Lumberjack Industrial Series User manual

Industrial Series TTA0750
Industrial Series TTA1000
Industrial Series TTA1500
Industrial Series TTA2000
Industrial Series TTA2500
Industrial Series TTA2563
Industrial Series TTA3000
Industrial Series TTA2000L
Industrial Series TTA2000E
Made in the U.S.A.
INDUSTRIAL SERIES – Dual Blade Tenon Cutters
Lumberjack Tools, Inc.
MODELS:
REV: 07/08/11
“In-Sight” Measurement
System
As with any new hobby or project, it will take time to get good at using our
tool and building furniture. You must first have a plan or sketch of what
you want to build, along with a tools and materials list before you begin.
This will allow you to obtain the raw materials, tools and other items
you’ll need before you get started and realize you forgot something.
Another important issue is reading the natural twist, stress or other
deformities in the logs and using these skills to your advantage allowing
your pieces to become more unique as your abilities grow. Also as
important is to not over complicate your first few pieces so you can have
a “positive” experience.
Thank you for purchasing our tools!
P.O. Box 63928 • Colorado Springs, CO 80962 • 719-282-3043
Figure: 1
Proper Cutting Technique
• Log and drill “on-center”
• Result - Straight Tenon
Improper Cutting Technique
• Log and drill “off-center”
• Result - Crooked Tenon

Thank you for purchasing our Dual Blade - Industrial Series Tenon Cutter!
Lumberjack Engineers, along with our craftsmen, have designed the safest,
easy-to-use self-centering tenon cutter on the market. By combining old-
world skills, along with DFMA principles and CNC technology, we’ve
eliminated the issues of off-center tenons and side-load cutting associated
with single-blade designs.
We’ve added value with the dual-blade technology which will cut the
tenon in half the time, and the two blades stay sharper, longer. The In-
Sight measurement system allows the craftsmen to cut the tenon to length
without the process of measuring with a tape measure each and every
piece before it is worked.
Our solid billet of aircraft-grade aluminum is designed to last a lifetime
under normal operating conditions. The aluminum body is CNC machined
to ensure precise cutting each and every time. The blades are stamped,
heat treated and precision ground to provide years of service when
properly maintained.
Before beginning any project, carefully read and follow all safety and
operational instructions for any tools or devices you will be using. Failure
to follow all safety instructions may cause bodily harm to yourself or
those around you. If you feel uncomfortable using our tenon cutter or
any other tools, stop immediately. We assume no responsibility for injury
caused to the operator, bystander or tools used in conjunction with the
use or misuse of our tenon cutters.
WARRANTY:
Our lifetime guarantee covers the tool body and shank. The blades are
covered for 90 days from the date of purchase for breakage under normal
working conditions. Blade sharpness is based on the type of wood, peeled
or unpeeled. Grit, dirt, etc will impact how long your blades stay sharp
and is not covered under this warranty. When making a claim, you must
show proof of purchase from an authorized distributor. This is valid only
to the original buyer and not for tools sold secondhand, used or sold “as
is” to a second party.
•WARNING: IF THE LOG COMES LOOSE OR UNCLAMPED
WHILE MAKING A TENON, DO NOT DROP THE DRILL OR
TRY TO GRAB THE LOG. HANG ON TO THE DRILL AND
POINT IT IN A SAFE DIRECTION (usually toward the ground)
AWAY FROM EVERYONE UNTIL IT COMES TO A
COMPLETE STOP.
• Do not remove the tool from the log until the drill comes to a
complete stop. Failure to do so will waffle cut the tenon or cause
harm to the operator. Do not place hands or body parts near the
tool or blades while in operation.
• Do not drop or allow the tool to fall to the floor by itself or while
in the drill. Doing so may bend the shank or damage the tool. This
damage is not covered by the warranty.
MAINTENANCE:
It is best if you keep the tenon cutter body clean of sap & build up.
Carefully clean the tool with the solvent or cleaner of your choice and
dry when done. Wear all protective safety devices including safety
glasses, gloves, etc. while cleaning tool.
Our blades are made from high-quality tool steel and may form oxidation.
This is a natural occurrence and will vary depending on your geographic
location, climate and shop environment, etc. You should periodically
clean the blades and apply a thin lm of oil. Every time you resharpen
the blades you must also apply a thin lm of oil. Use extreme caution
when doing this so you don’t cut yourself.

SAFETY:
GENERAL SAFETY RULES
• never operate this tool under the influence of alcohol, drugs or
medication.
• you must wear safety glasses, dust mask and all other safety
devices that are required.
• before installing/removing the tool, the drill must come to a
complete stop and the power must be disconnected.
• do not wear gloves, loose clothing or other items that may get
caught in the moving parts.
• never operate this tool in a drill press, lathe or any other device
except for a 1/2” or 3/4” hand drill. Doing so voids the warranty.
• recommended RPMs is 500 or less, and we suggest a single-speed,
gear-driven drill and not a variable-speed drill.
• overloading or exceeding the RPMs can result in annealing the
blade or shank failure.
• the log must be secured in a vise or clamp before beginning. Failure
to do so may cause bodily harm.
• do not run this tool into a nail, metal or foreign object. Doing so
will ruin the blades or tool and voids the warranty.
• do not alter or misuse this tool in any fashion.
• remember the blades are sharp, use caution when handling.
• do not apply side force on the drill while in operation or it could
result in premature shank failure or blade damage.
GETTING STARTED:
WARNING: Securing the log is probably the most important SAFETY
factor that will arise while building log furniture.
• Obtain the log you what to tenon. Cut it to length and make sure
the end is square.
• Secure the log in a vise or clamp it to a table in a V-shaped notch.
• Carefully install the tenon cutter into an unplugged 1/2” or 3/4”
drill and tighten it firmly. A tee handle is also recommended.
• Anytime you adjust the blades or to retighten the chuck, you must
always unplug the drill.
CUTTING TENONS:
• If the log diameter is greater than what the tool will accept, use a
drawknife to taper the end of the log like a “pencil” to get the tool
started.
• With your log securely clamped, position the tenon cutter face
squarely against the log you’re going to tenon.
• DO NOT depress the trigger or start the drill before positioning it
against the log. Doing so could harm yourself or the tool.
• While holding the drill squarely against the log, apply body
pressure (straight in-line) with the drill and depress the trigger.
Note: Apply quite a little force. Lean into the drill so that it does
not jump around or skip off the log. See Figure: 1.
• DO NOT allow the drill to be stopped by the wood while making a
tenon.
• You should now be cutting your tenon to the desired length.
• Once the cutting has begun, you may ease up on the pressure and
the dual-blade technology will basically “pull” the tool into the log.

BLADE ASSEMBLY / SETTING:
• Insert the allen wrench (included) into the cap screw and
loosen the bolt.
• Make sure the blade gap setting is the same distance apart for both
blades, about 1/8”– 3/16”.
• You can slightly change the tenon diameter by sliding the blade in
or out. Sliding it in will reduce the diameter and sliding it back will
increase the diameter. Do not slide it beyond 1/4” from the face of
the cutout. Doing so will not cut a tenon, the blade must be
exposed (see pg 5).
• The amount of “bite” or cut is preset at the factory and should not
be shimmed.
• Securely tighten the cap screw but take caution not to strip it. Re-
check both screws before starting.
USING THE In-Sight Measurement System:
SAFETY continued:
• this tool must be maintained by keeping the blades sharp and clean
of buildup.
• when excessive force is required to cut, resharpen or replace the
blades. A sharp tool is a safe tool!
• under severe working conditions of dry or knotty hardwoods, other
natural stresses in the wood or overloading / side loading the tool
may potentially cause the shank to fail or blade damage. (4) “In-Sight”
slots every 90º
for ease of sight
Radial Measurement
Rings every 1/2”
1-1/2” long tenon
to the first Radial
Measurement Ring
Models: TTA0750,
TTA1000, TTA1500,
TTA2000, TTA2500,
TTA2563, TTA3000.
Blade Gap
1/8” - 3/16”
normal settings.
Keep both blade gaps the same.
NOTE: Do Not slide it back more
than 1/4” or it will not cut. Make
sure blade is fully exposed.
Sliding blade forward will reduce
tenon diameter slightly, retracting
it back will increase the size.