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Shopsmith 555970 - page 1
MARK V – MOUNTED OVERARM PIN ROUTER 555970 1 MARK V MOUNTED O VERARM PIN ROUTER 555970 T ABLE OF CONTENTS INTRODUCTION ................................................................................................................... ..... 2 SAFETY .................................................................................................. ...
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Shopsmith 555970 - page 2
555970 MARK V – MOUNTED OVERARM PIN ROUTER 2 INTRODUCTION Shopsmith’s MARK-V Mounted Overarm Pin Router can perform many jobs that are normally intended for other tool s... and it can usually perform these operations much faster and with far greater precision and re- peatability than you could hope to achieve using more conventional methods. It ...
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Shopsmith 555970 - page 3
MARK V – MOUNTED OVERARM PIN ROUTER 555970 3 is traced over the table pin, creating a fin- ished piece that’s exactly the same size and shape as the groove in your template or fixture • Remove the workpiece, replace with a new blank and repeat the process abov e...a s many times as you like Once you’ve made a template or fixture, cut out as ...
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Shopsmith 555970 - page 4
555970 MARK V – MOUNTED OVERARM PIN ROUTER 4 Throughout this manual, we list W ARN- INGS, CAUTIONS, and NOTES. W e advise that when you come to one of these listings, please read and understand it fully . Their meanings are: W ARNING A W ARNING is given when failur e to follow the directions is likely to result in injury , loss of limb, or life. ...
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Shopsmith 555970 - page 5
MARK V – MOUNTED OVERARM PIN ROUTER 555970 5 NOTE Customer Service representatives and Store personnel will help you select the proper motor . • Use only UL Approved router motors. • Motor housing must be round, not square, for router arm. • Motor must be 2-1/2" to 4" in diameter . • Motor power cord must be located so it comes ...
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Shopsmith 555970 - page 6
555970 MARK V – MOUNTED OVERARM PIN ROUTER 6 grounding type receptacle, the green con- ductor in the cord is the grounding wire. Never connect the green wire to a live terminal. • W ear proper eye and ear protection. Also, wear a dust mask. • Keep guards in place. Always keep guards in working order and in proper alignment and adjustment. Mos ...
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Shopsmith 555970 - page 7
MARK V – MOUNTED OVERARM PIN ROUTER 555970 7 SAFETY RULES FOR THE SHOPSMITH OVERARM ROUTER • Be sure to read and understand this entire Owners Manual before using the Overarm Router . Also, do not use the Overarm Router unless you are sure it is assembled properly , all safety devices are installed, and you understand the operations you are att ...
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Shopsmith 555970 - page 8
555970 MARK V – MOUNTED OVERARM PIN ROUTER 8 • When routing oversize stock, always use at least one push block to help control the workpiece firmly against the fence. • Do not work with stock that is too small or too large to handle safely; that is warped, bowed or cupped; or that has loose knots or other defects. • Plan the operation befor ...
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Shopsmith 555970 - page 9
MARK V – MOUNTED OVERARM PIN ROUTER 555970 9 ...
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Shopsmith 555970 - page 10
555970 MARK V – MOUNTED OVERARM PIN ROUTER 10 TERMS TO KNO W It’s important that you become familiar with all of your Overarm Router‘s functions and parts before you begin to use it. The functioning parts of the Router Arm are: 1 . W orktable – Made of a durable lami- nate-covered MDF (medium density fiberboard) the Overarm Router ’ s W o ...
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Shopsmith 555970 - page 11
MARK V – MOUNTED OVERARM PIN ROUTER 555970 11 4 . Motor Brackets – Firmly hold any round, hand-held router motor from 2-1/2" to 4" in diameter . These dimen- sions are for the motor only (the router base is removed during operations). 5. Brass Gib – Adjusts with four Allen set screws to eliminate side-to-side move- ment of the motor ...
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Shopsmith 555970 - page 12
555970 MARK V – MOUNTED OVERARM PIN ROUTER 12 BEFORE YOU BEGI N... It’s a good idea to clean all major metal parts with mineral spirits to remove any dirt or grease residue. Any burrs found on parts should be removed with a fine file or emery cloth. If required, clean your router motor according to the instructions in its Owner ’ s Manual. W ...
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Shopsmith 555970 - page 13
MARK V – MOUNTED OVERARM PIN ROUTER 555970 13 RE-INST ALL THE MARK V WORKT ABLE Loosen the T able Tilt Lock Lever, tilt your T able to 90° (as you would when setting up for Drill Press) and tighten the Lever . Install the W orktable in the Carriage, slide it “back” until its edge is 3" from the W ay T ubes. T ighten the T able Height Lo ...
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Shopsmith 555970 - page 14
555970 MARK V – MOUNTED OVERARM PIN ROUTER 14 CAUTION Over-tightening the Motor Bracket nut s may cause damage to the motor and/or housing of your router . INST ALL THE REAR GUARD AND DUST COLLECTOR ASSEMBL Y Install a flat washer over each stud of the front Motor Clamp, and then slip the rear guard/dust chute with strip brushes onto the clamp st ...
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Shopsmith 555970 - page 15
MARK V – MOUNTED OVERARM PIN ROUTER 555970 15 W ARNING This set-up will make it impossible for you to use your T wo-Piece Overarm Router Fence safely . Position the two T -nuts in the “front” Miter Gauge slot of your MARK V’ s W orktable, near the two ends of the slot. Lay the Over- arm Router T able onto the surface of the MARK V T able. A ...
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Shopsmith 555970 - page 16
555970 MARK V – MOUNTED OVERARM PIN ROUTER 16 There are 2 T able Inserts (60/61), see Fig. 7). • The one on the left in Fig. 7 offers a 1-3 /8" diameter round hole in the center and a brass threaded insert at its outer edge for a Starter Pin. This insert is used for most conventional, non pin-routing operations. • The other features two ...
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Shopsmith 555970 - page 17
MARK V – MOUNTED OVERARM PIN ROUTER 555970 17 ROUTER BIT T O GUIDE PIN ALIGNMENT When performing pin routing operations, it’ s critical that the Router Bit and Guide Pin be in perfect alignment with one another . T o check this alignment, insert a 3/8" diam- eter straight Router Bit into the collet of your Router Motor and tighten securely ...
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Shopsmith 555970 - page 18
555970 MARK V – MOUNTED OVERARM PIN ROUTER 18 T able to the MARK V W orktabl e... then slid- ing the table left or right and tightening the screws once proper alignment is achieved. On Model 500 MARK V’s, these adjustments are made by loosening the two roundhead machine screws in the elongated slots to the left and right of the Router T able In ...
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Shopsmith 555970 - page 19
MARK V – MOUNTED OVERARM PIN ROUTER 555970 19 lent size. Small workpieces can be very difficult to control during op- erations without appropriate holding and guiding devices. • For overarm routing operations, the T able Insert must always be posi- tioned with the threaded brass starter pin hole to the left of the threaded Guide Pin hole or cen ...
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Shopsmith 555970 - page 20
555970 MARK V – MOUNTED OVERARM PIN ROUTER 20 Re-position the depth control handle for each additional pass until the final depth-of-cut is attained. Once you’ve completed your final pass, loosen the Depth Control Handle, raise the motor , retighten the Handle and turn off the motor . Only when the motor has stopped completely should you re- mo ...
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Shopsmith 555970 - page 21
MARK V – MOUNTED OVERARM PIN ROUTER 555970 21 ample fixture shown in Figure 10 will produce two different sized oval picture frames, one oval plaque and a rectan- gular picture frame with an oval openin g... all from a single workpiece. CAUTION Be sure to use screws to hold every piece of stock that will be sep arated when you make your through-c ...
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Shopsmith 555970 - page 22
555970 MARK V – MOUNTED OVERARM PIN ROUTER 22 keep it from sliding around while you make your cuts. T o seat the stock in a profile fixture, just position it properly and tap it gently with the heel of your hand or a non-metallic mallet to seat the screw or nail tips. AN OVER VIEW OF PIN ROUTING WITH FIXTURES The basic principle of all Pin Routin ...
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Shopsmith 555970 - page 23
MARK V – MOUNTED OVERARM PIN ROUTER 555970 23 2 . Cut out your fixture blank – As men- tioned, fixtures should be made of a laminate-covered material, such as 3/4" thick sink cut-outs. Be sure to make your fixture blank about 4" longer and 4" wider than your finished project, so you have room to grip your fixture and still keep y ...
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Shopsmith 555970 - page 24
555970 MARK V – MOUNTED OVERARM PIN ROUTER 24 For most applications, we recommend using a 3/8" diameter Guide Pin. IMPOR T ANT : The distances between your template segments must remain exact, all the way around its perimeter . Any variations here and your fixture will not function properly . 4 . Set up your Overarm Router for fix- ture-maki ...
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Shopsmith 555970 - page 25
MARK V – MOUNTED OVERARM PIN ROUTER 555970 25 8 . Save your fixture-making templates – Set your templates aside in the event you need to make more fixtures or re- place one that has been damaged. HOW TO MAKE PROFILE FIXTURES Profile fixtures are used for shaping the out- side edges of workpieces only . In our picket fence example (See Fig. 12), ...
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Shopsmith 555970 - page 26
555970 MARK V – MOUNTED OVERARM PIN ROUTER 26 Screw-down fixtures are the easiest type of fixture to use and generally take less time to make than clamp-in fixtures. As shown in our example, they can be used to duplicate such things as award or tole painting plaques, round or oval picture frames and similar items. If you’re making a large quant ...
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Shopsmith 555970 - page 27
MARK V – MOUNTED OVERARM PIN ROUTER 555970 27 Step 6: Remove your completed project from the fixture, attach a new workpiece blank and repeat steps 4, 5 and 6. NOTE • Apply a coating of furniture P ASTE wax to the Guide Pin, the bottom of your fix- ture and the insides of the grooves to ease the movement of the fixture through your cuts. Be sur ...
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Shopsmith 555970 - page 28
555970 MARK V – MOUNTED OVERARM PIN ROUTER 28 Step 4: Drop the fixture groove over the T able Pin, turn on your router motor , plunge your rotating bit into the workpiece about 1/4" and start moving your fixture (with workpiece attached) in a counter -clockwise motion until you’ve completed your initial cut in the first groove (See Fig. 19 ...
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Shopsmith 555970 - page 29
MARK V – MOUNTED OVERARM PIN ROUTER 555970 29 Cutting decorative internal and external edges using a fixture Figure 21 shows a finished plaque, still at- tached to its fixture. Only the top surface of the edge was cut. Step 1. Set your router bit to produce the desired depth-of-cut. T o do this, use your fixture to cut out a practice sample of yo ...
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Shopsmith 555970 - page 30
555970 MARK V – MOUNTED OVERARM PIN ROUTER 30 CONVENTIONAL ROUTING OPERA TIONS WITH THE OVERARM ROUTER The Shopsmith Overarm Pin Router is also well suited for more ordinary routing operation s... functioning in a very similar fashion to more conventional under-table router set-ups. There are a few dif ferences: • W ith the Overarm Router , you ...
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Shopsmith 555970 - page 31
MARK V – MOUNTED OVERARM PIN ROUTER 555970 31 moving your workpiece into the bit un- til the edge of your stock also makes contact with the Guide Pin. Once contact is made with the Guide Pin, move the workpiece around and away from the Starter Pin, maintaining contact with the Guide Pin at all times until you’ve completed your cut. Re-position ...
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Shopsmith 555970 - page 32
555970 MARK V – MOUNTED OVERARM PIN ROUTER 32 • The hardness of the stock you’re cutting. If you’re working with hard maple, oak, ash, cherry , hickory or other tough stock, it may be necessary to make two or three passes to produce your full profile with- out burning or tear -out. Performing these operations is basically the same, whether ...
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Shopsmith 555970 - page 33
MARK V – MOUNTED OVERARM PIN ROUTER 555970 33 USING NON-PILOTED BITS FOR DECORA TIVE EDGING This method is basically the same as for decorative external or internal edging with a piloted Bit. However , since these Bits have no pilot to control your lateral depth-of-cut, you’ll have to rely on a Guide Pin (of a smaller diameter than your router ...
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Shopsmith 555970 - page 34
555970 MARK V – MOUNTED OVERARM PIN ROUTER 34 Bit dia. minus Guide Pin dia. 2 For example: A 3/4" diameter straight bit mi- nus a 1/4" diameter Guide Pin equals 1/2". 1/2" divided by 2 equals a 1/4 wide rabbet. STRAIGHT -LINE ROUTING T o perform straight-line routing, you will need to use the two-piece aluminum Over- arm Route ...
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Shopsmith 555970 - page 35
MARK V – MOUNTED OVERARM PIN ROUTER 555970 35 W ARNING Depending on the size of your workpiece, you may have to use a push stick (see Fig. 28), push block (see Fig. 29) or Feather Board(s) (see Fig. 30) in order to keep you hands at a safe dis- tance when feeding the workpiece against the Fence and Bit. NOTE For some operations, you may need to u ...
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Shopsmith 555970 - page 36
555970 MARK V – MOUNTED OVERARM PIN ROUTER 36 3 . Select and install the appropriate straight router Bit and set your depth- of-cut. It’s best to make a trial cut in a piece of same-sized scrap stock first, to “prove” the location and depth of your cut, before cutting your actual work- piece. Adjustments to the position of your groove can b ...
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Shopsmith 555970 - page 37
MARK V – MOUNTED OVERARM PIN ROUTER 555970 37 Making stopped cuts using the Fence A stopped cut is any cut made in a workpiece that does not go completely from end-to-end or from side-to-side. Some ex- amples of stopped cuts include mortises, travel slots and similar cuts. If your project calls for square-ended cuts, the rounded ends left by rout ...
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Shopsmith 555970 - page 38
555970 MARK V – MOUNTED OVERARM PIN ROUTER 38 3. Rout out a slot. T o repair damage such as that shown in Figure 34, rout out a rounded-end slot that’ s longer and wider than the damaged area (See Fig. 35). Set your depth-of-cut to be only as deep as the damaged wood. If you’re repairing a surface defect on a veneer , cut only to the depth of ...
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Shopsmith 555970 - page 39
MARK V – MOUNTED OVERARM PIN ROUTER 555970 39 STRUCTURAL JOINTS The versatile Shopsmith Overarm Pin Router makes easy work of forming all the joints you need for structural framework- with greater accuracy and finer precision than most other tools. Here are some examples of the joints that can be formed with the Overarm Router (See Fig. 37). CARI ...
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Shopsmith 555970 - page 40
555970 MARK V – MOUNTED OVERARM PIN ROUTER 40 After vacuuming, clean all major metal parts of the Overarm Router (except the router motor) with mineral spirits to remove all dirt, grease, and any built-up wood pitch. Use a clean, slightly damp cloth to wipe all residue from the Guard and W orktable. Clean your router motor as instructed in the ro ...
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Shopsmith 555970 - page 41
MARK V – MOUNTED OVERARM PIN ROUTER 555970 41 MAINTENANCE The maintenance intervals listed here are based on normal operation and assume that you will be careful not to abuse your Over- arm Router . Obviously , if you work the unit unusually hard, you’ll need to maintain it more often. If an unusual noise or vibration develops, turn off the mot ...
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Shopsmith 555970 - page 42
555970 MARK V – MOUNTED OVERARM PIN ROUTER 42 Problem Possible Cause Solution TROUBLESHOOTING GUIDE Problems with your Overarm Router usually have simple solutions. Under normal use, you should rarely have to service the T ool. Most problems can be corrected by simple maintenance, alignment, adjustment or a change in your work habits. This T roub ...
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Shopsmith 555970 - page 43
MARK V – MOUNTED OVERARM PIN ROUTER 555970 43 How to Order Parts T o order replacement parts, first consult the Parts List. Then write or call for current price informa- tion. How to Return Parts Should you need to return the equipment, call Customer Services for packing and shipping in- formation. Customer Services Where to W rite — Send inqui ...
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Shopsmith 555970 - page 44
555970 MARK V – MOUNTED OVERARM PIN ROUTER 44 6530 Poe A venue Dayton, OH 4541 4-2591 845556 Rev . A 6/05 © 2005 Shopsmith, Inc. All Rights Reserved Printed in U.S.A. The contents of this publication may not be reproduced either in whole or in p art without the consent of the copyright owner . Shopsmith ® is a registered trademark of Shopsmith, ...
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