a power tool while you are
tired or under the inuence of drugs, alcohol or medication.
Serious personal injury could result if complete attention is not
given while operating power tools.
ii) Always wear safety glasses. Everyday eyeglasses are not
safety glasses. Safety glasses have specially constructed
frames, lenses and side shields for better protection.
iii) Use safety equipment. Use a face or dust mask when
the cutting operation is dusty. Safety equipment such as dust
masks, hard hats, non-skid safety shoes and hearing protection
reduces personal injuries when used for appropriate conditions.
If devices and tools allow for dust extraction and collection,
ensure these are connected and properly used.
iv) Do not overreach. Keep proper footing and balance at all
times. This allows for better control of the power tool in
unexpected situations.
v) Never stand on the machine. Serious injury could occur if
the tool tips or if the cutting tool is unintentionally contacted.
vi) Secure workpieces. Use clamps or vises to hold work when
practical. This is safer than using your hands and frees both
hands to operate the tools.
vii) Dress appropriately. Do not wear loose clothing or jewelry.
Ensure you keep clothing, hair and gloves away from moving
parts. Loose clothing, jewelry or long hair can be caught in
moving parts. Roll up long sleeves to the elbow. Wear
protective hair covering to contain long hair.
viii) Avoid accidental starting. Ensure the switch is in the off
position before you plug it in. Carrying a power tool in you
hands with your nger on the switch or plugging in a power tool
that has the switch on is inviting accidents.
ix) Remove any adjusting key or wrench before turning the
power tool on. A wrench or a key left attached to a rotating part
of the power tool could result in personal injury.
B) Work Area Safety
i) Make your workshop child proof. Use padlocks, master
switches, or remove starter keys. ii) Keep work area clean and
well lit. Clutter and/or dark areas encourage accidents.
ii) Keep children and bystanders away while operating a power
tool. Complete attention is required when operating a powertool.
C) Electrical Safety
i) Ground electrical tools. If the tool is equipped with a three-
prong plug, it must only be plugged into a grounded three-hole
electrical outlet. If required, a qualied elctrician can install one.
Never remove the third prong or modify the plug that is provided
in any way.
ii) Never expose a power tool to rain or wet conditions. You will
increase the risk of electric shock if water enters the powertool.
iii) Using power tools in damp or wet locations or conditions is
extremely dangerous.
iv) Do not operate any power tool in an explosive atmosphere,
in the presence of ammable liquids, gases or dust. Power tools
can create sparks which may ignite the fumes or dust.
Suggested Router Bit Speeds
Bit Diameter Max. Speed
1” (25mm) 21,000 RPM
1-1/4” - 2” (30-50mm) 18,000 RPM
2-1/4” - 2-1/2” (55-65mm) 16,000 RPM
3” - 3-1/2” (75-90mm) 12,000 RPM

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CONTENTS OF PACKAGING
Item No. Part Description Qty
-MAST-R-FENCE III Assembly 1
2 Guard 1
5 Track Clamping Knob 2
9 Guard Mount 1
18 Fence Track 2
20 Fence Mounting Angle 2
33 Fence Shimming Bar 2
TOOLS REQUIRED FOR ASSEMBLY (SUPPLIED)
Item No. Part Description Qty
-JessEm T-25 Torx Screwdriver 1
-3⁄16" Hex Key 1
-5⁄64" Hex Key 1
HARDWARE INCLUDED
Item No. Part Description Qty
1 Guard Height Adjustment Knob 2
4 Track Clamping Knob Washer 2
8 Guard Mount Clamping Knob 1
10 ¼"-20 X 1-½" Hex Head Screw 1
19 #10-24 X ½" Self Tapping Pan Head Torx Screw (Self tapping screws have a at notch on
the end to facilitate cutting into the phenolic) 8
23 ¼" Washer 6
28 ¼"-20 Square Nut 6
29 ¼"-20 X 5⁄8" Socket Head Cap Screw 6
36 Fence Knob T-Nut 2

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THE FOLLOWING INSTRUCTIONS ARE FOR MOUNTING THE #04400 MAST-R-FENCE III
TO A JESSEM MAST-R-TOP OR A JESSEM MAST-R-LIFT EXCEL II TOP
THE FOLLOWING INSTRUCTIONS ARE FOR MOUNTING THE #04400 MAST-R-FENCE III
TO A NON-JESSEM TOP
NOTE: If you are mounting your Mast-R-Fence III to a Non-JessEm top, please skip to step 2.
Step 1: Securing fence mounting angles (part #20) to table top
a. JessEm’s Mast-R-Top and Mast-R-Lift Excel II table tops are
pre-drilled for easy assembly.
b. Using two wooden spacers, at least 2" high ip your table top
upside down on a table to raise the table off your working sur-
face a couple of inches. See Figure 1.
c. Position the left and right fence mounting angles on each side
of the table (part #20).
d. With the #10-24 x ½" self tapping torx drive screws (part #19),
fasten and secure the fence mounting angle to the table. See
Figure 1.
e. Skip to step 3.
Figure 1
Step 2: Marking and drilling your holes
a. Take one of your fence mounting angles and with a pencil,
mark your holes on the underside of your table top, using the
fence mounting angle (part #20) as a template. See Figure 2.
NOTE: THE MOUNTING ANGLES SHOULD BE APPROXI-
MATELY 1-1⁄4"FROM THE BACK OF THE TOP.
b. Pre-drill the holes using a 1⁄16" diameter drill bit and be sure you
do not drill through the table top surface. It is suggested you
use masking tape on your drill bit to prevent this.
c. Secure the track mounting angles to the table top with the #10
wood screws you sourced. Repeat this step for the other side.
1-1/4"
MARK 4 HOLES ON EACH SIDE
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Figure 2
NOTE: You will need to source (8) wood screws. The length of the screws will depend on the thickness of your
table top. Typically you would want screws that are about ¼" less than the thickness of your top. (Example: 1"
table top would require ¾" screws.)
NOTE: If you are mounting your Mast-R-Fence III to a JessEm top, please skip step 2.
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Step 4: Mounting of tracks to mounting angles
a. Place 1⁄4" washers (part #23) onto the 1⁄4"-20 X 5⁄8" socket head
cap screws (part #29).
b. Slide the screws through the slots in the left and right hand
track (part #18) See gure 3.
c. Thread the square nuts (part #28) onto the screws. (DO NOT
tighten the square nuts. Leave loose for the next step)
a. Slide the square nuts (part #28) into the T-slot in the mounting
angle (part #20). See gure 4.
b. Align the track so that the back of the track is ush with the
back of the top. See gure 5.
c. Snug the 1⁄4"-20 X 5⁄8" socket head cap screws (part #29).
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23
18
28
Figure 3
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282920
Figure 4
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Figure 5
Step 3: Attaching the square nuts
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29
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282920
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Step 6: Mounting your fence to the tracks
a. Slide the ¾" x 2-1⁄2" rectangular T-nut (part # 36) for the ex-
tension knob into the T-slot. See Figure 7. Slide the clamping
T-nut into the T-slot until the threaded hole aligns with the hole
in the knob mount (part #7). Repeat this step for the other side
of the fence.
a. Loosen the (4) #10-24 X ½" pan head torx screws (part #3) so
that the knob mounts (part #7) can slide.
b. Slide the clamping knob washers (part #4) onto the clamping
knob studs (part #6).
c. Tighten the clamping knobs into the clamping knob T-nuts (part
#36).
d. Once the fence is centred and the clamping knobs are tight;
tighten the (4) #10-24 X ½" pan head torx screws (part #3).
Repeat step 6 for both sides of the fence.
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Figure 7
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4
6
3
7
Figure 8
Step 5: Levelling the tracks to the table top
a. Turn your top right side up on the 2" spacers or you can now
mount the top to a stand.
b. Place the fence on the table top in its upright position and allow
it to hang over the table edge and lie across the front end of
the fence track.
c. Loosen the (3) 1⁄4"-20 x 5⁄8" socket head cap screws (part #29).
Raise the fence track so that it is ush with the bottom of the
fence. See gure 6.
d. With the 3⁄16" hex key provided, tighten the front screw.
e. Move the fence to the back of the table and use it to position
the rear end of the track in the same way.
f. Tighten the center screw to complete the leveling of the fence
track. Repeat step 5 to level the fence track on the other side
of the table.
g. Check that the tracks are ush with the table top and readjust
as necessary.
NOTE: The Tracks of the Mast-R-
Fence III are slotted to allow for
vertical adjustment to ensure the
fence tracks are perfectly ush with
the table top.
14 29 18
Figure 6 182914
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MOUNTING THE MAST-R-FENCE III TO EMBEDDED TABLE TOP TRACKS
SETTING FENCE SCALES
NOTE: You will need to source a T-nut or hex nut with a 3⁄8"-16 thread which matches the width of the T-slot
in your top.
NOTE: If you are mounting your Mast-R-Fence III with the provided tracks, please skip step 7.
Step 8: Now that your fence is fastened to the fence tracks, you will need to align the fence to
the bit opening and adjust your scales accordingly.
a. Ensure your router is mounted in the table top with a router bit
in your router.
b. Loosen the clamping knobs (part # 5), and slide your fence so
it is centred around the router bit.
c. Check that the fence is parallel to the front edge of the table.
d. Tighten the fence clamping knobs.
Figure 11
Step 7: Mounting your fence to in table T-slots
a. Remove the (2) #10-24 X ½" pan head torx screws (part #3)
from each knob mount (part #7).
b. Move the knob mount (part #7) to the pre-drilled holes in the
base (part #14). See gure 10.
c. Retighten the #10-24 X ½" torx screws to secure the knob
mount in place.
d. Refer to step #6 for mounting the clamping knobs to the tracks.
3 7
5
4
6
Figure 10
645
3 7
3
7
Figure 9
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Step 9: Attaching the guard to the fence
a. Slide the 1⁄4"-20 X 1-1⁄2" hex head screw (part #10) up through
the centre hole in the guard mount. See gure 13. Thread the
guard mount clamping knob (part #8) onto the hex head screw.
DO NOT tighten all the way. Leave loose enough to slide into
the T-slot in the upper fence (part #11).
e. Ensure the right and left hand track scale (part #17 & #35) are
on the proper sides. See Figure 12.
f. With the 1⁄8" hex key provided, loosen the set screws (part #16)
on the front of the left and right hand scales. See Figure 12.
g. Slide the scale to align the “0” on the scale with the front edge
of the fence. See Figure 12.
h. Tighten the set screw. Repeat this for the other scale on the
opposite side of the fence. The Mast-R-Fence III should now
be centred on your router table.
b. Slide the guard mount (part #9) into the T-slot by aligning the
1⁄4"-20 X 1-1⁄2" hex head screw (part #10) in the top of the upper
fence (part #11).
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9
8
Figure 13
16
35
Figure 12
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10
11
Figure 14
Assembling the guard mount:
Attaching the guard mount to the fence:
Step 8: Continued
ASSEMBLING AND ATTACHING THE MAST-R-FENCE III GUARD
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Step 9: Continued
a. Attach the guard (part #2) to the guard mount (part #9) using
the (2) guard height adjustment knobs (part #1).
b. To adjust the height of the guard during use, loosen the guard
height adjustment knobs and slide the guard to the desired
height; then re-tighten.
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2 1
Figure 15
Attaching the guard:
Step 10: Loosen the (4) fence face clamping knobs (part #22). See gure 16.
Step 11: To avoid damaging the wooden fence faces, slide to desired width so your fence faces
completely clear your router bit. Re-tighten the (4) fence face clamping knobs to clamp the fence
faces in place. See Figure 16.
22222222
Figure 16
ADJUSTING THE WOODEN FENCE FACE (PART #37) ON THE MAST-R-FENCE III
CAUTION
ENSURE THE FENCE FACES COMPLETELY CLEAR THE
DIAMETER OF THE ROUTER BIT BEFORE STARTING THE ROUTER.
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REPLACING THE WOODEN FENCE FACE (PART #37) ON THE MAST-R-FENCE III
Step 12: Removing the fence faces
a. Remove the (2) fence face clamping knobs (part #22) from
the backside of the fence. (HINT: If the knobs are too tight to
remove use a 1⁄4" hex key to loosen).
b. Slide the fence face straight out the front (the fence face screw
(part #38) will stay in the fence face (part #37)). Using a ham-
mer or something hard, tap the fence face screws (part #38)
out of the fence face (part #37).
38 37
22
Figure 17
3"
10"
17 3
4
"
2 1
2
"
1 1
4
"
1
4
" THRU
3/4" 1/8"
FRONT VIEW
1
8
"
3
4
"
BOTTOM VIEW
The above drawing is for personal use
only and is not to be distributed unless
otherwise approved by JessEm Tool
Company.
MAST-R-FENCE III
FENCE FACE
Wooden Fence Face Drawing
Figure 18
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3738

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Step 13: Attaching new fence faces
a. Slide the fence face clamping knobs (part #38) into the previ-
ously drilled holes in your new fence faces. See gure 19.
b. Slide the fence face clamping knobs into the slots in the fence
uprights (part #12).
c. Reattach with clamping knobs (part #22).
38 37
22
Figure 19
MAST-R-FENCE III JOINTING
Step 14: Storage of shimming bars (when not in use)
Step 15: Using the shimming bars
a. Slide the shimming bars (part #33) into the shimming bar hold-
ers (part #21) until the detent “clicks” into place.
a. Loosen the fence face clamping knobs (part #22) until there is
enough play behind the fence face to slide the shimming bars
behind.
b. Slide the fence shimming bars (part #33) into the matching
grooves on the left hand fence upright (part #12, outfeed side).
c. When sliding the shimming bars into the left hand fence upright
(part #12) match the laser engraved feed direction to the de-
sired jointing spacing. (1⁄16" or 1⁄32").
d. Once the shimming bar is behind the fence face, tighten the
fence face clamping knobs (part #22).
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Figure 20
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Figure 21
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3738
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33
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MAST-R-FENCE III™ PARTS LIST
Item No. Part No. Part Description Qty
1 S0053-17 Guard Height Adjustment Knob 2
2 M0286 Guard 1
3 F0363 #10-24 X ½" Pan Head Torx Screw 12
4 S0064-12 Track Clamping Knob Washer 2
5 E0131-5 Track Clamping Knob 2
6 S0065-10 Track Clamping Knob Stud 2
7 E0041-4 Track Clamping Knob Mount 2
8 S0053-6 Guard Mount Clamping Knob 1
9 E0312-1 Guard Mount 1
10 F0501 ¼"-20 X 1-½" Hex Head Screw 1
11 E0256-2-3 Upper Fence 1
12 E0309-1 Left Hand Fence Upright 1
13 F0364 #10-24 X ¾" Flat Head Torx Screw 6
14 M0378-1 Base 1
15 E0314-1 Fence Upright Bracket 4
16 F0355 #8-32 X 3⁄16" Flat Point Set Screw 2
17 E0295-3 Left Hand Scale Bar 1
18 E0306-1 Fence Track 2
19 F0330 #10-24 X ½" Self Tapping Pan Head Torx Screw 8
20 E0307-1 Fence Mounting Angle 2
21 E0228-3 Shimming Bar Holder 2
22 S0053-1 Fence Face Clamping Knob 4
23 F0348 ¼" Washer 10
24 M0280 Vacuum Shroud 1
25 F0365 ¼"-20 X 1" Pan Head Torx Screw 2
26 F0435 #10-24 X 5⁄8" Pan Head Torx Screw 8
27 F0370 #10-24 X ¾" Pan Head Torx Screw 4
28 F0028 ¼"-20 Square Nut 6
29 F0347 ¼"-20 X 5⁄8" Socket Head Cap Screw 6
30 S0075-4 Spring Plunger 2
31 M0391 Spring Plunger Compression Spring 2
32 F0433 ¼"-20 X 3⁄16" Cup Point Set Screw 2
33 E0308-1 Fence Shimming Bar 2
34 E0309-2 Right Hand Fence Upright 1
35 E0295-3 Right Hand Scale Bar 1
36 S0014-5 Fence Clamping T-Nut 2
37 M0401-1 Fence Face 2
38 S0053-37-C Fence Face Screw 4