Woodhaven 8615 User manual

Parts List:
Part Description Quantity
8615B 35mm Cup Routing Plate . . . . . . . . . . . 1
8615A Mounting Plate . . . . . . . . . . . . . . . . . . . . 1
8615C Stop ..............................1
4212 12” One Track . . . . . . . . . . . . . . . . . . . . . 1
6305B Clamp Riser Pad . . . . . . . . . . . . . . . . . . . 1
6305 Toggle Clamp . . . . . . . . . . . . . . . . . . . . . 1
Part# Description Qty.
5760B Oval Nut 2
Part# Description Qty.
NUT015 Hex Nut 2
Part# Description Qty.
5772B 1” Screw 4
Part# Description Qty.
5770B 1/2” Screw 2
Part# Description Qty.
5765B Offset Oval Nut 4
Part# Description Qty.
BUSH002 1/4" Spacer 2
8615
Hinge Routing Jig
Please Read Carefully!
Part# Description Qty.
5771B 3/4" Screw 2
Part# Description Qty.
HB030 1" Bolt 1
Part# Description Qty.
WB002 Washer 3
Part# Description Qty.
BUSH001 1/8" Spacer 2
Part# Description Qty.
NUT250 Cap Nut 2
Part# Description Qty.
SD430 3” Stud 1
Part# Description Qty.
5540 Knob 1

BEFORE BEGINNING
 Identifyandverifythatyouhavealltheparts
listed.Readtheinstructionsatleastonce,familiarizing
yourselfwiththepartsbeforebeginning.You'll
needa#3Phillipsscrewdriverforassembly.
ASSEMBLY
 Attachthe12"OneTrack(4212)totheMounting
Plate(8615A)usingtwo3/4"screws(5771B)andtwo
OffsetOvalNuts(5765B).Settheassemblyonedgeso
theedgeoftheOneTrackandtheedgeoftheMounting
Plateareevenwitheachother,thencentertheOneTrack
ontheMountingPlateandtightenthescrews.See fig. 1
Inserttwo1"Screws(5772B)thruthefront
mountingholesintheToggleClamp(6305),insertthe
non-threadedholesintheClampPad(6305B)overthe
endsofthescrews,thentightenthescrewsinthetwo
threadedholesintheMountingPlate.See fig. 2
 Setthe35mmCupRoutingPlate(8615B),withits
recessedslotsfacingup,intherecessedareaontheMounting
Plate.SetanOvalNut(5760B - raised side up)ineach
slottedrecessintheCupRoutingPlate.Installa1/8"Spacer
(BUSH001)oneachoftwo1"Screws(5772B)andinsertthe
screwsthrutheholesintheMountingPlateoneithersideof
theToggleClamp,intotheovalnutsandtighten.See fig. 3
 Installa1/4"Spacer(BUSH002)ontwoofthe1/2"
Screws(5770B).StartanOffsetOvalNut(5765B) on
theendofeachscrewandinsertoneineachendofthe
OneTracksothere’soneoneachsideoftheMounting
Plate.Turntheoffsetportionoftheovalnuttowards
theMountingPlatewhenyouinstallit.See fig. 4

1
2
3
1
4
The edge of the slot
nearest the center of the
Cup Routing Plate is the
center line of the jig.
5771B
5765B
4412
8615A
8615B
5760B
5772B
5772B
BUSH001
5770B, BUSH002 & 5765B
6305
6305B

7
2
 Insertthe3"Stud(SD430)thrutheholeinthe
Stop(8515C),installawasher(WB002)andHexNut
(NUT015)oneachendoftheStud.CentertheStud
intheStopandtightenthenuts.InstallaCapNut
(NUT250)oneachendoftheStud. See fig. 5.
 Inserta1"Bolt(HB030)thrutheholeinthe
notchoftheStop.InstallaWasher(WB002)andKnob
(5540)ontheendofthebolt.SlidetheStopinthe
OneTrackandtightentheKnob.See fig. 5 & 6
USING THE JIG
 Theinsideedgeoftheslot(nearthecenter)
intheCupRoutingPlaterepresentsthecenter
lineofthejigandcanbeusedtoreferencethejig
toanindexmarkonthework.See fig. 3
 MeasurefromtheCapNutontheStoptothecenter
oftheCupRoutingPlateandadjusttheStoptothedistance
needed(upto4-1/4"or108mmmax.).UsetheScrew/1/4"
SpacerbetweentheMountingPlateandtheStopasastop
fortheStop.Byadjustingthisstoponeachsideofthejig,
youcanmovetheStopfromonesideofthejigtotheother
whenswitchingbetweenrightandleftorupanddown.
 LoosenthetwoscrewsfasteningtheCupRouting
PlatetotheMountingPlate.Measurebetweenthe
edgeoftheMountingPlateandtheinsideedgeof
theCupRoutingPlatetosetthehingebackset(upto
23mmmax.),thentightenthescrews.See fig. 7
Continue on back page.
5
6

ButttheStopagainstthework,adjusttheToggleClamp
pressureandclampthejigtothework.Makesureyou
tightenthenutsontheToggleClampSpindlesecurelyso
theydon’tloosenduringtheroutingoperation.See fig. 8
 Installtherouterbit(8505, 3/4" cut length, 1/2" diameter
with a 5/8" bearing and a 1/4" shank)ora5/8"bushing
and1/2"routerbit,inyourplungerouter.Ifusingthe8505
Hinge Bit,makesurethebearingridesfirmlyontheedgeof
thejigbeforeattemptinganycuts.Setthecuttingdepthof
thebit,takingintoaccountthethicknessofthejig.Plunge
therouterbitslowlyintotheapproximatecenterofthehinge
cupopeningintheCupRoutingPlate,movinginasmall
clockwisecircleasyouplungetocutareliefopening. 
 Movetowardsanedgeofthehingecupopening,
thenmoveclockwise,followingtheedgeofthehingecup
openinguntilthehingecuphasbeencut.See fig. 9
 Beforemovingthejig,usea1/4"MarkingPunch(8600)
tomarkthetwohingemountingholesoneithersideofthe
hingecupforlaterdrilling,oruseaSelf-Centeringbit(6505
or 6507) todrillthetwoscrewpilotholesforthehingecup.
See fig. 9
©Copyright WOODHAVEN INC. 1/7/15
[phone] or WWW.WOODHAVEN.COM
3
9
8