RoutingJigs Adjustable Lock Jig Manual

Adjustable Lock JigAdjustable Lock Jig
nContains four templates to control the width of the lock and face plate :-
Face plate widths are 25.4mm and 22.5mm; lock widths are 16mm and 19mm.
nThe length of the lock jig aperture can be adjusted from 0 to 208mm.
nQuick and easy to set up.
nThe jig has engraved markings to aid setting up.
Other Equipment required:-
n12.7mm diameter straight cutter.
n16mm diameter guide bush.
nAt least two clamps to secure jig to door.
nPhilips screwdriver.
Instruction LeafletInstruction Leaflet
4 interchangeable templates
to control the width of the aperture.
Face plates templates:-
A = 25.4mm
B = 22.5mm
Lock templates:-
1 = 16mm
2 = 19mm
Centre Line markings
to centre the jig to
the door.
Adjustable
Length Plates.
Key hole slots for
quick and easy
template changing
Use a set of clamps on
the fixing plates to secure
the jig to the door.
Jig centring adjustment.
Length adjustment
engraving.

Adjustable Lock Jig
1. Positioning the Lock Jig1. Positioning the Lock Jig
1. Mark where you want the centre of the lock to be
on the height of the door. Use the engraved centre
line to position the lock jig.
2. Clamp the fixing plates to the door.
3. Mark on the door above the jig the centre line. This
centre line refers to the centre of the lock - see
photo left.
4. Mark on the door below the jig to indicate the
centre of the lock - see photo left.
Screws
Fixing Pate
Centre Line
Mark

Adjustable Lock Jig
5. Loosen the two screws securing the lock jig to the
fixing plates.
6. Align the centre line engraving on the jig (CL) to
the centre line markings which were made on the
door.
7. Once the jig is positioned correctly, tighten the two
screws to secure the fixing plates to the jig.
1. The length of the aperture for the face plate has to
be set. Measure the face plate length.
For this exercise lets assume that the face plate is
100mm (4”) long.
2. Loosen the bottom length adjustment screw, and
slide it to 50 (half of 100mm). Note: The top edge
of the bottom adjustment has to be in line with 50.
If your face plate was 150mm long then slide the
bottom adjustment so that it is in line with 75.
3. Tighten the screw to secure the bottom adjustment
in place.
4. Repeat this process for the top adjustment. For
instance, if your face plate is 100mm long then
move the top adjustment to 50.
5. Tighten the screw to secure the top adjustment in
place.
6. The aperture length (the distance from the top
adjustment to the bottom adjustment) should be
3.3mm longer than the actual face plate. This is
due to the cutter and bush offset.
For instance, if your face plate is 100mm long then
the distance between the adjustment plates should
be 103.3mm. See the diagram on the next page for
an explanation.
Positioning the Lock Jig cont...Positioning the Lock Jig cont...
Fixing Pate
Screws
Centre Line
Engraving
Bottom
Length
Adjustment
2. Setting up the Lock Face Plate2. Setting up the Lock Face Plate
Top
Length
Adjustment

12.7mm (1/2”) cutter
16mm
Dia bush Adjustment Plate
Jig
Actual Face Plate Size
1.65mm 1.65mm
Adjustment Plate
Adjustable Lock Jig
This diagram explains the offset between the cutter
and the bush.
7. The width of the face plate/lock is governed by any
of the four templates you use. Each has a letter or
a number engraved on it which relates to the
following widths:-
Face Plate Template “A” = 25.4mm
Face Plate Template “B” = 22.5mm
Lock Template “1” = 16mm
Lock Template “2” = 19mm
8. Decide upon the template and attach it to the jig
using the keyhole slots. Make sure the arrows line
up. Tighten the screws to secure the template.
9. The lock jig is now set. Set your router to cut the
thickness of the face plate - refer to the router
manual.
10. Continue to rout the face plate aperture.
Setting up the Lock Face Plate cont...Setting up the Lock Face Plate cont...
Template
Keyhole
slot

3. Setting up the Lock Aperture3. Setting up the Lock Aperture
Adjustable Lock Jig
1. Do not release the clamps or the screws holding
the fixing plates.
2. Loosen the screws which secure the template in
place.
3. Remove the template.
4. Loosen the length adjustment screws and move
the plates to suit the length of the lock.
Example, if the lock is 80mm long then move the
top plate to 40, and the bottom plate to 40.
5. The distance between the adjustments plates
should be 3.3mm longer than the actual lock
because of the cutter and bush offset (see
previous page)
6. Tighten the screws to secure the adjustments
plates.
7. Select the correct lock template. See previous
page.
8. Insert the template into the jig and tighten the
screws to secure in place.
9. Continue to rout the aperture for the lock. Do not
exceed 5mm depth per pass.
10. Remove the lock jig and square off any corners
which may obstruct the face plate and lock.
Adjustment
Plates
Fixing
Plate