~MLCS USER’S MANUAL~

For Cast Iron Router Table Extension #9587 + #9588

We appreciate your purchase. This table can be mounted easily to a table saw, cabinet, or open
steel stand.

If you wish to mount this table to the right of your saw blade, not directly to the table saw’s
table, a T-square type rip fence with heavy steel rails will be needed to support the table.
Support legs will also be required. You can make your own or modify existing legs.

WARNING: Please read this manual fully and be sure you understand its instructions
prior to operating or assembling this tool. Inspect for damage and missing parts upon
receipt. Please contact MLCS Woodworking with any problems or questions.

Copyright 2007 MLCS 1

 PARTS LIST & CONTENTS

Part no. Description Quantity

1 Cast Iron Router Table 1

2 L-Aluminum Router Table Fence 1
3 Laminated MDF Fence Faces 2
4 Clear Plastic Dust Hood 1
5 Clear Plastic Double Ended Bit Guard 1
6 Aluminum Bars for Jointing Operations 2
Owner's Manual 1

Hardware (see Hardware Parts list--next page)

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 HARDWARE PARTS LIST

PART # NAME SPECIFICATION Q’TY

The 1st Bag
1 flat washer 10mm 8
2 spring washer 13.6*1.8 4
3 hex head bolt 5/16"-18tpi *1-1/2" 4
4 hex nut 5/16"-18tpi 4
The 2nd Bag
5 hex head screw 7/16"-20tpi*1-1/2" 3
6 screw (to secure dust guard) M4*8mm 1
7 set screw (for miter track adjustment) 1/4"-20tpi*1/2" 12
8 allen wrench 3mm 1
The 3rd Bag
9 low head cap screw 1/4"-20tpi*5/8" 3
10 hex head screw 1/4"-20tpi*3/4" 2
11 hex head screw 3/8"-16tpi*1-1/2" 2
12 allen wrench 4mm 1
The 4th Bag
13 hex head screw M10*40mm 3
14 hex nut 1/4"-20tpi 2
15 J-screw hook 1/4"-20tpi 2
16 nylon washer 19*11*2mm 2
Knob set
17 through hole knob 3/8"-16tpi 2
18 through hole knob 1/4"-20tpi 6
19 square washer 32*25mm 4
20 allen head bolt 1/4"-20tpi*1-1/2" 4

RECOMMENDED ACCESSORIES

 Router Speed Control (MLCS Item #9000 or #9400)

 Featherboards (MLCS Item #9478)

 Push Sticks and Blocks (MLCS Set #9167 or #9169)

Copyright 2007 MLCS 3

 IMPORTANT GENERAL SAFETY TIPS

NOTE: Please read entire manual before using your Table. Application –specific safety
information is included throughout this manual! This manual is not intended as a general
instruction guide for woodworking or use of power tools. Appropriate guidance and training
should be sought from other sources and use of this product should not be attempted without
appropriate background knowledge.

1) Do not stand or sit on your new router table.

2) Properly secure and level your table and base prior to each use.

3) Work area should always be clean, dry, and well-lit.

4) For safety, always use bit guard, dust collection and a router table fence or starting pin.

5) Use a variable speed router or router speed control to reduce the speeds when cutting large
diameter bits, as follows: 1/4" to 2" D bits: 18,000 RPM; 2-1/8" to 2-1/2" D bits: 16,000 RPM; 2-
5/8" to 3-1/2" D Bits: 12,000 RPM. Bits with a carbide height greater than 1-1/2" should also be
run at 16,000 RPM or less and it is EXTREMELY important to make multiple passes with these
router bits.

6) Always choose an appropriate tool for the job. Forcing a tool to due a job for which it was not
designed can cause damage and injury.

7) Featherboards, clamps, and vises should be used to secure your work when needed.

8) Wear appropriate protective gear, including face shield, dust mask, ear protection and safety
glasses. Standard eyeglasses do NOT provide appropriate protection in the workshop
environment.

9) Gloves, jewelry, and loose clothing should not be worn when operating power tools, as they
can become caught in the machine, causing serious injury. Long hair should also be tied back.

10) Always keep your tools and accessories in good repair. Inspect frequently for signs of wear,
misalignment, breakage, weakened mountings, and other potential operating issues. Damaged
parts should be promptly repaired or replaced.

11) Always disconnect the power before moving, repairing or performing maintenance on
machinery.

12) Never allow those who may disregard safety into the work area, especially children and pets.

13) Never reach too far. Always maintain your balance and footing when working with power
tools.

14) Pay careful attention to your environment and always use good judgment.

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 ASSEMBLY INSTRUCTIONS

(These instructions are intended ONLY when directly mounting your table to a cast iron table
saw. A minimum 27” table depth is required for proper mounting. If your table is deeper than
27”, you will need shims (not included) to fill the extra space.)

1) Detach your table saw’s left extension wing.

2) Install your router table using the included hardware. NOTE: Do not use the factory bolts
from your table saw, as they may not be the proper length or grade. If the provided bolts are not
the proper size for your table saw, you should obtain your own Grade 5 bolts.

3) Determine if your saw uses a 3 or 4 bolt pattern. Tip: Craftsman and Ridgid saws use four
bolts. Most other brands of saws use 3.

a) Four Hole Mounting: Typically, 5/16” bolts are used with a 4-hole mounting system.
In the (2) middle holes, use the heavy rectangle washers. Each bolt should be installed with (2)
10mm flat washers, (1) lock washer and (1) nut. Some Ridgid models may have tapped rather
than through holes. If your table saw requires bolts other than 5/16”-18 TPI, you will need to
obtain Grade 5 bolts on your own.

b) Three Hole Mounting: Always use the heavy rectangle washers on each bolt. Delta
table saws use 7/16”-20 TPI x 1-1/2” hex bolts, while most other imported models use M10 x 1.5
x 40 mm hex bolts. If your table saw requires a different size, you will need to obtain Grade 5
bolts on your own.

4) Lift the router table into place. This is a 2-person operation! Snug the bolts while a friend
secures the table in position. Both surfaces should be smooth and flat before attempting this
step.

5) Secure the router table. Tighten the bolts into place slowly and evenly. A soft-tipped mallet
can be used to gently tap the table surfaces. Paper or brass shims may be needed if the (2)
tables’ edges are not flat.

6) Fit the miter gauge track to your miter

gauge (not included). Place your miter
gauge in the track to check the fit. To
widen the track, use a pair of channel
locks to squeeze the gib against the front
wall of the miter track (something
should be used to prevent aluminum
marring). Then, install the (12) 1/4"-28
TPI x 1/2” set screws. As you tighten Miter Gauge Track Assembly (see step 6)
the screws, the gib will deflect into your
miter gauge. Gradually and uniformly tighten all screws until proper fit is obtained.

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7) Install the accessory/miter gauge track with the
(3) 1/4”-20 TPI x 5/8” Allen head cap screws,
tightening with an 1/8” hex wrench.

8) Install the dust port. Slide the dust port in the

45-degree grooves on back of the fence until is in
place. Use M4 x 8mm screw to lock the dust port in
position.

Miter Gauge Track Installation

(see step 7)

9) Attach the (2) MDF subfences to the fence with (4)

1/4”-20 TPI X 1-1/2" shoulder bolts in the counter-
bored recess. In order to fully seat the bolts, light
force may need to be applied. The tight fit prevents
spinning.

Dust Port Installation (see step 8) 10) Attach the fence with (2) 3/8”-16 TPI x 1-1/2”
hex bolts, (2) 3/8” nylon washers and (2) 3/8” T-
Knobs.

11) Pre-assemble the bit guard with (2) 1/4”-20 TPI x

3/4” hex bolts and (2) knobs. Both bolt heads then
slide into the T-Slot in the router fence to attach.

NOTE: This is a dual position bit guard. When

doing general routing with large to mid-size bits, use
the larger, curved side. For edge jointing and small
diameter bits, the smaller, angled side should be used.

12) Mount your router to the MLCS All-in-One Router

Plate #9338 or MLCS Aluminum Router Plate #9334. Bit Guard Installation (see step 11)
For most common routers, the MLCS Aluminum Plate
#9334 is pre-marked. The All-in-One Router Plate Kit
#9338 is not marked. For either plate, you will need to drill holes to mount your router.

13) Insert your router and plate into the router tabletop. You may need to make the plate flush by
adjusting the (4) Allen head leveling screws in the corners of the plate.

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14) Screw the fence hang hooks into the table about
3/8”. Then use a 7/16” wrench to tighten the 1/4” jam
nuts.

15) When not in use, you should hang the fence on

the (2) J-hooks.

TIPS FOR PROPER OPERATION

1) File Sharp Edges. If your table saw has a bevel Fence Hang Hooks (see step 14)
on the leading edge, you may wish to file your router
table to match.

2) Dust Collection. Dust collection is essential when operating your router table. The port on
your table accepts a 2-1/2” fitting as used on most Shop Vacs. To ensure proper air flow over
the router motor and to properly remove the most dust and chips, a hose of 2-1/2” or larger is
strongly recommended. You may need an adapter (not included) for a hose larger or smaller
than the standard 2-1/2”.

3) Miter Gauge Usage. Your Miter Track is equipped

with (2) slots: a T-Bar compatible miter gauge slot and an
accessory T-slot. The accessory t-slot (the narrower of
the two) accepts 1/4” hex bolts for attaching
featherboards. The miter gauge slot is for use with a
miter gauge and is compatible with standard 3/8” x 3/4”
miter bars, with or without the T-bar. (Miter Gauge not
included.)

If you wish to adjust the fence perpendicular to

the miter gauge, you should position the miter gauge at 90-degrees and place it into the
slot. Loosen the T-knobs and use a square to align it to the fence, as shown (see picture).

4) Feed Direction. The workpiece should always be fed AGAINST the cutter rotation (see
picture). Feeding the workpiece with the cutter direction is called “climb-cutting” and is
extremely dangerous, as the cutter will pull the workpiece out of your grasp.

Be sure you fully understand bit

rotation and feed direction prior to
operating your router in this table. If
you need assistance, ask a router
retailer, call and speak to one of our
woodworkers, or refer to a Guide
Book for router usage.

REMEMBER--NEVER
CLIMB CUT!

Copyright 2007 MLCS 7

5) Adjusting the Subfences. Each MDF subfence can move along the main fence about 2”,
allowing an opening for your router bit from 0” to 4”.

1) The “Close” Setting: This is a very common setting for many applications. It is similar
to a “Zero Clearance” setting but avoids cutting or damaging the subfences. After
properly setting your fence and bit height, move the subfences inward toward the bit to
close the space. Always ensure that the bit can spin freely BEFORE turning on your
router.

2) The “Zero Clearance” Setting: By cutting the subfences into the bit profile, a zero
clearance setting is achieved, removing the gap between the router bit and fence face. In
this case, the workpiece will not be pulled into the fence ahead of the router bit. Zero
clearance allows a cleaner cut, as the subfence supports the workpiece. However, this will
permanently alter the fence faces by cutting into them. To set for true Zero Clearance:

a) Set the bit height and fence position. Do not allow the router bit and subfences to
touch at this time.

b) Position and secure the bit guard.

c) Turn on your router. Working from behind the fence, loosen the knobs and push the
infeed subfence into the spinning cutter. Hold onto the subfence knobs.

d) Fully tighten the knobs on the subfence when the subfence has reached the bit’s guide
bearing. (For bits without bearings, you should tighten the knobs when the subfence is
half-way into the bit).

KNOBS.
REMEMBER: ALWAYS MAKE THESE ADJUSTMENTS FROM THE BACK OF THE
FENCE WITH BOTH HANDS ON THE ADJUSTMENT KNOBS.

6) Jointing. Jointing Allows you to make flat, straight, square matching edges, such as are
required when boards are edge glued to form larger panels, to fit pieces together, or to trim stock
to size.

Do not use router table jointing as a

substitute for a power jointer with stock
over 1-1/4” width. However, the router
table is useful for jointing small and
short pieces of wood safely, as the fence
opening can be greatly reduced, to about
1/2”. The faster rotation speed of the
router bit also produces a cleaner cut
than a jointer cutter head. Woods prone
to tear-out, like maple and cherry, can
especially benefit, as long as you do not Aluminum Jointer Bars Installed Between
feed too slowly, which could cause Fence Face and Fence Body
burning of the workpiece.

Copyright 2007 MLCS 8

The built-in jointing slots in your router table allow insertion of the (2) small aluminum jointer
bars that were included with your table. When used in pairs, these bars move the outfeed fence
1/32” or 5/64”, depending on which recessed slots they are inserted into.

Set-up.

1) Unplug the router before inserting a 1/2” diameter spiral or straight router bit into the collet.

When jointing, for safety you MUST use a 1/2” shank bit with a cutting length under 1-1/4”
and the bit height set under 1-1/4”.

2) After loosening the outfeed subfence mounting knobs, move the aluminum jointer bars (in
pairs) below the outfeed subfence, either in the 2nd and 4th slots (for 1/32” cuts) or the 1st and 3rd
slots (for 5/64” cuts).

3) Align the router bit and outfeed subfence into the same plane using a straight edge. Then
remove the straight edge.

4) Move the subfences inward to close the opening around the bit but do not allow them to touch
the bit. The bit should not contact the aluminum body of the fence, either. Then, tighten the
knobs on the subfence and position the bit guard.

5) Use scrap stock for a test cut and re-adjust if needed.

MLCS ONE-YEAR WARRANTY AND SATISFACTION GUARANTEE

MLCS is dedicated to ensuring the quality and durability of every product we sell. We guarantee
to the purchaser that this product is free of defects in materials and workmanship for 1 year.
Guarantee is limited to repair, replacement, or refund at MLCS’s discretion and does not cover
any coincidental loss, economic or otherwise.

Warranty Terms and Conditions: Please contact MLCS within 30 days of discovering a
problem. Defects caused by misuse, abuse, negligence, accidents, or after-purchase alterations
will not be covered. Using this item for other than its intended purpose will void the warranty.

Warranty Procedure: Defective product must be returned to MLCS before a refund or

replacement can be processed. Please contact us at 1-800-533-9298 to have a return label sent to
you. Upon inspection of the returned product, we will repair and return the product, replace it, or
issue a credit at our discretion. If the product is found not to be defective, a nominal 10%
restocking fee will be deducted from any credit to cover costs of shipping, checking, and
repackaging the product.

Copyright 2007 MLCS 9