USER MANUALINDUSTRIAL & COMMERCIAL SERIES

(60° Shoulder Profile)Dual Blade Tenon Cutters

MODELS:Industrial Series - TTA0750Industrial Series - TTA1000Industrial Series - TTA1500Industrial Series - TTA2000Industrial Series - TTA2000LIndustrial Series - TTA2563Industrial Series - TTA3000Commercial Series - TAC1000Commercial Series - TAC1500Commercial Series - TAC2000

Lumberjack Tools Inc.PO Box 730Chippewa Falls, WI 54729www.lumberjacktools.comEmail: info@lumberjacktools.comPhone: 715-720-4719Rev: 2/17

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Our lifetime guarantee covers the tool body and shank. The blades arecovered for 90 days from the date of purchase for breakage under normalworking conditions. Blades will dull faster cutting hardwoods vssoftwoods (peeled or unpeeled). Soil and other abrasive substances willreduce blade life and is not covered under this warranty. When making aclaim, you must show proof of purchase from an authorized distributor.This is valid only to the original buyer, and not for tools sold secondhand,used, or sold “as is” to a second party.

What Voids WarrantyIn order to keep our lifetime and 90 day warranty you must AVOID thefollowing actions:

● Operating the tool in a drill press or lathe (or any system other than ahand-held drill)

● Running the tool into a nail or foreign object● Altering or misusing the tool

About Your ProductThank you for purchasing our Dual Blade - Tapered Shoulder Tenon Cutter!Lumberjack engineers, along with our craftsmen, have designed the safest,easiest-to-use tenon cutters on the market. By combining old world skillswith 3D CAD modeling and CNC manufacturing, we have created the idealtenon cutter: straight tenons, smooth finish, precision operation, and longlife.

Dual-bladed tenon tools will cut a tenon in half the time of a single-bladedtool. Wear is reduced by putting force of cutting across two blades insteadof one. The blades are stamped, heat treated and precision ground toprovide years of service if properly maintained. The Industrial tools aremachined from a solid aluminum billet and the Commercial tools are madeof die-cast aluminum.

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SAFETYBefore beginning any project, carefully read and follow ALL safety and

operational instructions for any tools or devices you will be using. Failure to doso may cause physical harm to yourself or those around you. If you feel

uncomfortable using our tenon cutters or any other tool, STOP immediately.Lumberjack Tools assumes no responsibility for injury caused to the operator,

bystander, or tools used in conjunction with the use or misuse of our tenoncutters.

NEVER OPERATE POWER TOOLS UNDER THE INFLUENCE OFDRUGS, ALCOHOL, OR ANY MEDICATIONS

ALWAYS WEAR SAFETY GLASSES, DUST MASK, AND ANY OTHERPERSONAL PROTECTION ITEMS AS NEEDED

NEVER WEAR LOOSE ITEMS THAT COULD BE CAUGHT IN MOVINGPARTS. SECURE LOOSE OR LONG HAIR AWAY FROM AREA

WE STRONGLY RECOMMEND A SINGLE-SPEED, GEAR DRIVENDRILL WITH RPMS OF 500 OR LESS. EXCEEDING THESE RPMS MAYRESULT IN DAMAGE TO THE TOOLALWAYS DISCONNECT POWER AND ALLOW DRILL TO COME TO ACOMPLETE STOP BEFORE INSTALLING, REMOVING, OR ADJUSTINGTHE TOOLNEVER APPLY BENDING FORCE (SIDE LOADING) TO THE TOOL. SIDELOADING COULD CAUSE THE SHANK TO FAIL, OR MAY RESULT INBLADE DAMAGE

ALWAYS SECURE THE LOG IN A VISE OR CLAMP PRIOR TOSTARTING YOUR DRILL. FAILURE TO DO SO MAY RESULT IN INJURY

ALWAYS HANDLE THE BLADES WITH EXTREME CARE! FAILURE TODO SO MAY RESULT IN SERIOUS INJURY

WHEN EXCESSIVE FORCE IS REQUIRED TO CUT, RE-SHARPEN ORREPLACE THE BLADES. A SHARP TOOL IS A SAFE TOOL!

NEVER PUT HANDS OR ANY BODY PART INSIDE THE TOOL WHILE THEBLADES ARE ATTACHED! DOING SO MAY CAUSE SERIOUS INJURY

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Industrial Series ONLY

Quick Stop Installation

● Install the quick stop pin throughthe tool body

● Secure with the supplied acorn nut

● The length of the tenon isdetermined by measuring fromthe top of the blade to the bottomof the Quick Stop Pin

● In the image to the left, dimension“X” represents the length of thetenon

X

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Correct (smaller tenon) Correct (larger tenon) WRONGThe tenon diameter is variable based on the blade offset. Smaller offset= smaller tenon, larger offset = larger tenon. 3/16” blade offset is agood place to start, but you will want to test tenon fit in holes toachieve the correct offset (we recommend writing the results down).DO NOT set the blades beyond 5/16” or the blade edge will not contactthe log and will not cut.

1/8” 1/4”

Setting the BladesMax Log Capacity

Series Max LogDia.

TTA0750 3.25”TTA1000 3.50”TTA1500 4.00”TTA2000 4.50”TTA2500 5.00”TTA3000 5.50”TAC1000 3.50”TAC1500 4.00”TAC2000 4.50”

● Install and securethe blades with theButton Head CapScrews

● Take care to keepthe blade offset ofboth blades equal(see below)

CardboardSpacer

Blade Offset

● The cardboard box that the toolcomes in is about 1/8”

● Remove a piece of box to use as aquick spacer for blade setting

TIP

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Included with your tool arethe TB2500 Blade Shims

Would you like to cut smoothertenons?

Pros of using shims:● Smoother tenon● Reduced drill torque● Less aggressive blade bite

Cons of using shims:● Increased time to cut● Slightly weaker glue joint

Installing shims:● Place a shim underneath a

TB2500 blade and secureboth with screws as shown

● The shim should NOTextend into cutting area orcover the sharp edge of theblade

● If installed properly the rightedge of the shim will beflush with the right edge ofthe blade (the non-cuttingedge)

Blade

●

Screw

●

Shim

●

Determine tenon length before cutting

● The key is to have a gapbetween the end of thetenon and bottom ofthe mortise hole

● This can be done bymaking the tenon 1/8”to 1/4” shorter than themortise hole is deep

Hole Depth

1/8” to 1/4”Gap

Tenon Length

Tenon Size

Desired TenonLength

Cut Mark

Log Diameter

Calculated Tenon Length

Cut Mark = [(Log Dia - Tenon Size) x .87] + Desired Tenon Length

Gather the followinginformation and use thecalculation providedbelow:

● Tenon Size● Log Diameter● Desired tenon

length

Simple Tenon LengthPlug Length

Tenon Length

● Tenon length can be controlled by usinga stop plug in the tool body

● Cut off a piece of tenon to use as a plug● Use the calculation:

Tenon Length = 2.9” - Plug Length● Example:

2.9” - 1.9”(plug length) = 1” tenon

Example:● Tenon Size = 1.5” (TAC1500)● Log Diameter = 3.25”● Desired Tenon Length = 1.75”

Cut Mark = [(3.25” - 1.5”) x .87] + 1.75”Cut Mark = [(1.75”) x .87] + 1.75”Cut Mark = [1.52”] + 1.75Cut Mark = 3.27”

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WARNING: If the log comes loose or unclamped while cutting the tenon,DO NOT drop the drill or try to grab the log! Stop the drill and remove itfrom the end of the log. Re-secure the log, and resume cutting

● Obtain the log you want to tenon

● Cut it to length and make sure the endsare flat. If the ends are not even/flat, thetenon will be crooked

● If the log diameter islarger than the tool canaccept, taper the endwith a draw knife

● Secure the log in a vise, clamp,or fixture with a “V” shapednotch

● The Log Lock (LL1545) is a safe,easy, economical way to clamplogs, and is available on ourwebsite

Cutting Tenons

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ALWAYS unplug the drill before adjusting the blades oradjusting the chuck

● Make sure the tool is square against the end of the logbefore cutting

● If the tool is held at an angle the tenon will be cut angled

Cutting Tenons (cont.)

4● Carefully install the tenon

cutter into an unplugged 1/2”drill, and tighten it firmly. Usethe tee handle to tighten thechuck

● Square up to the log so thatthe cutter is flush against theflat face of the log

● Apply body pressure by leaninginto the drill before starting thedrill

● Pull the trigger to cut the tenon

● Wait until the drill comes to astop before removing thecutter from the log

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CORRECTDrill in-line with log

WRONGDrill not in-line with log (crooked)

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Drilling Holes (Mortise)

● Measure and mark the locations of allholes before drilling

● Place the center of the bit on thedesired hole location

● Take care to hold the drill perpendicularto the log

● Use a forstner bit (or spade bit) to drillthe hole

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2● Drill mortise between

1/3 and 1/2 of the logdiameter

● Do not drill more than1/2 of the logdiameter unless aspecific project callsfor a deeper mortise

Additional Tips● It takes time to master using

these tools● Make a plan of what you want

to build before you begin● Have a list of all tools and

materials you will need

● Do not over complicate your firstfew projects

● Practice reading the natural twistsand defects in the wood

● Practice cutting tenons and usingthe tools on scrap material

1/3 Diameter

1/2 Diameter

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Maintenance

● Body- Cleaning○ Keep the tenon cutter body clear of sap and other build-up○ Always remove the blades before cleaning○ Clean the tool with a solvent (such as mineral spirits)

● Blades- Care○ Always wipe blades with a thin film of oil at the end of the day

to help prevent oxidation- Cleaning○ Clean the blades with a solvent (such as mineral spirits) and

immediately apply a thin film of oil to prevent oxidation- Sharpening○ Use a sharpening stone or file to re-sharpen the blades, then

clean the blades and apply a thin film of oil● Shank

- Replacement○ If your shank breaks, we offer replacement shanks (see first

page for contact information)○ Turn the shank counter-clockwise to remove○ Turn the shank clockwise to install

WARNING: ALWAYS HANDLE THE BLADES WITH EXTREME CARE!FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY

TASK EACH USE MONTHLY

Clean blade pockets X

Clean cutter bore X

Clean blades X

Inspect blades X

Oil blades X

Oil shank & screws X

PO Box 730 • Chippewa Falls, WI 54729 • 715.720.4719 • www.lumberjacktools.com

Thank you again for purchasing our tools!

PROBLEM CAUSE SOLUTION

• Tool Skips offto one side orbounces around

• Log is larger than tool willaccept

• Taper down the end of thelog with a draw knife

• Not enough pressure is beingapplied • Lean into drill with body

• Not cutting log

• Log is larger than tool willaccept

• Taper down the end of thelog with a draw knife

• Blades are slid too far back • Position blades so they areback no further than 5/16"

• Blades are dull• Not applying enoughpressure

• Sharpen blades• Purchase new blades• Lean into drill with body

• Takes toomuch of a "bite"

• Aggressive cutting from dualblades

• Remove one blade or"shim" blade up to .020”

• Crooked Joint • Holding drill crooked whilecutting

• Position the drill squareagainst the log before cutting

• Drill stops orcuts on smalldiameter logsbut not largerones

• Using a variable speed drill• Make sure you are using asingle-speed drill with lowRPMs

• Using a non-Milwaukeebrand drill

• We recommend purchasinga Milwaukee brand hole hogdrill

• Spiral grooveson the tenonjoint

• Lateral wobbling of the drill • Hold the drill as steady asyou can while cutting

• Removing the cutter whiledrill is still spinning

• DO NOT remove the cutteruntil the drill has come to acomplete stop

Troubleshooting

Engineers and Quality Control staff at Lumberjack Tools have providedyou with one of the easiest to use and safest tenon cutters on themarket. However, there is always the unexpected chance of failure.● Please contact our customer support for a replacement if a failure

ever occurs to the tool body, shank or blades

Unexpected Occurrences