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Endura TRILENNIUM Series User Manual

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TRILENNIUM FULL SCOPE (FS) TEMPLATE INSTRUCTIONS
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Overview
Parts Included in Template System:
Additional Parts Required:
Full Scope (FS) Template Rails, with ø 2-1/8" Crossbore Guides.
FS Router Carrier (for 1-3/4", 2" & 2-1/4" Doors)
FS Bridges, Stops and Twist Bolts
13/16" x 5" Router Bit
9" Magnum Bolt
Deadbolt Actuator Wrench
Lock Actuator Wrench
Instructional Video on USB Drive
All parts above available in Endura Item #: TC-TEMP-FS- Complete.
FS Router Carrier
13/16" x 5" Router Bit
Magnum Bolt
Deadbolt Actuator
Lever
(6) FS Bridges
(2) FS Template
Rails
Porter Cable Router #7538 or #7539
1"x 2-1/2" Router Bit for 3000 Series Installation
57/64" x 2-1/2" Router Bit for 3070 Series Installation. (Endura Item# TC-TEMP-RTBIT-088)
1/2" Drill Bit
#9 VIX- Drill Bit
Optional- Ø1-11/16" Crossbore Guides (Endura Item# TC-TEMP-BUSHING168)
(2) FS Stops with Twist Bolts
Lock Actuator
Wrench

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Endura TRILENNIUM Series Specifications

General IconGeneral
BrandEndura
ModelTRILENNIUM Series
CategoryPower Tool Accessories
LanguageEnglish

Summary

Overview

Safety Warnings

Router Stop Setup

Router Turret Setup

Configure router turret stops for specific bit positions and depths.

Vertical Height Setup

Adjust router stop nuts to their maximum height for vertical alignment.

Position Template on Door Panel

Mount and Stabilize Door

Secure the door panel with hinge edge facing downward.

Mark Crossbore Centerline

Locate and mark the precise centerline for the crossbore.

Install Stops and Template

Place stops per door size and install template on the stile edge.

Align and Secure Template Rails

Align template marks with crossbore center and secure rails with twist bolts and clamps.

Drilling Crossbores and Mounting Holes

Determine Crossbore Size

Select the correct crossbore diameter based on handle set style.

Drill Crossbores

Drill two crossbores halfway from each side for a smooth finish.

Drill Mounting Screw Hole

Drill the 1/2" mounting screw hole, halfway from each side.

Routing for Lock Channel

Install Router Bit

Insert and securely tighten the appropriate router bit into the collet.

Center Router Carrier

Place router on template rails and adjust turn knobs to center it.

Set Plunge Depth Stop

Set the router's plunge depth stop to 1/2" for the stroke.

Route Faceplate Slot

Route the faceplate slot by traveling the entire distance between stops.

Check Slot Fabrication with Lock

Verify the routed channel fits the lock I-beam flush with the stile.

Routing for Main and Auxiliary Locks (2" Deep Cut)

Install Ø13/16" Router Bit

Set the 13/16" router bit projection for the 3/8" to 7/16" depth.

Plunge Router to 2" Depth

Use the yellow stop position to plunge the router to a 2" depth.

Install Bridges for 3000/3070 Locks

Place six bridges in yellow positions on template rails for 3000/3070 locks.

Install Bridges for 3500/3020 Locks

Install two bridges for mortise lock and auxiliary locks per yellow positions.

Route Sections Between Bridges

Route sections between installed bridges, following depth and caution notes.

Routing for Main and Auxiliary Locks (3-1/4" Deep Cut)

Rotate Router Stop Turret

Adjust the router stop turret to the red position for the new depth.

Relocate Bridges to Red Positions

Move all six bridges to the new red positions on the template rails.

Route Three Pockets to 3-1/4" Depth

Mount router and create three pockets to a depth of 3-1/4".

Routing Upper Auxiliary Lock for 9/0 and 10/0 Panels

Align Template for Upper Lock

Slide template to align crossbore centerline with score marks for upper lock routing.

Route for Upper Auxiliary Locks

Perform 1-1/2", 2", and 3-1/4" deep routes for upper auxiliary locks.

Install Lock

Check Completed Fabrication

Clean channels and place lock face up, ensuring flush fit with the stile.

Drive Screws into Lock Faceplate

Pilot drill and install mounting screws, ensuring flush screw heads.

Final Check

Check Deadbolt and Latch Functions

Verify lock and handle operation using actuator wrenches, checking latch extension.

Troubleshoot Lock Issues

Address potential issues like depressed deadbolts or exterior lever operation when locked.

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