Kval Commander - Front Section; Commander Hinge Section; Hinge Locations; Standard Hinge Center Set up

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FRONT SECTION
Commander Hinge Section:
You will need a damaged door or a cull door to use when you make your initial set up. Roll
the door into the machine and pull it back against the in-feed stop. Consider this stop to be the
fixed stop. It is on the left end of your machine, calibrate all the tapes for setting hinge and
lock locations from this location. Please don’t move this stop unless you want to calibrate
every tape on the machine.
Hinge Locations:
The commander will do almost any common door size and hinge routing pattern, the versatility
comes at a price however, since door swing change-overs are slower than most straight pre
hanging machines when you switch from interior to exterior doors. There’s a simple way to
make it just as fast explained below under “Alternate Pre Hanging Set Up”
Standard Hinge Center Set Up:
Reference hinge locations from the top of the door; to the top of each hinge pocket. For
instance 7’-11” hinge centers on an 80” door requires setting the first and third collars 7” and
65-1/2”. To move a hinge location, loosen the appropriate collar on the shaft below the hinge
router. Slide it so that its left edge indicates the measurement on the tape. Notice that there’s
two center shaft supports just in case your collar location overlaps. Be sure to set the collars so
that the tightening screws are horizontal, or the screw heads set the ferrous proximity sensors
on the router carriage. Tighten the collars firmly.
Instead of moving the collars for popular hinge patterns you can buy extra collar bars and the
exchange the whole bar with another that’s already set up. Three bolts secure the shaft in
place. The collars can even be roll pinned in place although a nail polish or paint slippage
mark make moving collars easy to spot.
Next, move the jamb reference blocks so they match the setting of the collars below. Use a
“T” handle Allen wrench (provided) to loosen the set screws clamping these reference blocks
in position. The white marks stamped into each block shows from which direction to read the
tape.
The door and jamb cylinder clamp fixtures that slide sideways so you can center them on the
jamb reference blocks. Loosen the four retaining knobs and line up the white plastic clamping
pads on the cylinders with the jamb clamping blocks.
Setting the Off Feed Stop:
To machine opposite swing doors, the off feed stop needs adjustment according to the formula.
Off Feed Stop = First Hinge + Last Hinge + Hinge Size