Incra Wonder Fence Manual - Fine Tools

Offset AdjustmentFollow these steps to adjust eitherthe infeed or outfeed fence for“in-line” or “offset” fence applications.See Fig. 9.Fig. 9Offset adjustmentSECOND: Slide black rear wedge left to movefence forward or right to move fence backward.Black rear wedgeCAUTION: To avoid disengaging thenut, do not loosen any of the socket headscrews more than one or two full turns.Using the supplied hex tool,loosen the two socket headscrews through the large holesin the front of the Wonder Fence half.Also loosen the wedge locking screw.The access hole for the wedge lockingscrew is located between the two largeholes. Loosen each of the (3) screwsone to two full turns depending on theamount of adjustment range needed.For a clear view of the screw heads,loosen the thumbscrew and slide theblack view panel located on the top ofthe Wonder Fence.1FIRST: Loosen (3) socket headscrews through access holes in fence.2Adjust the fence by sliding theblack rear wedge: To move the fence forward, slide thewedge to the left. (This moves the end of the scale towards the cursor.)Slide view panel to the sideTHIRD: Retighten (3) socket headscrews and slide view panel back in place.3Tighten the three sockethead cap screws to securethe fence position then slidethe view panel back in place andtighten the thumbscrew.–To move the fence backward, slidethe wedge to the right. (This moves the– end of the scale towards the cursor.)NOTE: The numbers on the scale represent hundredths of an inch fence offset.Each of the smaller tick marks on the scale represent .002" (2 thousandths of an inch).Gap AdjustmentFollow these steps to adjust theopening between the infeed and outfeedfences, see Fig 10.CAUTION: When adjusting thefence gap, never position the endsof the aluminum fences closerthan 1 8" from the router bit.Using the supplied hex key, loosenthe two socket head screwsthrough the large access holeslocated in the front of each WonderFence half. DO NOT loosen the wedgelocking screw located between the twolarge holes. For a clear view of the screwheads, loosen the thumbscrews and slidethe black view panels located on the topof each half of the Wonder Fence.1Fig. 10SECOND: Slide fences toopen or close fence gap.Gap adjustmentFIRST: Loosen (2) socket headscrews through large accessholes in each fence half.2Slide the infeed and/or outfeedfences to open or close thefence gap. THIRD: Tighten (2) socket head screwson each fence and slide view panels backin place.Tighten the two socket headscrews on each fence half,then slide the view panelsback in place and tighten thethumbscrews.3

In-line Fence ApplicationsOnce set to the in-line/mid-rangeposition as described on page 4, yournew INCRA Wonder Fence can beused for a variety of typical in-linefence applications, including grooving,dadoing, and edge forming operationssuch as rabbeting, chamfering, androundovers. You’ll also find the inline position useful for many specialtyoperations. With the Hi-Rise fencecap, you’ll be able to use vertical panelraising bits to make raised panelsfor cabinetry, and since its designis compatible with all INCRA jointmaking accessories, you’ll be able touse the Wonder Fence in conjunctionwith your INCRA Jig Ultra as a jointmaking fence.Vertical Panel RaisingThe introduction of the vertical panelraising bit has made cutting the revealon a raised panel a relatively simpleoperation for the router table. You’ll findyour new Wonder Fence, with its built-indust collection, adjustable fence gap,and Hi-Rise fence cap, perfect for thisoperation. The setup is as follows: Fig. 11:1Install vertical panel raising bit andset appropriate depth of cut.2Adjust fence gap as necessary(see Gap Adjustment on page 5).3Adjust infeed/outfeed fences tothe in-line/mid-range position asdescribed on page 4.Fig. 11Vertical panelraisingUse a straightedge to adjust theHi-Rise fence cap in line with theinfeed and outfeed fences. (Seepage 10)4Remember: Do not make the fullwidth of the cut in a single pass.Instead, use several light sideby-side passes, moving the fence back1 16" or so after each pass.5Safety Whenever using large diametervertical or horizontal panelraising bits or any other largediameter bit, always followthat router bit manufacturer’soperation and safetyrecommendations. Whenever it is necessary toremove large amounts ofstock, always use multipleside-by-side passes to achievethe final cut. Several shallowcuts are safer and will yieldbetter results.Joint Making (INCRA Jig Ultra required)Adding an INCRA Jig Ultra to your WonderFence makes precise placement of multipleside-by-side cuts a cinch. One suchoperation requiring this kind of precisionis joint making. Once placed in the inline/mid-range position, your new WonderFence becomes a perfect replacementfor the standard straight fence commonlyused with the INCRA Jig. It is completelycompatible with all of the INCRA jointmaking accessories, including the INCRARight Angle Fixture, Stop, and joinerytemplates. The setup follows, see Fig. 12:1Adjust infeed/outfeed fences tothe in-line/mid-range position,see page 4.2Adjust fence gap as described onpage 5.Clearance is provided for between the Hi-Rise fence cap, the bracesand all INCRA joint-making accessories. However, since the Hi-Rise fencecap and braces are not necessary for joinery, you may remove them from theWonder Fence if you prefer. Just loosen the (2) socket head fasteners thatsecure the fence cap braces, and slide the assembly off of the Wonder Fence.Fig. 12Joint MakingFollow the instructions for thejoint you wish to cut as detailedin the INCRA Master ReferenceGuide and Template Library.3

Offset Fence ApplicationsOne of the most valuable features of the Wonder Fence is the Fig. 13ability to offset the infeed and outfeed fences. The offset fence Jointingadds a whole new dimension to the router table, allowing it toperform two new operations – jointing, and shaping.JointingMost woodworking projects require that your boards beginwith at least one straight edge. This one straight edge thenbecomes the reference surface for subsequent perpendicularor parallel cuts. By using your Wonder Fence and thetechnique described below, you’ll be able to put a perfectlystraight edge on your board at the router table and, becauseof the higher RPM of the router, you’ll find the freshly jointededge far smoother than any jointer machine can produce.1Install a 1 2" diameter (or larger) straight bit and set thedepth of cut to slightly greater than the thickness ofstock to be joined.2Adjust fence gap as necessary (see Gap Adjustment onpage 5).3Adjust infeed/outfeed fences to the in-line/ mid-rangeposition as described on page 4.Fig. 14Jointing setupAdjust the location of the Wonder Fence at yourrouter table to place the outfeed fence in line with theoutermost cutting arc of the router bit. (A straightedgeplaced against the outfeed fence can be used to help align thefence with the cutter.) Fig. 14.InfeedfenceSecond:Microadjustinfeed fencebackward(-)4OutfeedfenceMicro adjust the infeed fence backward (-). The readingon the scale will represent the amount of stock youwish to remove from the board’s edge on each pass. Alight cut (infeed cursor reading between -1 and -2) will yieldthe smoothest results.5First: Position WonderFence to align fencewith cutting wing on therouter bitStraightedgeShapingFig. 15Many shaping operations involve the removal of the entire edge Shapingof a square piece of stock as it is moved past the cutter. Oncethe stock is removed from the edge, it becomes necessary tosupport the freshly cut surface by moving the outfeed fenceforward. Although similar to jointing, the setup is slightlydifferent. Here’s how:1Install router bit and set desired depth of cut.2Adjust fence gap as necessary (see Gap Adjustment onpage 5).3Adjust infeed/outfeed fences to the in-line/mid-rangeposition as described on page 4.4Adjust the location of the Wonder Fence at your routerShapingsetuptable to achieve the desired cut profile. Use a scrappiece of wood and make trial cuts to help in determiningthe fence position.Make a fresh test cut about 3" long on a piece of scrapstock, then turn off the router. You’ll notice a gapbetween the freshly cut surface and the outfeed fence,Fig. 16. Simply micro adjust the outfeed fence forward by thisamount to support the stock’s edge as it passes the cutter.Fig. 165Outfeedfence7InfeedfenceDistancebetweenstock andoutfeedfence –microadjustoutfeedfenceforward( ) by thisamount

Zero Clearance SubfencesAdding a zero clearance subfence to your Wonder Fenceis a perfect solution to providing tearout control andadditional support for your workpiece when using largediameter cutters. Typically a zero clearance subfenceis a long piece of wood with the profile of a particularcutter bandsawn into the face. When attached to therouter table fence and moved into position, the routerbit nestles into the cutout. This close fit around thecutter provides the tearout control and support foryour workpiece, Fig. 17. Here’s how to prepare a zeroclearance subfence for your Wonder Fence:Fig. 17Zero clearance subfenceFig. 18Making a zero clearance subfence blankBegin with one piece of 3 4" medium density fiberboard3 1 16" x 32". Layout the Detail 18drill and counterbore3 4" dia. x 3 8"deep counterborecenters as shown in Fig.‑18,then cut to the length asshown. Drill and counterboreat each center mark using thedimensions in Detail‑18.5 16" dia. through hole12Connect the through holes with a slot8"3 3 4"15 1 2"8"1 3 4"3 3 4"Slot dimensions5 16"wide slotconnecting both 5 16"through holesFig. 20Connect throughholes with slotFirst: Turn onrouter and lowerstock onto cutterSecond: Slidestock forward.Stop cut whenrouter bit is seenentering rear hole.Repeat this cut for the other zero clearancefence. Next, increase the depth of cut by 1 4"and repeat the cutting process for both pieces.Finally raise the bit to cut completely throughthe stock and repeat the cuts.CAUTION: The cutter will be cuttingthrough the top of the stock. Keep yourfingers clear of the line of cut.(See TIP above and Fig. 20.)15 1 2"Fig. 19In order to later access the fence offset adjustmentscrews on your Wonder Fence, you’ll need to connectthe through holes on your zero clearance fence halves with aslot. See Fig 19. Install a 5 16" straight bit in your router tableand set the depth of cut to 1 4". Position your fence so that therouter bit will nestle into the through hole located at one endof the subfence. Clamp a stop on your infeed fence againstthe end of the zero clearance fence. Lift the zero clearancefence off of the router and place the end of the zero clearancefence against the stop. Now slowly lower the piece onto thecutter. Slide the zero clearance fence forward until the routerbit is seen entering the rear hole. Slide the piece back to thestarting position and turn off the router.To make this cutting operationsafer, use double-faced tape toattach a scrap block of wood to thezero clearance fence. The scrap can beused as a handle to safely raise andlower the stock.Subfence dimensionsThird: Slide stockback to startingposition and turnoff router.1 st Pass: 5 16"diameter cutter, 1 4 depth of cut2 nd Pass: 1 2"depth of cut3rd Pass: 3 4"depth of cut8Double face tapeholds scrap ofwood to stock foruse as handle

Cutting the Zero Clearance Profile1Attach subfences to infeed andoutfeed fences.Fig. 21Attach subfences1 4 -Place a washer on each of the (4)20‑x 3 4" socket head cap screws provided andinsert into the counterbores. Loosely thread onthe 1 4 -20 rectangular nuts, then slide the nutsinto the T-slot located on the front of the WonderFence. Both subfences must be insertedfrom the end of the infeed fence. Slide bothsubfences to align the ends flush with the endsof the aluminum fences (nearest the cut area)and tighten the fasteners. Fig. 21.2Position fence for initial profilecuttingInstall desired cutter and set the fencegap as described on page 5. The fence endsshould be no closer than 1 8" from the cutter.Tighten the fasteners. Slide the entire WonderFence up to the cutter and position it so the rearface of the subfence is in front of the center ofthe cutter. See overhead view, Fig. 22. Lockyour Incra Jig’s carriage clamp or, if using theWonder Fence in the freestanding mode, tightenthe two table clamps.Slide 1 4 -20rectangular nutinto T-slot onWonder FenceFig. 22Position fencefor initial cutMake the profiling cuts4Slide the subfence into finalpositionLoosen the two socket head cap screwsthat secure the infeed subfence. Now turnon the router and, using a good rubber soledpush block, advance the subfence forward intothe cut. When the subfence touches the outfeedfence (or the bearing on some cutters), back thesubfence out of the cut and turn off the router.Unlock your Incra Jig, or loosen the table clampsif using in the freestanding mode, and move theWonder Fence back 1 8". Relock the clamps,then repeat the cut. Continue this process untilyou have cut completely through the subfence.minimumFront ofsubfenceRear ofsubfence31 8"Rear face ofsubfence in front ofcenter line of cutterCAUTION: The nature of zero clearance places the subfencevery close to the cutter. NEVER attempt to move your fence ormake any adjustment to the setup until the router bit has come to acomplete stop.Now you can slide the completed subfenceinto its final position on the infeed fence andtighten the mounting screws. Final positioningshould always be done with the router turned offand the carriage clamp locked.9

Hi-Rise Fence CapYou’ll find the Hi-Rise fence cap great for supportinglarge vertical panel work. Here’s how to attach theFence Cap and braces.Detail 231Attach the fence capbraces‑‑Sliderectangularnut into1 4 "Place awasher on each of(2) 1 4 -20 x 1 2" socket head capscrews and insert through the hole onthe front of each fence brace. Looselythread on a 1 4 -20 rectangular nut (theraised rim on the nut should face awayfrom the brace), then slide the nut intothe forward T-slot located in the topof the Wonder Fence assembly. SeeFig.‑23 and Detail 23. Locate the twobraces on the fence 7 5 8" apart. Tighten thefasteners with the supplied hex tool.2Attach the cap extender3Attach and align fencecapFig. 23 Attach fence cap bracesNOTE: When removing the fencecap assembly from the INCRATS Tablesaw Fence, loosen thefasteners and tilt the assembly toclear the fence mounting bracket.Forward Tslot1 4-20 x 1 2" socket headcap screw with 1 4" washer7 5 8"Fig. 24Place a 1 4 " washer on each of the (2) Attach cap #10-32 x 1 2" phillipspan head phillips screws and insertextenderscrew with 1 4" washerthrough the slotted holes located in theFirst: Insert fasteners and slidefence cap extender. Loosely thread a #10#10-32 hex nuts into T-slot on32 hex nut onto each fastener, then slide thetop of braceshex nuts into the T-slot located on the top ofeach fence cap brace. Position the cap Detail 24Cap extenderextender so you can later gain accessThird: Slide capto the socket head fasteners on eachextender forward toFencefence cap brace through the slottedcontactcapholes. Pull the cap extender forwardbrace, thenextenderuntil it firmly contacts the back of each tighten screwsbrace and tighten the (2) phillips headBracescrews. See Fig.‑24 and Detail 24.Place the 24" long fence capon top of the cap extender andattach using the (2) 1 4 -20 x 5 8" sockethead cap screws with 1 4 " washers andlock nuts. Use a straightedge to alignthe leading edge of the fence cap withthe front face of the Wonder Fence andtighten the two cap mounting screws.See Fig. 25. To remove the fence capand braces, just loosen the two sockethead cap screws that secure the bracesand slide the entire assembly off of theWonder Fence.Fence cap braceFig. 25Attach and align fence capExtend fence cap out totouch straight edgeFIRST: Attach fence cap to cap extenderwith (2) 1 4-20 x 5 8" socket headscrews, washers andlock nutsFencecapSECOND: Use a straightedge toalign fence cap with Wonder Fence,then tighten fasteners.10Second: Position cap extender toallow future access to socket headcap screws throughslotted hole.

9 16" dia.x 3 8"deep counterboreThe fence and Hi-Rise fence capprovide the support necessary forlarge vertical panel work. If youwant to add an auxiliary fenceto bridge the gap between thetwo, use the drill and counterboredimensions shown in theillustration. Use 1 4 -20 x 3 4"machine screws with washersand hex nuts to attach theauxiliary‑fence.5 16"dia.throughholeHex nut capturedin T-slot1 4-20 x 3 4" machinescrew w/ washer7 15 16"Fence1 3 4"3 4"stockFence Squaring AdjustmentsTo adjust the angle of the fenceperfectly square with your routertable, loosen all five of the sockethead screws through the holesin the front face of each WonderFence half. Slide one or more ofthe supplied plastic shims betweenthe gold wedge and the rear of thefence. Place the shim above thefasteners to decrease the angle.Place the shim below the fastenersto increase the angle. Tighten allfasteners.Fig. 26Shim below fastenerto increase angleFastenerGold wedge11

WarrantyTaylor Design Group, Inc. warrants this product for one year fromdate of purchase. We will repair any defects due to faulty material orworkmanship, or at our option, replace the product free of charge.Please return the failing component only, postage prepaid, along witha description of the problem to the address below. This warrantydoes not apply to parts which have been subjected to improper use,alteration, or abuse.LIFETIME WARRANTY ON POSITIONING RACKSIf an INCRA positioning rack in this tool becomes damaged for ANYreason, Taylor Design Group will replace it free of charge for as longas you own your tool. Return the damaged rack, postage prepaid, andallow 1 to 2 weeks for delivery.NOTE:Replacements cannot be sent unless damaged racks have beenreceived by Taylor Design Group at P.O. Box 810262, Dallas, TX 75381For a product information brochure,call, write or fax to:For a product information update onthe complete INCRA line of tools,please see your nearest dealer.If you are unable to locate a storenearby, or if you have

the INCRA Wonder Fence as a free-standing router table fence or you can mount it directly to the INCRA Jig Ultra for the ultimate router table fence setup . If you have purchased the TS/Wonder Fence table saw fence upgrade kit, you can mount the fences directly to your INCRA TS table saw fence for use with a router table extension wing .