MasterGage Classic User manual

MasterGage Corporation, 1534 N. Moorpark Rd # 505, Thousand Oaks, California 91360
TOLL FREE: 1-888-893-8300 www.mastergage.com 2012 Edition
MasterGage/Classic
Owner’s Manual
“Master Your Machinery”™
Getting control of all of your woodworking machinery with the
powerful features of the MasterGage/Classic

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Award
We are proud to announce that the
MasterGage/Classic
won the distinguished
Wood Magazine “TOP TOOL” Award
in August, 2003
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Preface
Machinery illustrated in this Manual is generic. There is a vast range of woodworking machinery
available, both domestic, imported - new and old. It is impossible to show all makes and models
of these machines, along with their adjustment features. Consult your machines Owner’s
Manual for methods of adjustment, etc. If you do not have a Manual, contact the manufacturer’s
dealer Legal Notice
Copyrights
© Copyright 1996-2012 MasterGage Corporation.All rights reserved. This Manual is
copyrighted, no part of this Manual may be reproduced without the prior written permission
of MasterGage Corporation.
Trademarks
MasterGage®and MasterPlate®are federally registered trademarks.SuperBar and “Master
Your Machinery” are trademarks of MasterGage Corporation.All custom graphics and
photo images are service marks, trademarks and/or are trade dress of MasterGage
Corporation.Patents
MasterGage/Classic and other MasterGage products have been awarded, and are
protected by the following eight United States Patents. Additional patents pending.
5,491,906 6,665,946 6,766,584 7,245,199
5,826,346 6,594,913 D574,862 6,901,672
No rights are extended to any entity to reproduce these patented features at
any time or place.
Product Improvement
We at MasterGage Corporation are constantly striving to improve our products. We reserve
the right to change specifications, modify products and/or prices at any time, and without
notice.
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SAFETY INSTRUCTIONS
ALWAYS TURN OFF AND UNPLUG the tool/machinery.BEFORE
using the MasterGage/Classic System on any power tool/machinery

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Welcome to MasterGage
Dear Customer:
I’d like to welcome you into our family of valued customers. MasterGage Corporation is a
manufacturer of high quality, precision tooling for those who demand the very best tools for their
craft.
All MasterGage products are innovative and original. To illustrate this point, I have been
awarded eight United States Patents, with other patents pending, in the development of the
MasterGage system. The tools that I present to you are the result of my 45+ years as a
practicing mechanical engineer involved in many industries designing precision tools and
mechanisms. As a woodworker, I found aligning, tuning and troubleshooting my machines to be
unnecessarily difficult. I also found setting the machines up for various operations and set-ups
time consuming and exasperating. This frustration led me to develop the MasterGage system.
The MasterGage/Classic is a powerful tool, as this Manual will demonstrate. It will allow you to
align, calibrate, trouble shoot and reduce set up time on any piece of equipment found in the
wood shop with ease. With the MasterGage/Classic you have control over any machine you
presently own – or any you plan to acquire in the future. Easily portable, you can use the
MasterGage/Classic on any machine in the production shop, in the field or in the home shop. No
need to rely on any machine scales, since you are always reading the laser precision scales on
the MasterGage/Classic or the super accurate Dial Indicator. You will also get automatic
conversions of any dimension from one system to another, whether it is in fractions, decimal
inches, millimeters or centimeters. Now you will have control of all your machinery.
Do keep in mind that all machines must be aligned and calibrated on a regular basis –
IT IS NOT A ONE TIME EVENT. The Classic really shines when it comes to set up and re-setup
of your machinery for any operation you desire. Machine set up that took hours, will now only
take minutes. With the user-friendly MasterGage/Classic, you can to get to the fun/business of
woodworking fast!
For even more versatility, I’ve developed many optional Accessories that allow you to
“customize” the MasterGage/Classic to your particular needs. As you grow in your measurement
and calibration needs, you will always find an Accessory to fit your requirements.
Craftsmen involved in any of the following disciplines will find these tools invaluable.
1. Woodworkers 5. Furniture makers 9. Machinists
2. Model makers 6. Cabinet makers 10. Tool makers
3. Pattern makers 7. Serious hobbyists 11. Sheet metal workers
4. Finish carpenters 8. Boat builders 12. And many other craftsmen
Thank you for your business!
Paul Reilly
President, Founder & Inventor
MasterGage.com MasterGage.com

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Your MasterGage/Classic Package
This package contains the following:
1. The MasterGage/Classic unit
2. The MasterGage/Classic Manual
3. A precision Dial Indicator, 0.001 [1/1000 inch] accuracy with ¼ inch travel
4. A 1.0 inch and 2.0 inch stainless steel dial indicator extension – extends the reach of
the Dial Indicator ( Page A9)
5. A 0.300 inch diameter flat, 400C stainless steel Dial Indicator tip – hardened to
Rockwell 52. Perfect for adjusting or replacing knives on jointers and planers.
Also for checking run out on drill presses and routers, etc. (Page A9)
6. Dial Indicator Adapter Assembly – allows you to position the Dial Indicator in different
directions. (Page A8)
7. A ¼ inch diameter x 3 ½ inch long stainless precision Depth Gauge Rod, designed for
measuring depths of dado cuts, mortise slots, blind drilled holes, etc.(Page A6 & A6.1)
8. A stainless steel Precision Dowel Rod, ½ inch diameter x 4 inches long. Perfect for
calibrating drill presses, routers, horizontal mortisers and lathes. (Page E1)
9. Magnetic Miter Slot Cradle Bar – Attaches to the bottom [and top] of the Classic.
It is used with the Classic to align the tablesaw blade and rip fence easily. (Page A7)
10. Hex wrench is used to secure the Magnetic Miter Slot Cradle Bar in the desired
position.(Page A7)
11. Hex wrench for calibrating the “Knife Edge” to 90 degrees, as required. ( Page A3)
12. A rugged, double walled carrying case, with handle. It is lined with custom cut foam
that nests and protects your MasterGage/Classic system. As an added feature, the
foam is removable – simply remove the bottom foam and store your MasterPlate
safely on the bottom of the carrying case, beneath the foam. Now, your valuable
MasterGage/Classic and accessories are now housed together in one safe place.
13. A roll of transparent tape for working surface protection. See Section K.
14. An enclosed stamped self addressed Post Card, asking you to supply us with a name.
We will engrave that name into a solid brass nameplate, ready for mounting onto the
MasterGage/Classic – free of charge. A nice way to personalize your Classic.
15. A 30 day Money Back Guarantee plus a One Year Guarantee on materials and
workmanship – including the dial indicator.
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MasterGage/Classic System
SECTION TABLE OF CONTENTS
A Getting Acquainted with your MasterGage/Classic
A1 MasterGage/Classic Features
A2 Illustrated Features
A3 Measuring and Reference Surfaces Defined
A4 Description of the Three Measuring Scales
A5 Fraction – Decimal – Millimeter Conversion Chart
A6 Using the Depth Gauge Rod
A7 Mounting and using the Miter Slot Cradle Bar
A8 Attaching the Dial Indicator
A9 Using the Dial Indicator
B TABLE SAW + ADD-ON SLIDING TABLE KIT + SLIDING TABLE PANEL SAW
C RADIAL ARM SAW + CHOP SAW + SLIDING COMPOUND SAW
D ROUTER + ROUTER TABLE + SHAPER + CNC ROUTERS & MILLS
E DRILL PRESS
F BAND SAW
G JOINTER
H PLANER
I DISK SANDERS + DRUM ROLLER SANDER
J HORIZONTAL MORTISER +DOWELER
K Care and Maintenance
L Useful Tips and Techniques
M Frequently Asked Questions - FAQ
N Accessories
O Ordering information
PONE YEAR GUARANTEE
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SECTION A
Getting Acquainted with your
MasterGage/Classic
MasterGage.com

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A1
A1
MasterGage/Classic Features
Your MasterGage/Classic is packed with exciting patented features that are built to last!
The body of the Classic is fabricated from rugged aircraft quality extruded aluminum. All sides
are ground flat and parallel to each other to within 0.001 [1/1000] inches [as a reference, the
human hair is 0.002 inches thick. Once ground, the body is then machined to exacting
tolerances [0.0004 inches] on computer numerically controlled machinery [CNC], the Classic is
then plated with a protective black anodized finish that also presents a superb black non-glare
surface for easy reading.
The unit is then precisely and permanently laser etched into its black non-glare surface with
scales that are in inches, millimeters and centimeters. This allows the Classic to be used on
any equipment worldwide, regardless of the measurement standards used
.
The Classic body has extruded “T” slots in both the top and bottom surfaces, allowing the owner
to use special magnets. This magnet accessory is a very powerful rare earth [neodymium
boron] magnet that fit into the “T” slots. A valuable Accessory that ensures rock solid rigidity
while making critical measurements.
The front edge of the Classic has a stainless steel working edge called a “knife edge”. This
1/16 thick piece of stainless steel is set precisely to 90 degrees. The thin knife edge makes it
easy to measure the squareness of saw blades, since it projects 1/16” forward of the base and
fits between the carbon tips of the saw blade. This feature allows the knife edge to fit flat
against the body of the saw blade giving you an exact 90 degree reading
The Level Arm is made of ½” x ¾” x 3 3/8 inch aircraft quality aluminum, hard anodized for
durability [hardness equal to sapphire]. The arm is spring loaded so that it automatically levels
itself for precise measuring. It never goes out of alignment. The Level Arm is self-cleaning, it
glides through sawdust and never clogs up.
Since all parts are so precisely made and interchangeable, a part made last year will fit a
Classic made today, next year and years to come! If a part is lost or damaged, it can be quickly
replaced by our factory.
As a new proud owner, we felt you would like to have your MasterGage/Classic personalized.
Simply fill out the enclosed post card with the name you would like to have engraved. We will
engrave that name on a solid brass nameplate for you - free of charge.
Your MasterGage/Classic has an embedded red aluminum medallion seal, laser etched with
the year your MasterGage/Classic was fabricated. Your Classic now becomes a collectable!
Your MasterGage/Classic comes with a written ONE YEAR GUARANTEE POLICY (Page O)
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A2 A2
ILLUSTRATED FEATURES
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BORED HOLE
ACCEPTS
MANY
ACCESSORIES
HARD ANODIZE
SURFACE STAINLESS STEEL
GUIDE RODS
1/16 THICK
STAINLESS STEEL
“KNIFE EDGE” SET
TO 90 DEGREES
The “KNIFE EDGE”
fits between the saw
teeth and comes in
full contact with the
saw blade body for
accurate 90 degree
settings. Perfect for
setting table saw,
radial arm saw and
chop saws square to
the table and miter
fence
BLACK
ANODIZED
PROTECTIVE
FINISH
PROVIDES
NON-GLARE
FEATURE
AIRCRAFT QUALITY
ALUMINUM
“T” SLOTS BOTH TOP AND
BOTTOM ACCEPT
POWERFUL MAGNET
ACCESSORY
ALL SCALES ARE
LASER ETCHED

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A3
A3
Measuring and Reference Surfaces Defined
YOU CAN MEASURE AND CALIBRATE FROM ANY ONE OF SEVEN
REFERENCE SURFACES SHOWN BELOW. ALL REFERENCE
SURFACES ARE GROUND FLAT TO LESS THAN 0.001 INCHES (1/1000”)
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90 degree
“Knife Edge” #4
BASE #1
TOP #2
BACK #3
TOP OF LEVEL ARM #5
BOTTOM OF LEVEL ARM #6
DIAL INDICATOR TIP #7

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A4 A4
Description of the Three Measuring Scales
All scales on the MasterGage/Classic are precision laser etched into an anti-glare black surface.
Notice that both the Fractional and Millimeter scales are specially designed, with each having a
vertical line to distinguish the coarse readings from the fine readings.
With the fractional, decimal and millimeter scales side by side - you can automatically translate
and/or compare one scale reading to another – another innovative feature.
Example: 1. 23 millimeters = .91 inches
2. 3/4 of an inch = 19 millimeters
The Level Arm is spring activated and automatically aligns itself level to all scales, and never
needs calibration. Readings can be taken from the top or bottom surface of the Level Arm -
depending on the machine you are working with.
The MasterGage/Classic can measure in any X,Yand Zaxis.
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Measure and Read
any Scale at Top of
Level Arm for the
following:
*Drill Press
*Radial Arm Saw
*Chop Saw
*Compound Miter
Measure and Read
any Scale at Bottom
of Level Arm for the
following:
*Table Saw
*Sliding Table Saw
*Router
*Router Table Unit
*Shaper
*Horizontal Mortiser
Measure/Set
90 degrees
relative to the
Top or Bottom
of the Classic
1/16 of
an inch
divisions
1/32 of
an inch
divisions
.02 inch
divisions
Fraction
Scale Decimal Scale Millimeter Scale
1 millimeter
divisions
½ millimeter
divisions
Level Arm
Centimeter
marking

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CONVERSION CHART
Convenient conversions of fractions, decimals and millimeters
Fractional Inches – Decimal Inches - Millimeters
Fraction of Inch Decimal of
Inch Decimal of Millimeters Fraction of Inch Decimal of Inch Decimal of Millimeters
1/64 .016 0.397 (NO FRACTION) 0.512 13.000
1/32 .031 0.793 33/64 0.516 13.097
(NO FRACTION) .039 1.000 17/32 0.531 13.494
3/64 .047 1.190 35/64 0.547 13.891
1/16 .063 1.588 (NO FRACTION) 0.551 14.000
5/64 .078 1.984 9/16 0.563 14.288
(NO FRACTION) .079 2.000 37/64 0.578 14.684
3/32 .094 2.381 (NO FRACTION) 0.591 15.000
7/64 .109 2.778 19/32 0.594 15.081
(NO FRACTION) .118 3.000 39/64 0.609 15.478
1/8 .125 3.175 5/8 0.625 15.875
9/64 .141 3.572 (NO FRACTION) 0.630 16.000
5/32 .156 3.969 41/64 0.641 16.272
(NO FRACTION) .158 4.000 21/32 0.656 16.669
11/64 .172 4.366 (NO FRACTION) 0.669 17.000
3/16 .188 4.763 43/64 0.672 17.066
(NO FRACTION) .197 5.000 11/16 0.688 17.463
13/64 .203 5.159 45/64 0.703 17.859
7/32 .219 5.556 (NO FRACTION) 0.709 18.000
15/64 .234 5.953 23/32 0.719 18.256
(NO FRACTION) .236 6.000 47/64 0.734 18.653
¼.250 6.350 (NO FRACTION) 0.748 19.000
17/64 .266 6.747 ¾0.750 19.050
(NO FRACTION) .276 7.000 49/64 0.766 19.447
9/32 .281 7.144 25/32 0.781 19.843
19/64 .297 7.541 (NO FRACTION) 0.787 20.000
5/16 .313 7.938 51/64 0.797 20.240
(NO FRACTION) .315 8.000 13/16 0.813 20.638
21/64 .328 8.334 (NO FRACTION) 0.827 21.000
11/32 .344 8.731 53/64 0.828 21.034
(NO FRACTION) .354 9.000 27/32 0.844 21.431
23/64 .359 9.128 55/64 0.859 21.828
3/8 .375 9.525 (NO FRACTION) 0.866 22.000
25/64 .391 9.922 7/8 0.875 22.225
(NO FRACTION) .393 10.000 57/64 0.891 22.622
13/32 .406 10.319 (NO FRACTION) 0.905 23.000
27/64 .422 10.716 29/32 0.906 23.019
(NO FRACTION) .433 11.000 59/64 0.922 23.416
7/16 .438 11.113 15/16 0.938 23.813
29/64 .453 11.509 (NO FRACTION) 0.945 24.000
15/32 .469 11.906 61/64 0.953 24.209
(NO FRACTION) .472 12.000 31/32 0.969 24.606
31/64 .484 12.303 (NO FRACTION) 0.984 25.000
1/2 .500 12.700 63/64 0.984 25.003
1 inch 1.000 25.400
For dimensions greater than 1.000 inch [25.400 mm]
Example: 1 9/32 inches is 1.000 inch + .281 inches [9/32] = 1.281 inches
1 9/32 in millimeters is 25.400 mm [1.000 inch] + 7.143 mm [9/32] = 32.543 mm
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A6 A6
Using the Depth Gauge Rod
The following three illustrations show how the Depth Gauge Rod can be used to determine dado
depth, mortise depth or the depth of a blind-drilled hole. It then becomes easy to measure and
cut the required tendon or mating part.
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The following illustrations show how the Depth Gauge Rod adds
additional capabilities to your MasterGage/Classic. Keep in mind
that this feature can be used in all X, Y and Z axis. A typical use in
the Z axis would be checking/setting the infeed/outfeed offset on a
split fence for a Shaper or Router Table system.
Move the Level Arm down against
the wood [zero position] and
tighten the Lock Screw. Insert the
depth Gauge Rod, leaving the
Lock Screw loose.
Lock Screw

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A6.1 A6.1
Using the Depth Gauge Rod
Read scale of choice for groove/slot/hole depth dimension
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Move the Depth Gauge Rod
over the groove-slot-hole and
allow it to bottom out.
Tighten the Lock Screw
Reposition the Classic to a
flat surface. Raise the Level
Arm and bottom out the
Depth Gauge Rod on the flat
surface. Then simply read
the selected scale under the
Level Arm for the groove-
slot-hole depth

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A7 A7
MOUNTING AND USING THE “MAGNETIC MITER SLOT CRADLE
BAR” ON THE MasterGage/Classic
The Patented, Magnetic Miter Slot Cradle Bar attaches to either the top or bottom “T” slot,
anywhere along the full length of the MasterGage/Classic. Two powerful rare earth magnets are
embedded into one side of the Cradle Bar, which is fabricated from Delrin, a special “space age”
polymer selected for its low friction properties. This innovative design achieves the following:
On steel table tops, it ensures absolute contact with only one miter slot wall. This
approach eliminates all tolerances and misalignments
As the Magnetic Miter Slot Cradle Bar glides smoothly along the full length of the miter
slot, the magnets cling to the miter slot wall, insuring constant contact with the side wall.
The magnetic feature allows the Magnetic Miter Slot Cradle Bar to be used on almost any
miter slot width without concern for miter slot width variations.
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embedded rare
earth magnets
This round “T” nut
locks the Cradle Bar
anywhere along the
length of the
MasterGage/Classic –
in either the bottom or
the top “T” slots.

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A8
A8
ATTACHING THE DIAL INDICATOR
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ATTACH DIAL INDICATOR IN THE
HORIZONTAL POSITION
[SHOWN] USING THE DIAL
INDICATOR ADAPTER
HARDWARE AS ILLUSTRATED
ATTACH DIAL INDICATOR WITH
THE STEM IN EITHER DOWN
POSITION [SHOWN] OR UP
POSITION WITH THIS LOCK KNOB
Your customized
brass nameplate
location

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A9 A9
USING THE DIAL INDICATOR
BEZEL LOCK KNOB
ROTATING
BEZEL
INTERCHANGABLE
ROUND AND FLAT TIPS
USE FLAT TIPS WHEN
MEASURING BLADES
SUCH AS JOINTERS,
PLANERS, SHAPERS
OR ROUND SURFACES
AS ILLUSTRATED
1.0 AND 2.0 INCH EXTENSIONS ARE
ALSO SUPPLIED
HOW THE DIAL INDICATOR WORKS
THE DIAL INDICATOR IS VERY EASY TO USE
THE DIAL INDICATOR HAS A TRAVEL RANGE OF .25 INCHES [1/4 INCH]
THE BLACK NUMBERS ON THE DIAL REPRESENT .010 [TEN THOUSANDTHS OF AN INCH]
EACH BLACK GRADUATION ON THE DIAL REPRESENTS .001 INCH [ONE THOUSANDTHS OF AN INCH]
EACH TIME THE INDICATOR ARM ROTATES 360 DEGREES [.100 INCH TRAVEL] THE SMALL DIAL MOVES TO A
NUMBER ON THE SMALL DIAL.
EXAMPLE: WHEN THE LARGE INDICATOR ARM ROTATES TWO TIMES, THE SMALL DIAL ARM WILL INDICATE 2,
WHICH IS .100 TIMES 2 OR .2 INCHES.
PROCEDURE FOR USING THE DIAL INDICATOR
MOVE THE DIAL INDICATOR SO THAT THE TIP OF THE INDICATOR IS TOUCHING THE DESIRED SURFACE.
ALLOW THE TIP TO DEFLECT THE DIAL INDICATOR ARM SLIGHTLY. THIS IS CALLED “PRELOADING” THE DIAL
INDICATOR
LOOSEN THE BEZEL LOCK SCREW AND ROTATE THE BEZEL SO THAT THE “0” ON THE DIAL LINES UP WITH THE
INDICATOR ARM - LOCK THE BEZEL KNOB.
YOU ARE NOW CALIBRATED TO MEASURE FROM THE DESIRED SURFACE.
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A10 A10
A NOTE ABOUT TOLERANCES
A common question customers ask is: “What kind of accuracy should I expect from my
woodworking machinery? How close should I measure, 1, 5, 10, 15 thousandths of an inch?
(A a reference, a human hair measures 0.002 inches - this page is 0.004 to 0.005 inches thick.)
The answer is as follows. Machines come in all sizes and quality levels. Many are built with
stout cast iron bodies and components, others with sheet metal and plastic. Obviously, one can
expect the cast iron fabrication to hold tight tolerances and for longer periods than a sheet metal
fabricated machine. The general answer is to align and calibrate as close as possible, without
making it a 3 day project. Then monitor the dimensions over time. Obviously, the cast iron
machine will stand more abuse over time, and still keep the tolerances versus the sheet metal
unit.
Here is a general overview of machinery available today.
Table top models: designed for high portability and minimum storage space
typical customer – home owners & trim carpenters
weight range – 25 to 75 pounds
construction: sheet metal, castings and plastic
expected accuracy: 0.010 to 0.015 inches
Contractor models: designed for mobility at home and to the job site
typical customer – home owners & job site carpenters
weight range – 50 to 200 pounds
construction: sheet metal and some castings
expected accuracy: 0.005 to 0.010 inches
Stationary machinery: designed for high production and are seldom moved
typical customer – cabinet shops, mill work houses, etc.
weight range – 500 to 5,000 pounds
construction: very heavy castings and machined parts
expected accuracy: 0.001 to 0.002 inches
Also asked is: “How often should I monitor my machinery for alignment and calibration?”
I would suggest setting up a written schedule for every machine alignment check. The schedule
would depend upon machine usage. Is your shop on a 8 hour/5 day or 16 hour/6 day work
week? How many different people use the equipment, etc. My feeling is to consider your shop
like an airplane. Before you “take off” on your business day, all machines should be checked for
running condition and accuracy. After all, your business and livelihood rely on these machines.
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SECTION B
TABLESAW
+
ADD-ON SLIDING TABLE KIT
+
SLIDING TABLE PANEL SAW
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B1 B1
TABLE SAW
– OVERVIEW OF TABLESAW ALIGNMENT –
Here are a few facts that become very obvious, once explained. A standard tablesaw
has a miter slot machined into the table top. Obviously it is a fixed reference feature that
cannot be adjusted. The manufacturers have built in adjustments into: A/ saw blade
trunnion B/, the rip fence assembly and C/ the miter gauge assembly. They all need to
be adjusted and aligned relative to the machined miter slot.
Adjusting the saw blade parallel to the miter slot: In the Contractors [motor outside of
frame] type saw, the trunnion is adjustable. On the Cabinet saw, [saw is totally enclosed]
the table top can be loosened for adjustability.
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Use the 2.0 inch dial indicator
extension with ¼ inch dial indicator
flat tip. Contact arbor shaft on
smooth surface [not threads].
Rotate arbor by hand. Readings
should be in the 0.001 inch range.
Using an accurate straight edge steel
rule, check the flatness of the table top.
TIP #1: Sprinkle talcum powder on the
table and drag the straight edge across
the surface carefully. Much like a
concrete mason dragging his top
leveler across the cement to get it flat.
This method will give you a visual
indication of the high and low spots of
the table top. When finished rub the
talcum power into the table top. It will
absorb any moisture within the pores of
the table top. The talcum will not harm
the tablesaw
TIP #2: Use feeler gauges with the
straight edge.