Toe Notch Plate

Abstract

The Toe Notch Plate attaches to a standard router and maintains the router at approximately a 75 degree angle from the work piece and is adjustable for use with ¾″ or ½″ material. It also maintains the router bit a consistent distance from the edge of the work piece. When the router is moved along the edge of the work piece it will create an angled groove providing a resting point for a nail gun and an entry point for brad nails. This allows the grooved piece to be toe nailed to another piece of wood which typically will be perpendicular.

Claims

1. The Toe Notch Plate is a plate that when attached to a router will create a groove the proper distance from the edge of a piece of wood to allow for the nose of a pneumatic nail or staple gun to rest on and provides an entry point for a nail or staple.

2. The toe notch method provides a means of attaching a face frame to a cabinet carcass with a nail gun without leaving blemishes on the finished side of the face frame.

3. The toe notch method provides a means of attaching a face frame to a cabinet carcass by providing a means to drive the nail from the cabinet side into the face frame, rather than through the face frame into the cabinet side.

4. The Toe Notch Method of attaching a face frame to a cabinet is stronger than nailing from the face frame into the plywood side.

5. The Toe Notch Method of attaching a face frame to a cabinet takes less time than the Biscuit, Pocket Hole, or Glue & Clamp methods.

6. A toe notch groove can be achieved with any device holding a cutter in this orientation or holding the cutter at 90 degrees from this orientation and using the side of the cutter. The toe notch groove allows the face frame to be mounted with a nail gun or staple gun but without visible nail heads or blemishes.

Description

DESCRIPTION OF THE DRAWINGS

[0011] FIG. A: This is the top view of the Toenail Plate. Number 1 is one router base mounting hole. Number 2 is the router bit clearance hole. Number 3 is the router base mounting hole for 0.75″ thick material. Number 4 is the router base mounting hole for 0.5″ thick material. Number 5 is the edge guide.

[0012] FIG. B: This is the end view of the Toenail Plate. Number 6 shows the router mounting surface. Number 7 shows the edge guide. Number 8 shows the work piece contact area.

[0013] FIG. C: This is a 3-D view of the Toenail Plate.

[0014] FIG. D: This is a 3-D view of the Toenail Plate with the router bit in the router bit hole. It also shows how the plate sits on the work piece.

[0015] FIG. E: This is the side view of FIG. D. Number 9 shows the work piece. Number 10 shows the Toenail Plate. Number 11 shows the router bit.

[0016] FIG. F: This shows the router bit. A standard 0.75″ dado bit can be used.

[0017] FIG. G: This is the end view of the Toenail Plate.

[0018] FIG. H: This is the side view of the work piece. Number 12 shows the angled groove that is cut by the router when the Toenail Plate is used.

[0019] FIG. I: This is a 3-D view of the work piece attached to the face frame with nails. Number 13 shows the nails attaching the two pieces.

[0020] FIG. J: This is a side view of the work piece attached to the face frame. Number 14 shows the work piece, which for cabinet making will be the sides, top or bottom of the cabinet carcass. Number 15 shows the nail attaching the two. Number 16 shows the face frame. Number 17 shows where the head of the nail gun rest and where the nail enters into the work piece.

DETAILED DESCRIPTION OF THE INVENTION

[0021] The Toe Notch Plate is made of a single piece of sheet metal (could be any rigid material) with 3 bends (FIG. B), three mounting holes (FIG. A, #1, 3 & 4) and one large clearance hole (FIG. A, #2) for the router bit (FIG. E, #11) to pass through. One of the bends creates an edge guide (FIG. B, #7) and the other two bends work together to create the work piece contact area (FIG. B, #8).

[0022] The Toe Notch Plate will typically be mounted to a standard router such as a Porter Cable Router. But it could be fastened to any type of motor. To do this the factory sub base must be first removed by removing the 3 mounting screws that hold the sub base onto the router base. Once these screws are removed, take off the sub base and set it aside. It will not be needed while using the Toe Notch Plate. With the router base facing up, place the Toe Notch Plate on the router base with the router mounting surface (FIG. B, #6) down so that it contacts the router base. Using the screws that were removed from the router sub base, insert a screw through screw clearance hole #1 in FIG. A. If working with 0.75″ material insert a screw through hole #3 in FIG. A. If working with 0.5″ material insert a screw through hole #4 FIG. A. Ensure all screws are tightened.

[0023] A 0.75″ router bit must be installed in the router as per the router manufacturer's procedures. When working with 0.75″ material, set the router bit so that it extrudes approximately 0.3125″ past the Toe Notch Plate. When working with 0.5″ material, set the router bit so that it extrudes approximately 0.25″ past the Toe Notch Plate.

[0024] Once the Toe Notch Plate is attached to the router, place a work piece securely on a worktable. With the router on, place the edge guide (FIG. B, #7) against the edge of the work piece and the work piece contact area (FIG. B, #8) on the top of the work piece (FIG. D). Traverse the router (with the Toe Notch Plate attached) along the desired length of the work piece to create the toe notch (FIG. H, #13)

[0025] Once you have the toe notch in the work piece, place the face frame adjacent to the work piece (FIG. J). Then place the nose of the brad or nail gun against the nail entry ridge (FIG. J, #18) and press the trigger inserting a nail (FIG. J, #16) through the work piece into the face frame

[0026] The Toe Notch Plate is made out of sheet metal, but is could also be made out of any hard material such as plastic or wood. It is used it for attaching a face frame to a cabinet box, but it also could be used in other applications that need an angled groove.