SAFETY

SAFETY

CONTENTS

CONTENTS

� When adjusting the fence opening, neverposition the infeed or outfeed fence endscloser than 1/8" from the router bit.

� After making adjustments to the fencepositions, be sure to tighten the two sockethead cap screws through the large holes inboth the infeed and outfeed fences.

� When using fence settings in which the routerbit is partially recessed in the fence opening,always insure that the bit is centered withinthe opening.

� Never let the router bit come into contact withthe aluminum body of the INCRA Intelli-Fenceor INCRA Stop.

� Whenever using large diameter vertical orhorizontal panel raising bits or any other large diameter bit, always follow that router bit manufacturerʼs operation and safetyrecommendations.

� Whenever it is necessary to remove largeamounts of stock, always use multiple side by side passes to achieve the final cut.Several shallow cuts are safer and will yield better results.

Please read this ownerʼsmanual before use andkeep it at hand forreference.

The micro adjustable split fence design ofthe INCRA Intelli-Fence™ provides accessto many operations previously reservedfor specialty machines. From the straightedge cutting abilities of the jointer to themany edge forming functions performedby the shaper, your new Intelli-Fenceoffers a host of exciting new possibilitiesfor your router and shaper table.

It all starts with intelligent designfeatures. The opposing wedge design ofthe infeed/outfeed offset mechanismspermits very fine continuous adjustment ofthe fence offset from zero to 1/8", and eachoffset mechanism has its own hairlinecursor and scale marked off in 2/1000 of aninch increments. Position the fences “ in-line” for typical router table fenceoperations, and with the included tableclamps, you can use the Intelli-Fence inthe freestanding mode. Or, you can mountit directly to your INCRA Jig Ultra or Profor the ultimate router table fence setup.Itʼs completely compatible with all INCRAjoint-making accessories. The unique Hi-Rise™ fence cap and an adjustablefence opening take the hassle out ofworking with large panels and large routerbits for panel raising operations. All thesefeatures combined with the patentedINCRA Stop and a universal dustcollection port make the INCRA Intelli-Fence the intelligent choice for your router or shaper table.

OWNER’S MANUAL

®

Assembly . . . . . . . . . . . . . . . . . . . . . . . . 2

Mounting to your Router Table . . . . . . . . 3Attaching to your INCRA Jig . . . . . . . . . 3Freestanding Mode . . . . . . . . . . . . . . . . 3

Operation . . . . . . . . . . . . . . . . . . . . . . . . 4Offset Adjustment . . . . . . . . . . . . . . . . . 4Gap Adjustment . . . . . . . . . . . . . . . . . . 5Initial Fence and Scale Setup . . . . . . . . 5Fence Bridge Adjustment . . . . . . . . . . . 6INCRA Stop . . . . . . . . . . . . . . . . . . . . . 6

In-line Fence Applications . . . . . . . . . . . 6Vertical Panel Raising . . . . . . . . . . . . . . 6Joint Making . . . . . . . . . . . . . . . . . . . . . 7

Offset Fence Applications . . . . . . . . . . . 7Jointing . . . . . . . . . . . . . . . . . . . . . . . . . 7Shaping . . . . . . . . . . . . . . . . . . . . . . . . 8

Product Information. . . . . . . . . . . . . . . . 8

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . 8

Important safety instructions for using the INCRA Intelli-Fence:� Before using the INCRA Intelli-Fence, read

and follow all of the instructions and safetyinformation in this manual.

� When using the INCRA Intelli-Fence inconjunction with any other tool, first readand follow all instructions and safetyinformation in that toolʼs ownerʼs manual.

� Use appropriate safety devices. Alwaysuse a push stick, rubber soled push block,or other safety devices to keep your handssafely away from the cutting tool.

� When used in the freestanding mode withthe supplied table clamps, always makesure the clamping knobs are tightenedsecurely in place before making any cuts.

� If attaching the INCRA Intelli-Fence to yourINCRA Jig Ultra or Pro, always make surethe carriage clamp on the INCRA Jig is inthe locked position and the base is heldsecurely in place before making any cuts.

� Always turn off the power and make surethat the router bit has come to a completestop before changing the setting of any partof the INCRA Intelli-Fence or INCRA Stop.

From the makers ofINCRA JIG!• Split fence design• Micro adjustable• Universal dust collection port• Adjustable fence gap• Compatible with all INCRA

joint-making accessories

Second: Position inner rack 1" from outer racks

Attach Hi-Rise fence capAttach the two Hi-Rise fence cap braces

using (2) #10-32 x 3/8" phillips pan headscrews, #10 washers and #10-32 rectangularnuts. See Fig. 1. Loosely attach therectangular nuts to the screws then slide thenuts into the two T-slots provided. See Fig 1A.The two braces should be approximatelycentered on the length of the fences andspaced 16" apart.

Using the (2) #10-32 x 1/2" phillips pan headscrews, 5/8" o.d. nylon washers, and #10-32hex nuts, attach the Hi-Rise fence cap to thetwo braces as shown in Fig. 1 The slottedholes in the fence cap should be aligned toprovide access through the slots to the frontbrace mounting screws. Use a straight edgeto align the leading edge of the fence capwith the front face of the infeed and outfeedfences and tighten the two cap mountingscrews, Fig. 1A.

Assemble INCRA StopUsing the (2) #8-32 x 3/8" phillips pan

head screws and #8-32 hex nuts, fasten oneof the blue INCRA racks to the INCRA Stopand tighten the screws. See Fig. 2. Slide the3/4" x 5" plastic strip into the slot in the stopand secure with two 1/4-20 x 1/2" nylonthumbscrews. Thread the (2) 3/8-16 x 1/2"nylon thumbscrews into the INCRA Stop asshown. One or both of these thumbscrewscan be used to clamp the INCRA Stop to thefence. In use, the plastic strip provides anon-metallic stop surface which can beshaped for special stop setups and can bemicro adjusted by loosening the smallerthumbscrews.

Install INCRA racks oninfeed/outfeed fences

Insert the #8-32 x 3/8" phillips pan head screwsthrough the blue INCRA racks as shown in Detail 3A and loosely attach the #8-32 hexnuts. Slide the hex nuts on the racks into thesmall T-slots on the back of each infeed/outfeedfence. Place two racks on each fence.Position the outer racks flush with the fenceends and tighten the mounting screws.Loosely position each of the inner racks about1" from the ends of the outer racks. Nowclamp the INCRA Stop to the infeed fence sothat it bridges the gap between the inner andouter racks and tighten the inner racksʼmounting screws. Repeat for the outfeedfence. This bridging process aligns the innerand outer racks with one another for accurateINCRA Stop operation.

Caution: Tighten both screws on each rack.

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ASSEMBLY

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FIG. 1Attach Hi-Rise fence

FIG. 1AAlign fence cap with fence

FIG. 2Assemble INCRA Stop

FIG. 3Install INCRA racks oninfeed/outfeed fences

Straightedge

Hi-Rise fence capFence cap brace

#10-32 x 1/2" phillips pan head screw

#8-32 x 3/8" phillips panhead screw

1/4-20 x 1/2" nylon thumbscrews

3/8-16 x 1/2" nylon thumbscrews

Plastic stop strip

INCRA rack

#8-32 hex nut

Outerrack

First: Align outer racks flushwith fence end and tightenmounting screwsThird: Bridge gap with INCRAStop and tighten inner racks’mounting screws

Outerrack

INCRA Stop

Note: Hi-Rise fence cap, braces, and dust collection part not shown for clarity

5/8" o.d. nylonwasher

#10-32 hex nut

Inner racks

DETAIL 3ADetail of installation

#10-32 x 3/8"phillips panhead screw

#10 flatwasher

#10-32 rectangular nuts

#8-32hex nut

#8-32 x 3/8" phillipspan head screw

Fencecap

Fence

Assemble table clampsWith the table clamps on a flat surface,

insert the (2) #10-32 x 1/2" phillips pan headscrews through the #10 flat washers thenthrough the holes in the clamp and looselyattach the (2) #10-32 hex nuts. See Fig. 5.Slide the hex nuts into the T-slot in the fencemounting bracket and tighten the screws.The ends of the fence mounting bracketshould be flush with the clamp edges.Repeat for the other clamp.

Attach table clamps toIntelli-Fence

Position the Intelli-Fence on your router tablewith the opening in the fence centered onyour routerʼs collet. Insert the 1/4-20 x 2"socket head cap screws through the 1/4"washers then through the fence mountingbracket and loosely attach the 1/4-20rectangular nuts. Now slide the rectangularnuts into the T-slots on the rear of theIntelli-Fence. Tighten the clamping knobs tosecure the clamps to the table edge, thentighten the two socket head cap screws usingthe supplied hex key, Fig. 6.

FIG. 5Assemble table clamps

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FIG. 4Attach to your INCRA Jig

MOUNTING TO YOUR ROUTER TABLE

Important: Your INCRA Jig Ultra or Pro mustbe mounted to a 3/4" plywood base and thecarriage clamp must be in the locked positionbefore installing the Intelli-Fence.

Insert the supplied #10-32 x 1" phillips panhead screws through the 5/8" o.d. (gold)washers then through the holes on the back ofthe INCRA Jig Ultraʼs fence mounting bracket.Loosely attach the (2) #10-32 rectangular nuts.Now slide the rectangular nuts into the T-slot onthe rear of the Intelli-Fence. Position the fenceso that the INCRA Jigʼs carriage isapproximately centered on the fence length and tighten the two mounting screws.

Note: For mounting to the INCRA Jig Pro usethe shorter #10-32 x 1/2" screws.

Your new INCRA Intelli-Fence can be usedeither by clamping directly to your routertable or by attaching first to your INCRA JigUltra or Pro. Mounting directly to yourINCRA Jig adds incremental positioning

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Freestanding Mode

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Note: The table clamps are designed towork on router tables from 11/8" to 13/8" thick.To increase the thickness of a table less than11/8" thick, use double faced tape or glue toattach a wooden strip to the underside of thetable edge.

#10-32 rectangular nut

#10-32 x 1" phillips pan head screw

5/8" o.d. goldwasher

#10-32 hex nutFencemountingbracket

#10 flat washer

Table clamp

#10-32 x 1/2" phillipspan head screws

By looseningthe two phillipshead screws onthe table clampsthe fence anglecan be adjustedperfectly square toyour router table.

FIG. 6Attach tableclamps toIntelli-Fence

1/4" flat washer

1/4 -20 x 2" socket headcap screw

1/4 -20 rectangular nut

Attaching to your INCRA Jig Ultra or Pro

control to the already substantialfeatures of your INCRA Intelli-Fence.However, if you donʼt already own anINCRA Jig or you just prefer to use theIntelli-Fence independent of your

INCRA Jig system, the suppliedclamps and instructions below willallow you to quickly set up anduse the Intelli-Fence in thefreestanding mode.

Follow these steps to adjust either the infeed or outfeed fence for“in-line” or “offset” fence applications, see Fig 7:

Loosen the rear mounting screws on the Hi-Rise fence brace.

Using the supplied hex key, loosen the two socket headscrews through the large holes in the fence. Loosen each

screw one to two full turns, depending on the amount ofadjustment range needed.

Adjust the fence by sliding the rear wedge:

(+) to move the fence forward, slide the wedgeto the left to move the (+) end of the scaletoward the hairline cursor.

(-) To move the fence backward, slide thewedge to the right to move the (-) end of thescale toward the hairline cursor.

Note: The numbers on the scale representhundredths of an inch. Each of the smallertick marks on the top of the scale represent.002" (two thousandths of an inch).

Tighten the two socket head screwsthrough the large holes in the fence.

Tighten the rear mounting screw on theHi-Rise fence brace.

First: Loosen rearbrace mounting screw

FIG. 7Offset adjustment–top view

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Offset adjustment

Offset Adjustment

Offset Adjustment

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OPERATION

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OperationThe infeed and outfeed fences of theIntelli-Fence can be moved independently in two directions to provide a variety of setup configurations. By making the offsetadjustments described below, you canposition the fences “in-line” for standardrouting operations such as grooving,rabbeting, and joint making, or you can“offset” the infeed and outfeed fences forspecialty cutting applications such asshaping or jointing an edge. The gapadjustment allows adjustment of the openingbetween the infeed and outfeed fences from5/8" to 33/4". Follow the step by stepinstructions below to familiarize yourself withthese two basic adjustments, then do theinitial fence and scale setup described onpage 5 and youʼll be ready to put your newIntelli-Fence to work.

Caution: Always turn off the power andmake sure the router bit has come to acomplete stop before changing the setting of any part of the Intelli-Fence.

Second: Loosen (2) socket headscrews through large holes in fence

Third: Slide rear wedge toadjust fence offset

Fourth: Re-tighten (2) socket head screws

Note: Hi-Rise fence cap removed for clarity

Fifth: Re-tighten rear brace mounting screw

Initial Fence and Scale Set Up (In-line/mid-range position)

Initial Fence and Scale Setup (In-line/mid-range position)

Tighten the two socket head screwsthrough the large holes in both the

infeed and outfeed fence.

Tighten the rear mounting screwson each of the Hi-Rise braces.

Test the in-line setup by sliding astraight edged board down the

length of the fences. Fine-tune either theinfeed or outfeed fence as necessary.

Once the fences are located in linewith one another slide the infeed

and outfeed scales to read “0” under thehairline cursors.

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FIG. 9In-line/mid-range position

In order to position the scales foraccurate readout, the infeed/outfeedfences must first be positioned in-linewith one another with the adjustmentwedges at mid-range. Once the scalesare positioned youʼll easily be able toreturn the infeed/outfeed fences to thisin-line/mid-range position for standardin-line fence applications. Youʼll also findthe in-line/mid-range position a goodstarting point for any of the offset fenceapplications. Hereʼs how, see Fig 9:

Loosen the rear mounting screwson both Hi-Rise fence braces.

Loosen the two socket head screwsthrough the large holes in both the

infeed and outfeed fence.

Slide the rear wedge on each fenceto align the ends of the rear wedge

flush with the ends of the front wedge.3

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First: Loosen rear brace mounting screwson both fence cap braces

Second: Loosen (2) socket head screws throughlarge holes in both infeed and outfeed fence

Third: Align ends of frontand rear wedges flush

Fifth: Tighten rearmounting screws onboth fence cap braces

Sixth: Fine tune as necessary, then slidescales to read “0” under hairline cursor

Fourth: Re-tighten all(4) socket head screws

Note: Hi-Rise fence cap removed for clarity

5

Note the scale setting, then holdthe front and rear wedges together

as you slide the outfeed fence to open orclose the gap.

Make sure the scale setting is stillthe same (slide the rear wedge to

adjust if necessary) then tighten the twosocket head screws through the largeholes in the fence.

Tighten the front screws on the Hi-Rise fence brace.

Align and tighten the Hi-Rise fencecap if it was moved to access the

fence brace screws (see Fig. 1A, page 2).

Repeat Steps 1-6 for the infeedfence.

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Follow these steps to adjust the openingbetween the infeed and outfeed fences, see Fig. 8:

Caution: When adjusting the fenceopening, never position the fence endscloser than 1/8" from the router bit.

Loosen the front mounting screw onthe Hi-Rise fence brace. You can

either use a long shank phillips screwdriver to access the screw through theslotted opening in the red fence cap orsimply loosen the fence cap retainingscrews and pivot the fence cap to provideaccess to the front fence brace screw.

Using the supplied hex key, loosen thetwo socket head cap screws through

the large holes in the outfeed fence.

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Gap adjustments

FIG. 8Gap adjustments–top view

First: Loosen front bracemounting screw

Second: Loosen (2) socket head screwsthrough large holes in fence

Fourth: Re-tighten (2)socket head screws

Fifth: Tighten front bracemounting screw

Note: Hi-Rise fence cap removed for clarity

To avoid accidentallychanging the fence offset, it

is usually best to begin in anyIntelli-Fence setup by making the fence gap adjustment beforesetting the fence offset.

Gap Adjustment

Third: Holding front and rear wedgestogether, slide fence to open or close gap

SAFETY

FIG. 12Vertical panel raising

Adjust infeed/outfeed fences to thein-line/mid-range position as

described on page 5.

Use a straight edge to adjust theHi-Rise fence cap in line with the

infeed and outfeed fences. (See Fig. 1Aon page 2.)

Remember: Do not make the fullwidth of the cut in a single pass.

Instead, use several light side-by-sidepasses, moving the fence back 1⁄16" or so after each pass.

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IN-LINE FENCE APPLICATIONSOnce set to the in-line/mid-rangeposition as described on page 5, yournew INCRA Intelli-Fence can be usedfor a variety of typical in-line fenceapplications, including grooving,dadoing, and edge forming operations

such as rabbeting, chamfering, androundovers. Youʼll also find the in-lineposition useful for many specialtyoperations. With the Hi-Rise fence cap,youʼll be able to use vertical panelraising bits to make raised panels for

cabinetry, and since its design iscompatible with all INCRA joint-makingaccessories, youʼll be able to use theIntelli-Fence in conjunction with your INCRA Jig Ultra or Pro as ajoint-making fence.

Vertical Panel Raising

The introduction of the vertical panelraising bit has made cutting the reveal ona raised panel a relatively simpleoperation for the router table. Youʼll findyour new Intelli-Fence, with its built-indust collection, adjustable fence gap, and Hi-Rise fence cap, perfect for thisoperation. The setup is as follows, Fig 12:

Install vertical panel raising bit andset appropriate depth of cut.

Adjust fence gap as necessary (see Gap Adjustment on page 5).

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� Whenever using large diametervertical or horizontal panel raising bits or any other largediameter bit, always follow that router bit manufacturerʼsoperation and safetyrecommendations.

� Whenever it is necessary toremove large amounts of stock, always use multiple side-by-side passes to achievethe final cut. Several shallowcuts are safer and will yieldbetter results.

FIG. 11INCRA Stop

When used in conjunction with your newINCRA Intelli-Fence, the INCRA Stopprovides the same precise rack positioningcapabilities that made the INCRA Jigfamous. The sliding scale in the top of thefence becomes a versatile reference for usein setting stop positions at the router table.The adjustable plastic stop permits microadjusting of the stop positions anywherebetween the 1⁄32" tooth spacing on theINCRA racks. The bi-directional designallows the INCRA Stop to function on theinfeed or outfeed end of the fence with anythickness of stock.

INCRA STOP

INCRA Stop

INCRA Stop

The fence bridge can be mounted with either the narrow

or wide end in the openingbetween the infeed and outfeedfences. With the narrow end forwardthe fence opening will be 5⁄8". Thisopening is great for smaller jointmaking bits like the 1⁄4" and 3⁄8"straight or the 1⁄4", 5⁄16", and 3⁄8"dovetails. With the wider end of thefence bridge forward the opening isincreased to 11⁄8", perfect for use with larger dovetail bits.

FIG. 10Fence bridge adjustmentThe adjustable fence bridge is used during

joint making to provide support for narrowvertically held stock as it is moved past theopening between the infeed and outfeedfences. For all other cutting operations thefence bridge can be positioned behind thefront face of the Intelli-Fence and tightenedin place. For use during joint making, firstreturn the fences to the in-line/mid-range

position described above. Loosen thescrews that secure the fence bridge andslide it forward into the opening betweenthe fences. Adjust the fence gap asdescribed on page 5 to close the fenceends on the bridge. Now use a straightedge to locate the fence bridge flush withthe front face of the fence and tighten themounting screws. See Fig 10.

Fence Bridge Adjustment

Loosen mounting screws

and slide fence bridge forward for joint

making applications

Use straight edge to align fencebridge flush with fences

Fencebridge

Jointing

Most woodworking projects require that your boards beginwith at least one straight edge. This one straight edge thenbecomes the reference surface for subsequentperpendicular or parallel cuts. By using your Intelli-Fenceand the technique described below, youʼll be able to put aperfectly straight edge on your board at the router tableand, because of the higher RPM of the router, youʼll findthe freshly jointed edge far smoother than any jointermachine can produce.

Install a 1/2" diameter (or larger) straight bit and setthe depth of cut to slightly greater than the thickness

of stock to be joined.Adjust fence gap as necessary (see Gap Adjustmenton page 5).Adjust infeed/outfeed fences to the in-line/mid-rangeposition as described on page 5.Adjust the location of the Intelli-Fence at your routertable to place the outfeed fence in line with the

outermost cutting arc of the router bit. (A straight edgeplaced against the outfeed fence can be used to helpalign the fence with the cutter.) Fig. 15.

Micro adjust the infeed fence backward (-). Thereading on the scale will represent the amount of

stock you wish to remove from the boardʼs edge on eachpass. A light cut (infeed cursor reading between -1 and -2)will yield the smoothest results.

Adding an INCRA Jig Ultra or Pro to yourIntelli-Fence makes precise placement ofmultiple side-by-side cuts a cinch. One suchoperation requiring this kind of precision isjoint making. Once placed in thein-line/mid-range position, your newIntelli-Fence becomes a perfect replacementfor the standard straight fence commonlyused with the INCRA Jig. It is completelycompatible with all of the INCRA joint-making accessories, including the INCRARight Angle Fixture, Stop, and joinerytemplates. The setup follows, see Fig 13:

Adjust infeed/outfeed fences to thein-line/mid-range position as described

on page 5.

Position fence bridge and adjust fencegap as described on page 6.

Follow the instructions for the joint youwish to cut as detailed in the INCRA

Master Reference Guide and TemplateLibrary.

One of the most valuable features of the Intelli-Fence isthe ability to offset the infeed and outfeed fences. Theoffset fence adds a whole new dimension to the routertable, allowing it to perform two new operations—jointing, and shaping.

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FIG. 14Jointing

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OFFSET FENCE APPLICATIONS

1FIG. 15Jointing setup

First: Position Intelli-Fence toalign fence with cutting wingon the router bit

Second: Microadjust infeed fencebackward (-)

Straight edge

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FIG. 13Joint Making

Joint Making (INCRA Jig Ultra or Pro required)

Clearance is provided for between the Hi-Rise fence cap, the braces and all INCRA joint-making accessories. However, since the Hi-Rise fence cap and

braces are not necessary for joinery, you may remove them from the Intelli-Fenceif you prefer. Just reverse the assembly instructions described on page 2.

Outfeed fence

Infeed fence

For a product information brochure, call, write or fax to:Taylor Design Group, Inc.P.O. Box 810262, Dallas, TX 75381Tel: (972) 418-4811 Fax: (972) 243-4277Web Site: www.incra.com

PRODUCT INFORMATION

8

Made in America by:Taylor Design Group, Inc. � P.O. Box 810262 � Dallas, Texas 75381 1195

Printed in the U.S.A. © 1995, Taylor Design Group, Inc. INCRA is a registered trademark of Taylor Design Group, Inc.

WARRANTYTaylor Design Group, Inc. warrants this product for one year from date of purchase. We will repairany defects due to faulty material or workmanship, or at our option, replace the product free ofcharge. Please return the failing component only, postage prepaid, along with a description of theproblem to the address below. This warranty does not apply to parts which have been subjected toimproper use, alteration, or abuse.

LIFETIME WARRANTY ON POSITIONING RACKSIf an INCRA positioning rack in this tool becomes damaged for ANY reason, Taylor Design Groupwill replace it free of charge for as long as you own your tool. Return the damaged rack, postageprepaid, and allow 1 to 2 weeks for delivery.NOTE:Replacements cannot be sent unless damaged racks have been received by Taylor Design Group.

FIG. 16Shaping

FIG. 17Shaping setup

Distance between stock and outfeed fence– micro adjustoutfeed fence forward by thisamount

Outfeed fence

Infeed fence

Many shaping operations involve the removal ofthe entire edge of a square piece of stock as it ismoved past the cutter. Once the stock isremoved from the edge, it becomes necessary tosupport the freshly cut surface by moving theoutfeed fence forward. Although similar tojointing, the setup is slightly different. Hereʼs how:

Install router bit and set desired depth ofcut.

Adjust fence gap as necessary (see GapAdjustment on page 5).

Adjust infeed/outfeed fences to thein-line/mid-range position as described on

page 5.

Adjust the location of the Intelli-Fence atyour router table to achieve the desired cut

profile. Use a scrap piece of wood and make trialcuts to help in determining the fence position.

Make a fresh test cut about 3" long on apiece of scrap stock, then turn off the

router. Youʼll notice a gap between the freshlycut surface and the outfeed fence, Fig. 17.Simply micro adjust the outfeed fence forward bythis amount to support the stockʼs edge as itpasses the cutter.

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Shaping

For a product information update on the completeINCRA line of tools, please see your nearest dealer.If you are unable to locate a store nearby, or if youhave trouble finding a particular product, we willhonor your order directly.

Taylor Design Group, Inc.P.O. Box 810262, Dallas, Texas 75381 P: 972-242-9975 Fax: 972-242-9985www.incra.com