Specification Sheet

61168/1 - 06.2016
CL400 Magnetic Handle Cutout Jig
CL400 Magnetic Striker Cutout Jig
CL400T0000 List price: $ 350
CL400T0003 List price: $ 250
CL400 Magnetic
Cutout Jigs
Note: The striker jig can be used only
on wooden jambs and will leave 3
small screw holes which will need to
be filled.
Cavity Sliders USA Inc.
PO Box 1392
Culver City
CA 90232
T [phone]
F [phone]
E [e-mail]
Quality products from:
www.cavitysliders.com
High quality
New Zealand made
products
This jig is made from quality materials that will last a lifetime. It allows for
accurate and consistent cutting of the handle recess for the CL400 Magnetic.
This jig is made from quality materials that will last a lifetime. It allows for
quick, accurate mounting of the CL400 Striker in any wooden closing jamb.
Contents
1. Handle Cutout Jig
2. 1/2” Guide Bush
3. Wavy Washer
4. Universal Nut
5. 1/2 inch Solid
Carbide Spiral
Cutter
6. 1/2” Alignment Pin
7. Instructions
Contents
1. Main Striker Jig
2. Striker Jig Insert
3. Screws
4. 1/4” Alignment Pin
5. 1/4” Solid Carbide
Spiral Cutter
6. 1/4” Guide Bush
7. Universal Nut
8. Wavy Washer
9. Instructions
1
7
9
Striker Cutout Jig Instructions
a
a
a
b
b
b
b
c
c
c
c
d
d
d
d
e
e
e
e
f
f
g
g
h
i
j
j
i
h
f
f
g
h
h
g
PAGE
PAGE
2
What’s included:
You will also require:
1
PAGE
PAGE
Go to page 2
Go to page 4
Go to page 3
Main Jig
Small Jig Insert
Screws
1/4” Striker
Alignment Pin
1/4” Solid Carbide
Spiral Cutter
(purchased separately)
1/4” Guide Bush
Universal Nut
Wavy Washer
Router
Base plate that
accepts router
template bush
guides
Safety
Equipment
Pen/Pencil
20mm (3/4”)Drill
Bit (approx.)
Masking Tape
Square
Important: The Router Base Plate must
have a (1-3/16”) through hole with a (1-
3/8”) diameter counter bore to accept the
guide bush provided. If the bush will not
fit your router plate, you can visit your
local power tool shop or buy online.
Wavy washer
between nut
and back side of
router plate
NZ: 09 276 0800, [e-mail]
AU: 02 9905 058, [e-mail]
US: [phone], [e-mail]
CL400
®
MAGNETIC STRIKER CUTOUT JIG
INSTRUCTIONS. 61163 - 05.2016
©
All copyright and other property in this
document is reserved by Cavity Sliders Ltd.
Details and specifications are subject to change without
notice. Whilst all care is taken to ensure the accuracy of all
information, no responsibility will be accepted for any errors
or omissions.
® CAVILOCK is a Registered Trademark. Patents pending.
Setting up Router with Cutter
1
. Remove standard routing plate.
2. Insert ½ to ¼ inch collet reducer.
3. Insert ¼” alignment pin and tighten in place.
It is important to tighten nut firmly.
5. Place router plate over ¼” alignment pin
and tighten screws evenly.
For flat closing jambs: Mark the closing
jamb either side of the CL400 side handle
when the door is hanging freely. Find the
centre point between these two marks
and extend into a vertical line. This is the
centreline of the door and will be used to
align the striker jig.
12. Remove jig and drive screws into the
closing jamb on these two marks, leaving
the screw heads approximately 10mm (3/8”)
proud of the closing jamb.
14. Slide jig back to centre of closing jamb
using the alignment cut-outs as guides and
align top edge of plate with horizontal line.
18. Drill a 20mm (3/4”) diameter hole into the
closing jamb aligned in the centre of the small
insert opening. Make it approximately 5mm
(3/16”) deeper than the cut depth in Step 19.
15. Firmly tighten screws.
16. Screw through slot in bottom of plate to
lock jig in position.
At least three screws should be used to hold
jig in place. If only hole B was used at the top,
use two screws in bottom slot.
Alignment cuts
A B C
Counter bores
facing out
6. Remove ¼” alignment pin, insert ¼” router
cutter and tighten collet.
7. If alignment (previous step) was done
correctly the router bit should be in the centre
of the guide bush. Make sure the bush does
not contact the router collet.
Preparation
8
. Close the door with the CL400 handle
mounted on the door. Make a mark on the
closing jamb in line with the top edge of the
CL400 side handle. Slide the door away from
the closing jamb.
4. Mount ¼” guide
bush in router plate:
Place ¼” bush into
counter bore in plate
(a), flip plate over,
drop wavy washer
over threaded
section of bush (b),
tighten universal nut
while holding bush
to avoid rotation (c).
9. Using a square, extend the line horizontally
across the closing jamb.
Note: When using this jig, disregard the
61.75mm offset stated in the CL400 Striker
Instructions.
10. Hold the jig up to the closing jamb with
the top edge aligned with the horizontal line.
Ensure the jig is centred on the closing jamb
by sighting through the alignment cuts in
the jig, using either the centreline or jambs/
planted stops as a guide.
11. Using a pen or pencil, mark through the
two counter bored holes (A & C) near the top
of the plate. These will be used to locate the
screws.
Note: If closing jamb is too narrow to use A
& C, mark hole B only and use one screw to
hold top of jig.
13. Flip jig over and place it over the two
screw heads.
17. Place small insert into jig and fix in
position with masking tape. Make sure edges
of tape are flat so they don’t catch on router
plate and peel off.
NOTE - READ THIS SAFET Y MESSAGE FROM START TO
FINISH BEFORE ATTEM PTING TO ROUTER THE JAMB.
This is a good quality, multi use cut out jig designed to be used by
competent tradesmen. With correct operation the cut out jig will
produce a neat, fast and accurate cut out to fit the CL400 striker.
Note: 3x 8 gauge screws will be required to hold the jig in place on the jamb, leaving
small holes.
TO REDUCE THE RISK OF ACC IDENTS, READ THE FOLLOWING :
1. Only at tempt this if you are a skilled trade sman with experience using r outers
2. Ear and eye protecti on must be worn when operating t he router
3. Do not use a blunt or damag ed router bit
4. Ensure you have a firm grip on the route r during operation
Routering
19
. Set router to cut inner section depth.
Refer to CL400 Striker Instructions.
20. With the router turned off, place the
Important Note: Ensure router is a lways held in the same orie ntation during each cu t.
If multiple cuts ar e made, the router must b e held in the same orienta tion from cut to cut.
i.e. always hold the right hand router handle in the same hand.
Only turn on router w hen it is held firmly agai nst the cutout jig. Make su re the
router cutte r is not contacting any thing when turning on.
Ensure router ha s come to a complete stop b efore removing from the jig .
Our bush may look the same a s other bushes you can buy off t he shelf but the
spigot dimensions are different. DO NOT USE OTHER BRANDS OF BUSHES ON
OUR TEMPLATES AS THE CUT OUT WIL L BE WRONG
a
router bit into the 20mm (3/4”) hole. Make
sure cutter is not contacting the jamb and
router is held firmly onto the jig.
Turn on router.
Completely router out the pocket then wait
for router bit to completely stop before
removing router from the jig.
21. Remove small insert.
22. Set router to correct depth to cut outer
section. Refer to CL400 Striker Instructions.
23. Place router onto jig with the router bit
near the middle of the previously routered
pocket (the cutter should not be contacting
anything). Turn on the router and completely
router out pocket.
Check pocket is completely routered before
removing jig.
24. Blow away any dust, then fit striker as per
CL400 Striker Instructions.
Phillips Driver
Drill
½” to
¼” Collet
Reducer
You must use a 1/4” cutter with this jig or cut will not be accurate
(a)
Screws sitting in
recessed slots
Visit our website for more info and instructional video
2
2 6
7
8
3
3
4
4
5
5
6
1
3. Make sure template tabs are firm against
front edge of door.
4. Clamp template firmly in place using
G-Clamps. Make sure clamps are clear of
router during the cut. Use pads with G-Clamp
to protect door.
Handle Cutout Jig Instructions
NOTE - READ THIS SAFET Y MESSAGE FROM START TO
FINISH BEFORE ATTEMP TING TO ROUTER THE DOOR.
This is a good qualit y, multi use cut out jig design ed to be used by
competent trad esmen. With corre ct operation the cu t out jig will
produce a neat, f ast and accurate cu t out to fit the CL400 han dle
range. It is desig ned to cut through the enti re thickness of the do or up
to 45mm (1 ¾”) in two or more pas ses*.
Setting up Router with Cutter
1
. Remove standard routing plate.
2. Insert ½” alignment pin into collet and
tighten.
3. Mount ½” guide
bush in router plate:
Place ½” guide
bush into counter
bore in plate (a),
flip plate over, drop
wavy washer over
threaded section
of bush (b), tighten
universal nut while
holding bush to
avoid rotation (c).
a
a
a
a
b
b
b
b
c
c
c
c
d
d
e
e
f
f
PAGE
3
PAGE
2
What’s included:
You will also require:
1
PAGE
PAGE
Go to page 2
Go to page 3
Cutout Jig
1/2” Guide Bush, Wavy Washer,
Universal Nut
1/2” Solid Carbide Spiral Cutter
& Alignment Pin
Safety Gear
Clamps
Measuring Equipment
Hammer & Chisel
Router
Base plate that accepts
router template guide
bush
Important: The Router Base Plate must
have a (1-3/16”) through hole with a
(1-3/8”) diameter counter bore to accept
the guide bush provided. If the bush will
not fit your router plate, you can visit
your local power tool shop or buy one
online.
CARE MUST BE TAKEN TO AVOID PERSONAL INJU RY OR DAMAGE TO THE DOOR
*The door must be cut in two or more passes depending on door thickness and door
hardness. E.g. if you are cutting out a 34mm (1 3/8”) thick hollow core door, two passes
is appropriate. If you are cutting out a 45mm (1 ¾”) thick solid core hardwood door,
three or more passes should be used. The number of passes needed to maintain a safe
environment is to be determined by a competent builder with experience in the trade.
TO REDUCE THE RISK OF ACC IDENTS, READ THE FOLLOWING :
1. Only att empt this if you are a skilled trades man with experience using ro uters
2. Ear and eye protectio n must be worn when operating th e router
3. Use a tradesman qualit y ½” router with good bearings and a minimum of 2 H P
4. Do not use a blunt or damage d router bit
5. Ensure you have a firm grip on the rout er during operation
6. Climb milling is required to make the i nitial relief cut on each pass ( Diagram A,
page 4). This must be und ertaken with care. Climb millin g must not be used for
the remainder of the operation.
7. En sure the guide bush is always rolling aga inst the steel jig.
8. Each pass should take n o more than 30 seconds, so ther e is no need to hurry.
Push the router into the cu t at a steady slow pace. Do not s top mid-cut as this
may dull the cutter.
TEST FIRST
To avoid damaging the door, a test cut out using the jig and router cutter on a
piece of 50x150mm (2x6”) timber (of similar thickness to the door) is recommended.
HARDWOOD DOORS
If you are fitting the handle to a hardwood door and the timber is particularly hard you
may need to use a variable speed router and slow the cutter’s rotation speed down.
5. Remove alignment pin, insert ½” router
cutter and tighten collet.
Note on Routering
The door cut out requires two or more
passes depending on door thickness and
door hardness, e.g. if you have a hollow core
35mm (1 3/8”) thick door, two passes would
be appropriate. If you have a solid core 45mm
(1 ¾”) thick hardwood door, three or more
passes would be appropriate.
Only climb mill the area shown red in the
diagram below to stop break out. This is only
a small cut but take care!
Step 2:
Conventional milling in
clockwise direction
Template tabs
Protect door
Step 1:
Climb mill this area
only to stop break out
TAKE CARE!
Step 1:
Climb mill this area
only to stop break out
TAKE CARE!
6. Fit CL400 handle as per instructions.
CL400
®
MAGNETIC HANDLE CUTOUT JIG
INSTRUCTIONS. ZNI090 / 61162 - 06.2016
©
All copyright and other property in this
document is reserved by Cavity Sliders Ltd.
Details and specifications are subject to change without
notice. Whilst all care is taken to ensure the accuracy of all
information, no responsibility will be accepted for any errors
or omissions.
® CAVILOCK is a Registered Trademark. Patents pending.
Wavy washer
between nut
and back side of
router plate
It is important to tighten nut firmly.
4. Place router plate over alignment pin and
tighten screws evenly.
5. Align the centreline of the cardboard door
cutout template (provided with CL400 handle)
with the centre mark of the cutout jig.
Mark the door at the edges labelled A A’.
Routering Instructions:
1. Secure the door using wedges or
clamps depending on door location.
2. First Pass: Climb mill the red part (take care).
3. Conventional mill the green part in a
clockwise direction. Each pass should take no
more than 30 seconds, so there is no need to
hurry. Push the router into the cut at a steady
slow pace. Do not stop mid-cut as this may
dull the cutter. Clean out swarf between cuts
4. Repeat for additional passes, making sure to
keep router in same orientation for each pass.
5. Use bevelled edge on 2” chisel to square
up corners.
Important Note: Ensure router is always held in the same orientation during each cut.
If multiple cuts are made, the router must be held in the same orientation from cut to cut.
i.e. always hold the right hand router handle in the same hand.
Only turn on router when it is held firmly against the cutout jig. Make sure the router
cutter is not contacting anything when turning on. Ensure router has come to a
complete stop before removing from the jig.
6. Transfer lines across front edge of door.
7. Use a chisel to create relief cuts on the
two marked lines approximately 2mm (1/16”)
deep. Orientate flat side of chisel away from
centre line, inside the marked lines.
(These cuts are to prevent the door chipping.)
Perform Test Cut
Test cut on 50x150mm (2x6”) timber (or
similar).
Because we cannot guarantee the accuracy
of the alignment of the guide bush and router
cutter it is important to do a test cut on a
piece of scrap timber.
Pick a router orientation (see Important Note,
Page 1) which is comfortable and do the test
cuts. Check that the faceplate of the CL400
sits flush or slightly below flush with the front
edge of the door. When cutting out the door,
make sure the orientation of the router is the
same as during the test cut, or the result will
vary.
Preparation
1
. Mark centre of handle position on one
of the door faces. Use square to mark
centre line perpendicular to door edge.
2. Line up centre mark on template with
centre line on door.
NZ:
09 276 0800, www.csfordoors.co.nz
AU: 02 9905 058, www.cavitysliders.com.au
US: [phone], [e-mail]
6. If alignment (above step) was done
correctly the router should be in the centre of
the ½” guide bush. Make sure the bush does
not contact the router collet.
Visit our website for more info and instructional video
(a)
(b)
(c)
Our bush may look the same as o ther bushes you can buy off th e shelf but the
spigot dimensions are different. DO NOT USE OTHER BRANDS OF BUSHES ON
OUR TEMPLATES AS THE CUT OUT WIL L BE WRONG
You must use a 1/2” cutter with this jig or cut will not be accurate
Diagram A