Kval Commander - Alternative Set up for Pre Hangers; Double Beveled Doors

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Alternative Set Up for Pre Hangers:
It’s clear at this point that adjustments for interior to exterior doors involve more than most
standard pre-hanging machines. We have a simple solution that eliminates adjustments to the
hinge centers, off feed end stops and left and right shift. Unfortunately you will need to live
with the same hinge centers for both interior and exterior doors.
For example, if you run 7-11 hinge locations with 3 ½” hinges on your interiors then your
exteriors with 4” butts will be 6 3/4” and 10 ¾” respectively.
Here’s how it works. Set the machine up normally for 3 ½” centers. We will send you a three
position turret to replace the pin on the left side of the hinge router that’s changed for ½” or 1
¼” diameter router bits. Two of the turret positions will do the same thing as the pins-set the
router for it diameter. The third position will be located ¼” back from the 1 ¼” diameter bit
position.
We will also send you a new four position turret to replace your standard 5/8” radius turret.
Three positions are standard, the fourth position is ¼” back from the 3 ½” hinge rout. When
both the special ¼” back positions are selected you will get a 4” hinge rout with the same
centers as the 3 ½” pocket.
All the settings for opposite swing doors will be the same as interiors since the pockets have
not shifted ½” towards the right. You should color code the new turret bolts for reference.
Also, when cutting 4” butts with this set up you must remember pockets will be shifted ¼”
from the collar settings on the router indexing shaft.
To machine special doors with centers different from your prehungs, we highly recommend
using the standard turret positions – with the standard hinge center set up explained earlier. It’s
just plain confusing otherwise.
Double Beveled Doors:
Since, the router depth must be readjusted; change to a worn out chip out block, or a used block
for beveled hinge pockets. Adjust the router to the correct depth and you are ready to go. If
you need to do the jamb at the same time as the door, you will need to install beveled jamb
referencing blocks (or “H” blocks) that we can supply; other wise, if you rarely rout jambs with
bevel doors we suggest routing the jambs separately before changing the router to 3 degrees.
You can even mount half hinges and then drive in the pins with door and jamb out of the
machine.