My router table was in need of some minor repairs. The Microdial feature was not working as it should be. This dial is used as a zero reference point to make micro adjustments to the cutting height. With this dial you can set a point and turn the dial to zero and make adjustments both up and down form a fixed height by taking note of the dial reading. This feature comes in very handing when you need to make height adjustments to make different cuts.
If you recall from my last post about building door cabinets, I used my router table to cut the stub tenons. I had to cut all the pieces for the bottom first and then flip the rail and stiles over to make the second cut to finish the tenon. Unfortunately, the Microdial was not turning as I made height adjustments to the router bit.
Tonight I decided to try and figure out what was causing the microdial not to turn. If you do not own any JessEm products I can assure you they are well machined and built. The Allan bolts were tight and easy to remove using an Allan key. There were a lot of bolts to remove to take the height adjustment assembly apart. I took a few pictures of it first in case I ran into trouble when it came time to put it all back together. (Thank god for my Andriod Phone HTC)
After what seemed to be an eternity I figured out what was causing the dial not to turn. There are three belts underneath that work in conjunction with a worm gear. There is a 90 degree change of direction from the actual router lift into a gear box and then directly over to the MicroDial assembly. I have taken a few pictures to help you understand what I am talking about.
The gear box assembly had to be taken apart by removing (4) smaller Allan bolts and then (4) more larger Allan bolts which sit up against the underside of the router table. Another (4) four Allan bolts on the top side of the router table also had to be removed.
Once I had the gear box assemble taken apart I found two gears mounted over a shaft held in place with a very small set screw (#6-32 16 TPI). When I examined these gears I noticed the one on top spun around on the shaft and the other gear was a fixed firmly to the shaft. As it turns out the gear on the top was responsible for turning the MicroDial. VOILÀ ! problem found.
I had to search for the smallest Allan key I had and removed the first gear which in turn was responsible for turning the MicroDial. Once the gear was removed I found a small indentation on the shaft which the set screw was pushed into, this in turn is suppose to hold the gear in place on the shaft and prevent it from turning.
The second gear was removed and I found the set screw turned well and past the inside diameter of the gear allowing the set screw to function properly. However, the first gear which turned the MicroDial would not protrude into the inside diameter and allow the set screw to wedge into the hole on the shaft and thus prevent it from turning. Hence the reason the gear would not function as intended, the set screw was unable to hold the gear in place because the set screw threads on the inside of the gear were stripped.
After figuring out the threads per inch (TPI) using a gauge I pulled out my tap and dye set. I took the #6-32 tap out and threaded it into the set screw hole of the gear which which had the stripped threads. Once I saw the tap go inside and protrude on the inside I knew I had the problem fixed. For good measure I did the other gear in case it was needed.
Much to my horror I dropped the small set screw.... I really thought I was screwed but after 5 minutes searching on my hands and knees I found it WHOA!
I put everything back together and believe it or not it all worked the way it should work. I wanted to share with the members on this forum because I am sure this will surface again and if it does now you know what to do.
Once again I took a few pictures and they include a brief narration explaining what I did to fix the router lift.
If you recall from my last post about building door cabinets, I used my router table to cut the stub tenons. I had to cut all the pieces for the bottom first and then flip the rail and stiles over to make the second cut to finish the tenon. Unfortunately, the Microdial was not turning as I made height adjustments to the router bit.
Tonight I decided to try and figure out what was causing the microdial not to turn. If you do not own any JessEm products I can assure you they are well machined and built. The Allan bolts were tight and easy to remove using an Allan key. There were a lot of bolts to remove to take the height adjustment assembly apart. I took a few pictures of it first in case I ran into trouble when it came time to put it all back together. (Thank god for my Andriod Phone HTC)
After what seemed to be an eternity I figured out what was causing the dial not to turn. There are three belts underneath that work in conjunction with a worm gear. There is a 90 degree change of direction from the actual router lift into a gear box and then directly over to the MicroDial assembly. I have taken a few pictures to help you understand what I am talking about.
The gear box assembly had to be taken apart by removing (4) smaller Allan bolts and then (4) more larger Allan bolts which sit up against the underside of the router table. Another (4) four Allan bolts on the top side of the router table also had to be removed.
Once I had the gear box assemble taken apart I found two gears mounted over a shaft held in place with a very small set screw (#6-32 16 TPI). When I examined these gears I noticed the one on top spun around on the shaft and the other gear was a fixed firmly to the shaft. As it turns out the gear on the top was responsible for turning the MicroDial. VOILÀ ! problem found.
I had to search for the smallest Allan key I had and removed the first gear which in turn was responsible for turning the MicroDial. Once the gear was removed I found a small indentation on the shaft which the set screw was pushed into, this in turn is suppose to hold the gear in place on the shaft and prevent it from turning.
The second gear was removed and I found the set screw turned well and past the inside diameter of the gear allowing the set screw to function properly. However, the first gear which turned the MicroDial would not protrude into the inside diameter and allow the set screw to wedge into the hole on the shaft and thus prevent it from turning. Hence the reason the gear would not function as intended, the set screw was unable to hold the gear in place because the set screw threads on the inside of the gear were stripped.
After figuring out the threads per inch (TPI) using a gauge I pulled out my tap and dye set. I took the #6-32 tap out and threaded it into the set screw hole of the gear which which had the stripped threads. Once I saw the tap go inside and protrude on the inside I knew I had the problem fixed. For good measure I did the other gear in case it was needed.
Much to my horror I dropped the small set screw.... I really thought I was screwed but after 5 minutes searching on my hands and knees I found it WHOA!
I put everything back together and believe it or not it all worked the way it should work. I wanted to share with the members on this forum because I am sure this will surface again and if it does now you know what to do.
Once again I took a few pictures and they include a brief narration explaining what I did to fix the router lift.
