Large Sheet Tool Assembly Documentation

Gather 4 rail support blocks, 8 ¼-20 Weld Nuts and 8 ¼-20 x ¾” BHSCS

Insert bolts, thread on nuts and set rail support blocks in the assembly jig as shown.

Slide a 36” section of 1.5” Square Extrusion into the assembly jig. Making sure that all weld nuts slide into the T-Slot.

Position the right end of the extrusion 7-3/16” from the right edge of the assembly jig. Tighten all bolts to lock the rail support blocks in place.

Set out 4 Beam Supports, 8 weld nuts and 8 ¼-20 x 7/8 BHSCS.

Slide Beam Supports into T slots and align with Rail Support Blocks. Tighten all bolts to lock Beam Supports in place.

Set aside 760mm Rail and 8 #6 x 1-1/4" Flat Head Screws.

Set the rail on the ledge in front of the blue Rail Support Blocks. Leave two open holes to the right of the rightmost rail support block. Drive the #6 screws through the rails and blue support block and into the yellow blocks to secure the rails.

Flip the assembly 90 degrees in the jig in preparation for attaching the front and back of the Large Sheet Tool Base.

Rotate the assembly jig 180 degrees to assemble the right side of the Large Sheet Tool Base. Set aside Rail Support Blocks, nuts and bolts as you did for the opposite side of the base. This side will hold the E-Chain and will require a special Rail Support Block with a slightly different hole pattern. This block should be set up in the slot marked orange on the jig.

Insert and align the aluminum extrusion--this time 7-3/16" from the left side of the assembly jig. Slide in the yellow support blocks and attach the rail--with two open holes on the left side.

Use three #10 x 1" PPH screws to attach the motor mount plate to the front plate as shown.

Flip the front plate over and gather 2 #10 x 1-1/2" PPH Screws and 1 #10 x 1" PPH Screw.

Insert the 2 #10 x 1-1/2" PPH Screws into the back side of the front plate--insert them as far as possible without allowing any of the screw to protrude from the other side of the plate--we'll drive them all the way in later in the assembly process.

Insert the #10 x 1" PPH Screw into the other end of the front plate--again without allowing the end of the screw to protrude from the opposite side of the plate.

Grab the Front Tie Plate along with 3 #10 x 1" PPH Screws and 1 #10 x 1-1/2" PPH Screw.

Press the Front Tie Plate into the Front plate, with the cut side of the tie plate facing the table (so that it will be hidden after assembly). Drive the 3 #10 x 1" PPH Screws into the first three holes from the left. Drive the #10 x 1-1/2 into the last hole on the right.

Grab the Front Right Side Gusset and 1 #10 x 1" PPH Screw.

Press the gusset through into place by inserting the long tab through the rectangular hole in the front tie plate. Secure it in place by tightening the 2 #10 x 1-1/2" PPH Screws that you inserted earlier, then insert the #10 x 1" PPH Screw through the hole in front of the long tab.

Grab the Front Left Side Gusset and 1 #10 x 1" PPH Screw.

Press the gusset into place and secure it by tightening the #10 x 1" PPH Screw that you inserted ealier. Insert the other #10 x 1" PPH Screw through the hole in front of the long tab.

Grab the Front Base Plate and Front Base Plate Glass, along with 7 #10 x 1/2 PPH Screws.

Attach the Glass to the Base Plate using the #10 x 1/2 Screws as shown. Be sure that the rectangular openings on both the glass and plate are lined up.