Woodstock Drill D4031 User Manual

Model D4031  
Mortising Kit  
Instruction Sheet  
Introduction  
The Model D4031 (Figure 1) Mortising Kit provides every-  
thing needed to produce mortises with your drill press.  
Inventory (Figure 2)  
A. Cone .........................................................1  
B. Fence Assembly............................................1  
C. Alignment Tool.............................................1  
D. Mortising Chisels...........................................4  
E. T-Nuts .......................................................4  
F. Mounting Sleeves:  
2.945" OD x 2.600" ID ..................................1  
2.600" OD x 2.366" ID ..................................1  
2.366" OD x 2.170" ID ..................................1  
G. Mounting Bushings:  
2.600" OD x 2.000" ID ..................................1  
2.600" OD x 1.880" ID ..................................1  
2.600" OD x 1.570" ID ..................................1  
H. Hold-Down Rods............................................2  
I. Hold-Down..................................................1  
J. Adjustable Handle.........................................2  
K. Rod...........................................................1  
Figure 1. Model D4031.  
Unplug your drill press before installing this mortising  
attachment. Failure to do so may result in serious  
I
B
personal injury.  
C
H
K
A
J
D
G
F
E
Figure 2. Inventory.  
COPYRIGHT © JULY, 2010 BY WOODSTOCK INTERNATIONAL, INC.  
WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT  
THE WRITTEN APPROVAL OF WOODSTOCK INTERNATIONAL, INC.  
#13055JB  
Printed in China  
 
D4031 Mortising Kit Instructions  
Making a Mortise  
Proper alignment of the workpiece and chisel is essential  
to making good mortise and tenon joints. The instructions  
below describe one method of creating square joints with  
an evenly-spaced mortise. Place a scrap board on top of  
the drill press table if a through-mortise is to be made.  
To make a mortise, do these steps:  
1. Install the chisel into the cone, rotate it so the  
opening is positioned toward the operator and is  
square to the fence, as shown in Figure 5, then  
secure with the knob.  
2. Secure the drill bit into the drill chuck. Slide the  
drill bit into the chisel as far as it will go and then  
allow it to drop back down 132" - 116", as shown in  
Figure 6. If this is not done, wood chips generated  
by the cutting action will have no place to go,  
resulting in excessive heat and damage to the tool.  
3. Measure the surface of the workpiece that is to have  
the mortise. Subtract the size of the mortise chisel  
and divide this number in half.  
Figure 5. Example of squaring a chisel.  
Workpiece =  
Chisel =  
0.75"  
-0.375"  
0.375" ÷ 2 = 0.1875"  
4. Mark the workpiece where you want the mortise and  
clamp it to the fence.  
5. Loosen the adjustable handles on the fence. Lower  
the chisel with the downfeed handles on the drill  
press and make adjustments to the fence until the  
marks on the workpiece are aligned with the chisel  
as in Figure 7. Tighten the adjustable handles. If the  
fence cannot be adjusted close enough, adjust the  
table on the drill press until the chisel and marks are  
aligned.  
Figure 6. Proper drill bit depth.  
6. Set the speed of the drill press between 900 and  
1200 RPM.  
7. Carefully inspect the alignment. When you are  
satisfied that the setup is worthy of being tested,  
replace the workpiece with a scrap piece of lumber  
that is the same size as the workpiece. Attach the  
hold-down bracket and rod(s) and make a cut.  
Figure 7. Aligning the chisel and marks.  
-3-  
 
D4031 Mortising Kit Instructions  
8. Watch the chips coming out of the slot on the shank  
of the chisel. If you don't see chips or there is a lot  
of smoke, raise the chisel, turn off the drill press  
and adjust the drill lower in the chisel. If burning  
still occurs, lower the speed the drill press. Some  
burning may occur with certain species of wood  
regardless of the settings but you will see wood  
chips while cutting mortises with this tool when it is  
operating correctly.  
4
9. Check the placement of the cut and make any  
adjustments to the setup before cutting a valuable  
workpiece.  
2
3
1
Cut Sequence  
Cutting mortises that are wider than the chisel must be  
done in proper sequence for best results. See Figure 8 for  
one possible sequence that will produce good results.  
Figure 8. Staggered cut sequence.  
D4031 Parts  
REF PART #  
DESCRIPTION  
XD4031001 ALIGNMENT TOOL  
XD4031002 CLAMP ROD  
20  
19  
18  
1
2
3
4
5
6
7
8
9
XD4031003 LARGE T-NUT 5/16-18  
XD4031004 SMALL T-NUT 5/16 X 18  
XD4031005 FENCE  
XD4031006 HOLD-DOWN ROD  
XPW07  
21  
17  
22  
FLAT WASHER 5/16  
23  
XD4031008 HANDLE MALE 5/16-18 X 2"  
XD4031009 HOLD-DOWN BRACKET  
16  
10 XD4031010 MORTISING CHISEL 1⁄2"  
11 XD4031011 MORTISING CHISEL 3⁄8"  
12 XD4031012 MORTISING CHISEL 5⁄16"  
13 XD4031013 MORTISING CHISEL 1⁄4"  
14 XD4031014 SQUARE HD BOLT 5⁄16"-18 X 2"  
15 XD4031015 KNOB BOLT  
15  
14  
1
16 XD4031016 CONE  
13  
17 XD4031017 HANDLE FEMALE 5/16-18"  
18 XD4031018 SLEEVE 2.945" X 2.6"  
19 XD4031019 SLEEVE 2.6" X 2.366"  
20 XD4031020 SLEEVE 2.366" X 2.17"  
21 XD4031021 BUSHING PAIR 2.6" X 2.00"  
22 XD4031022 BUSHING PAIR 2.6" X 1.88"  
23 XD4031023 BUSHING PAIR 2.6" X 1.57"  
12  
5
11  
10  
9
8
6
7
2
4
3
-4-  
 

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