Pic 1 - Double TK MJ Splitter

Pic 2 - A Neat Idea - Two Saw Slots on the Same ZCI

Pic 3 - Double MJ Splitter Installed

Pic 4 - Check the Distance Behind the Saw Blade

Pic 5 - Mark the MJ Splitter Inserts

Pic 6 - Two Setup Boards are Required

Pic 7 - Create a Saw Kerf on Setup Board A

Pic 8 - Line Up the Drill Guide with the Saw Kerf

Pic 9 - Aligning the Drill Guide for the First TK MJ Splitter

Pic 10 - Securing Setup Board A

Pic 11 - Securing the Drill Guide on Setup Board A

Pic 12 - Drilling the MJ Splitter Location Holes

Pic 13 - Chamfer the Mounting Holes and Make a Test Cut

Pic 14 - Ripping Setup Board B

Pic 15 - Top View of TK MJ Splitter in the Kerf

Pic 16 – How To Determine the Width of the Gap

Pic 17 - Fill the Gap with Masking Tape

Pic 18 - Check the Fit

Pic 19 - Apply Masking Tape to the Drill Guide

Pic 20 - Insert the Drill Guide into the Saw Kerf

Pic 21 - Aligning the Drill Guide for the Second TK MJ Splitter

Pic 22 - Securing Setup Board A

Pic 23 - Securing Drill Guide on Setup Board A

Pic 24 - Drilling the location holes for second TK MJ Splitter

Pic 25 - Chamfer the Mounting Holes

Pic 26 - Choose the Second TK MJ Splitter

Pic 27 - Mark Both TK MJ Splitter Locations

Pic 28 - Ripping Sheet Stock

If you are new to the MJ Splitter, please watch the slide show in the 1/8" kerf MJ Splitter page for a full understanding of the basics before continuing on to this slide show.

Using Double Thin Kerf MJ Splitters for simultaneous use on both sides of stock is a revolutionary concept that now delivers a mirror copy of the same splitter duty to the off-cut side while keeping the same control on the keeper piece. It is now a FULL KERF splitter regardless of any variances caused by saw vibration or the thickness differences in saw blades. It is almost impossible to have a burn mark on either side of the stock with this setup when proper feeding technique is used.

This slide show is for illustration of the double MJ Splitter concept, and not as a printable set of illustrated instructions. Printable Installation Instructions will be available shortly on this web page.

Made in USA - Patent Pending

Certain table saws allow the ZCI to be rotated 180º. This feature allows the user to create two saw slots on the same ZCI. For example, one slot for a fully raised saw blade as instructed in the standard setup of a single MJ Splitter, and the other slot for a saw blade raised at only 1-1/8" for use with 3/4" stock. The shorter saw blade slot allows the MJ Splitter to be installed closer to the saw blade with a reduced gap distance.

Note:

(1) If your ZCI is equipped with a removable safety pin in the back, drill a matching hole in the front for the pin when the ZCI is used in reverse.

(2) The ZCI MUST fit in the opening snugly.

(3) The finger pull holes should be located in the center near both ends of the ZCI.

When using a saw slot for a 1-1/8" saw blade height, certain table saws allow for two MJ Splitters to be installed behind the saw blade. If your table saw does not allow the ZCI to be used in reverse, you may still install the double MJ Splitter with a new ZCI as long as you have enough room behind the saw blade. Measure the distance as shown in the next drawing (Pic 4) to determine if your ZCI is capable of this installation.

Place your mouse over the thumbnail to see the picture number.

With your original throat plate and saw blade raised to 1-1/8", measure the distance from the first exposed saw tooth at the back (level with ZCI) to the end of the ZCI (in a straight line). A minimum distance of 4" is required for the installation of two MJ Splitters behind the saw blade. If the distance is just shy of 4", lower the saw blade (not less than 1" above the ZCI - for 3/4" stock). You should not install double MJ Splitters if the distance is still less than 4".

Note: You may further lower your saw blade to obtain the 4" distance, but it will only allow thinner stock to be cut with that particular saw blade height.

We suggest you to note the height of the saw blade that achieves the 4" space and mark the saw blade height onto the ZCI for this setup as a reminder of the maximum height of saw blade and as a future installation reference.

For the double MJ Splitter installation, we suggest that you purchase an extra set of the Thin Kerf MJ Splitter inserts or the complete kit Model # SP-0100TK-4i (when it becomes available). Chances are two Splitter A or two Splitter B may be required for both the first and the second splitter locations to achieve the best effect.

For the best and most accurate results, we suggest that you number every insert. There are two small circular indentations on Splitter A "0" surface and the Splitter B one "+" sign surface. Write the number as shown and highlight all the "0" ,"+", “++” and “+++” signs on all surfaces with an ultra fine permanent marker.

Prepare two Setup Boards from 1/2" thick stock, preferably MDF or dimensionally stable plywood that is dead flat.

Dimension (both Setup Boards): 1/2" Thick x 15" Length x 4-1/8"Width

Setup Board A: Draw three pencil lines at the locations as shown - the drill guide will be installed on this board.

Setup Board B: Draw one pencil line that is 3" from the rear end of the board. This board is for measuring the offset distance for drilling the mounting holes for the second MJ Splitter.

Make sure the saw blade is raised at 1/4" above the top surface of the Setup Board and protrudes through the shorter slot on the ZCI created by the same Thin Kerf saw blade, which is raised not more than 1-1/8" in height.

Secure the rip fence at 2” to the right of and parallel to the saw blade.

IMPORTANT: Keep the rip fence locked in position until the installation is complete.

The saw kerf that you are going to create will be the alignment path for the drill guide. It is extremely important that the saw kerf is parallel to the right edge of the Setup Board. Using the GRR-Ripper® for this ripping procedure is the best way to ensure a parallel cut.

Feed Setup Board A through the saw blade and stop at the 3" pencil line from the rear.

*** Disconnect the power from the table saw ***

(1) Remove Setup Board A, raise the saw blade to 1-1/8" to fill up the entire length of the short slot, or to the maximum height at which the saw slot was created on the ZCI. Make sure there is at least 4" of space in a straight line from the end of the saw slot to the end of the ZCI.

(2) Replace Setup Board A in position and place the drill guide on Setup Board A by inserting the bottom center rib into the saw kerf.

Rotate the saw blade by hand with a working glove or a shop rag and adjust the location of Setup Board A back and forth so the first exposed carbide tooth at the back is flush and aligned with the first pencil line (3-1/4" from the front of the board - ref to Pic 6).

Place your mouse over the thumbnail to see the picture number.

Clean up any debris or chips between all contacting surfaces. Clamp Setup Board A in position while applying firm finger pressure (or very light feather board pressure) on Setup Board A against the fence so that the Drill Guide is tight in the saw kerf. This ensures that the right edge of the bottom rib on the Drill Guide is in full contact with the right edge of the saw kerf. This will also align the centers of the guide holes at the pre-determined distance from and parallel to the right edge of the saw kerf (the actual cut edge of the keeper piece), regardless of the saw blade’s thickness tolerance or any vibration.



Note: The illustration shows a fast and simple way of clamping the Setup Board by using a Hold-Down Clamp and the Stop from Micro Jig’s ZeroPlay Guide Bar System. You may also clamp a board bridged over the Setup Board from the edge of your table saw top.

*** Lower the saw blade just below the top surface of the board to keep the kerf fully open and to avoid accidental hand contact ***

1) Secure the Drill Guide onto Setup Board A using (4) #8 x 1/2" wood screws (provided). Pilot holes are not required if you use a power hand drill (the bottom of the screw holes are countersunk to accommodate any swarf from the drilling operation). DO NOT drive the screws all the way with the power drill to prevent stripping the threads - lightly tighten the screws with a Robertson or Phillips screwdriver.

2) If you prefer pilot holes, use a 1/8" bit to drill the pilot holes NOT MORE than 1/8" deep, and lightly tighten the screws by hand.

*** Lower the saw blade completely to avoid drill bit contact ***

Chuck the 5/32" drill bit into a power hand drill and carefully line up the drill with one of the guide holes. Hold the hand drill as perpendicular and steady as possible and drill through the four guide holes to make the TK MJ Splitter location holes on the ZCI.

IMPORTANT: Drill each hole in one single quick and continuous motion. DO NOT stop and go or re-drill the same hole, as this will enlarge the MJ Splitter location hole and the guide hole, thus resulting in a loosely fitting MJ Splitter.

Note: The pins on the MJ Splitters are 3/8” in length. Preferably, drill through holes on the ZCI. If your ZCI uses replaceable blanks thinner than 3/8” and has a metal frame under the required hole locations, the pins of the MJ Splitters need to be shortened.

The Thin Kerf MJ Splitter is designed with complex connecting features between the pins and insert body. It is best to have the rim of the mounting holes chamfered about 1/32" deep to provide relief to the radius edges on the pins. If the fitting is too tight, you may dip the pins in paste wax for easier insertion and removal.

** Make sure that you DO NOT move the rip fence and plug in the power to the table saw **

With the "0" side of the TK MJ Splitter facing the rip fence, make a rip cut on Setup Board B and stop at the 3" line from the rear.

** Now disconnect the power from the table saw again **

Test different Feather Effects from different surfaces facing the rip fence by feeding the Setup Board B through the TK MJ Splitter. Choose and keep the surface of your preference toward the rip fence. Note the insert number (ref Pic 5) and the surface (number of "+" signs) that is facing the rip fence.

We suggest you to choose the surface that just barely touches the kerf edge of the keeper piece, so you can "FEEL" the keeper portion of the Setup Board B comes in contact with the surface of the TK MJ Splitter that is facing the rip fence. That "FEEL" provides the "Mini Feather Board" effect and sends the "It is now safe" signal to you.

With the keeper piece portion in full contact with the rip fence, look down from the top of the TK MJ Splitter while it is in the saw kerf. You will notice the right surface of the TK MJ Splitter is in contact with the keeper piece and that there is a gap between the left surface of the TK MJ Splitter and the off-cut piece. The second TK MJ Splitter to be installed will eliminate that gap to provide a safer and cleaner cut.

To find out the width of the gap, it is best to use a feeler gauge. Completely fill the gap with a feeler gauge of the correct thickness - without pushing the off-cut piece away from its position. A feeler gauge is inexpensive and readily available through most automotive parts stores.

If you do not want to purchase a feeler gauge, you can use the method from the next drawing Pic 17.

Remove Setup Board B. From the reading on the feeler gauge, you can determine how many layers of masking tape will equal the thickness of the feeler gauge. We suggest using the blue masking tape from 3M, which is 0.004" in thickness. For example, if your feeler gauge reads 0.020", then you will need to apply five (5) layers of 3M blue masking tape to the left surface of the TK MJ Splitter.

If you do not have a feeler gauge, try to fill up the gap by adding one layer of masking tape at a time until it completely fills the gap.

With layers of masking tape applied on the left side of the TK MJ Splitter, replace Setup Board B in position to check the fit.

Remove the drill guide from Setup Board A. Layer equal amounts of 3M masking tape in strips of 3/8" x 1 - 3/4" and apply to the RIGHT surface of the bottom rib of the drill guide. Make sure the masking tape is not overlapping onto any other surface. Using a sharp razor or utility blade, trim off the masking tape around the guide hole areas. Apply finger pressure over the layers of masking tape to ensure that they stay securely in place.

Carefully insert the Drill Guide with the masking tape back into the saw kerf of Setup Board A, and make sure the masking tape remains in place.

((1) Raise the saw blade to 1-1/8" to fill up the entire length of the short slot, or at the maximum height at which the saw slot was created on the ZCI.

(2) Rotate the saw blade by hand with a working glove or a shop rag and adjust the location of Setup Board A back and forth so the first exposed carbide tooth at the back is flush and aligned with the second pencil line (4-3/4" from the front of the board - ref to Pic 6).

Clamp the Setup Board in position while applying firm finger pressure (or very light feather board pressure) on Setup Board A against the fence so that the Drill Guide is tight in the saw kerf. This ensures that the right edge of the bottom rib with the masking tape on the Drill Guide is in full contact with the right edge of the saw kerf.

*** Lower the saw blade just below the top surface of the board to keep the kerf fully open and to avoid accidental hand contact ***

Reinstall the Drill Guide onto Setup Board A using the (4) #8 x 1/2" wood screws. It is best to secure the screws manually to avoid stripping the holes.

*** Lower the saw blade completely to avoid drill bit contact ***

Use the same 5/32" drill bit to drill the location holes for the second TK MJ Splitter.

Observe the same precaution as illustrated in Pic 12.

The centers of the mounting holes for the second MJ Splitter are now offset to the left in relation to the mounting holes of the first MJ Splitter by a distance equal to the thickness of the masking tape used.

Chamfer the rim of the mounting holes about 1/32" deep.

Without turning on the table saw, use the existing saw kerf from Setup Board B and test the effects using the different surfaces of the remaining TK MJ Splitters. We suggest that you use the surface that just barely touches the kerf edge of the off-cut piece for the second TK MJ Splitter.

If possible, mark the insert number and number of "+" signs for the first and the second TK MJ Splitters on the ZCI. Very likely you will be using the same insert for both locations. These markings will ensure that you use the same insert in the same location each time they are removed and reinstalled. This will also eliminate any differences due to unavoidable manufacturing tolerances. You may also want to mark the saw blade height as a reminder.

We suggest that you obtain an extra set of TK MJ Splitter inserts or purchase the complete kit Model # SP-0100TK-4i (with four inserts) for the Double TK MJ Splitter installation.

The Double TK MJ Splitter concept not only works with smaller stock, it also works extremely well with sheet stock cut on the table saw. Feeding sheet stock on the table saw is usually performed using both hands. In order to keep the stock firmly against the rip fence during the cutting operation, the feeding pressure from left hand often pushes the work slightly towards the fence as well. This common but incorrect feeding technique also pushes the off-cut side against the left side of the spinning saw blade, which will cause burn marks or possibly even kickback. The Double TK MJ Splitter setup will not only prevent such occurrences, it will result in a much cleaner cut.

IMPORTANT: The MJ Splitter is a low profile splitter. The stock used must remain in contact with the top surface of the table saw, and proper hold-down pressure is always recommended. When feeding long stock, do not apply downward pressure on stock that is beyond the area of the table top, which will cause the front edge of the stock to lift.