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
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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 1⁄32" - 1⁄16", 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.
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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.
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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
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