Installation Guide: Vacuumless Jig

Vacuumless Jig

Included with your vacuumless jig kit you will find the following items (laminate trimmer not included):

  • Jig including ellipse and cavity plates for original LokBox

  • Centering target (locator)

  • Dummy fins

  • Angle thickness guide

  • Instruction manual

  • New MicroBox plates available for additional cost

Step #1

Start by positioning the jig over the rear fin. On the target you will see 3 vertical lines, and one horizontal line that says "LOKBOX". Position the jig so that the horizontal line is lined up with the shapers rear mark, and the center vertical line is centered on the stringer. Once the jig is in position, remove the target and place the ellipse template onto the jig.

Step #2

Place the router on top of the ellipse template. Next you'll need to zero the router by loosening it and pushing it down until the router bit is just contacting the surface of the board. Take note of the adjustment line on the router. These are small hash marks on the body of the router. At this point we recommend keeping the router adjustment loosened so you can take small passes on the stringer until you have routed 3/16ths, or 3 hash marks deeper than the position where the router was zeroed. Once you have the stringer removed to 3/16ths depth you can lock the router adjustment screw to avoid accidentally routing deeper then you need to while routing the remaining portion of the ellipse pattern. Continue routing in a clockwise pattern until all material is removed.

Step #3

Switch to the cavity template. The cavity template can be placed on the jig with the notch going in either direction. For thruster center fins place the cavity template on the jig with the notch to your left. You'll notice that the ellipse template has a wood spacer attached to the underside and the cavity template does not. This automatically adjusts the router for your second (deeper) cut. You will now need to remove another half inch of stringer, and to avoid laboring the router or having it jump around on you we suggest keeping the router loosened and like the first cut, take small passes until you have dropped the router down to you original depth line or hash mark. One you have reached that depth, lock the router adjustment screw and continue routing the entire cavity template. When finished remove the cavity template. Using a LOKBOX and an installation fin pressed together, dry fit the box to check for adequate depth. Do not remove the jig until you have dry fit a box and adequate rout depth has been achieved. *Note* installing a LOKBOX perfectly flush does not allow for any cant adjustment. By routing the hole slightly deeper (1/32nd) you will have about 2 to 4 degrees of cant adjustment in either direction when you resin in the boxes. *LOKBOXes must be installed flush or slightly below flush. They cannot be protruding at all*

Step #4

*Note* On quads we recommend routing the front holes first, then the rear holes.
Position the jig over the fin area, and offset it by using the two outside vertical lines on the target. *All side fins get offset outwards towards the rails*.
When standing at the back of the board with the bottom up, go to the right fin first, then to the left. When doing the right side fin(s) you will use the vertical line on the left, and the horizontal line that says LOKBOX. Line up the front shapers dot with the vertical line on the left. When doing the left side fin(s) you will use the vertical line on the right.

Step #5

Position the router onto the jig and zero the router as mentioned in step #1.
* If you are routing a board with parabolic stringers, use step #2 for the routing process*
If you are doing a board with a center stringer you will not be routing through wood on the side cuts. You can zero the router then increase the depth by three hash marks on the router body (3/16ths). At this point you can lock the router adjustment screw and roll the router into the glass or foam carefully as to not nick the templates on the way in. Once you've routed the ellipse template completely in a clockwise pattern, you can them move to the cavity template and repeat the same steps.
**Please note:  When installing the new MicroBox, do not cut the hole any deeper than 3/16-inch!

Step #6

Remove the ellipse template and place the cavity template onto the jig with notch facing inwards or (towards the stringer). Carefully roll the router into the template without hitting the sides with the spinning bit. Once you've got the router in continue around the cavity template in a clockwise pattern until all material is removed. Dry fit a box with installation fin and check to make sure you have adequate depth. If so you can remove the jig and prepare to install the boxes.

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