Bartender’s Bottle Opener Hardware Kit Instructions

For safe and effective operation, read these instructions fully before use.

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> For any tool used in conjunction with this product, always read, understand and follow the instructions and safety warnings for that tool.

> Before using this product, review and verify that all tools to be used with it have safety equipment installed and are in proper working order as definedbythetools’owner’smanuals.

> Do not use this product until you have read and are confident you understand the: • General Safety Warnings; • Selecting the Scales for the Handle; • Cut the Scales; • Mount the Scales; • Shape, Sand and Finish the Scales.

> Remain alert and use good judgment when using this tool. Do not use this tool if you are in any way impaired by medications, alcohol, drugs or fatigue.

> Dress appropriately and remove all jewelry, secure loose clothing and tie up long hair before using this tool.

> It is the sole responsibility of the purchaser of this tool to ensure that any third party reads and complies with all the instructions and safety precautions outlined in this manual prior to using the tool.

> Maintain these instructions and warnings as long as you own the tool. Keep this booklet in a place where it will be readily available for reference.

> The user assumes all risk for the proper use of this tool and for ensuring product suitability for intended application.

> Always wear safety glasses in compliance with ANSI safety standards and hearing protection and follow all standard shop safety practices including: • Keep your work area well lit and clean; • Use dust collection tools and dust face masks to reduce exposure to dust; • Use accessory safety equipment such as feather boards, push sticks and push blocks whenever appropriate; • Do not use power tools in explosive environments (e.g., in the presence of flammable liquids, fumes or dust); • Keep children and bystanders away while operating your tools; • Maintain proper footing at all times and do not overreach; • Do not force the tool; • Unplug all power tools before making any adjustments or changing accessories.

> These warnings and instructions do not represent the total of all information available regarding tool safety, use and technique. Always seek out opportunities to learn more and improve your skills and knowledge.

This tool is designed for specific applications as defined in the instructions and should not be modified and/or used foranyotherapplications.BeforeusingtheBartender’sBottleOpenerHardwareKit,read,understandandfollowallinstructions and safety information provided. KEEP THESE INSTRUCTIONS FOR FUTURE REFERENCE.

GENERAL SAFETY WARNINGS

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Selecting the “Scales” for the Handle1. The pieces for the handle are called “scales” and can be cut from domestic or exotic hardwoods, acrylic, bone, antler or other suitable material. (They are not included with the kit.) For this kit, start with scales that are at least 6" long by 2" wide and 1/4" to 3/8" thick.

2. Identify and label the inside and outside face of each scale.

Cut the Scales1. Decide how you want to shape the ends of the scales. See the Shop Drawing on page 4 for three possible templates, or come up with your own shape.

2. If using one of the shapes from the Shop Drawing, make sure to print it out at 100%. Cut out the template and trace the shape on each scale, taking care to position the template in similar locations on the scales to preserve grain symmetry. (If not using the templates, draw the desired shape on the ends of the scales and use the Bottle Opener body to trace the curves on the sides.)

3. Using a coping saw, scroll saw or band saw, cut the scales to shape, leaving the trace line.

4. Sand the end profiles through progressive grits, up to 600, to finalize the shape and smooth the edges.

Mount the ScalesThe kit comes with one long Pin that can be cut with a hacksaw and be used to help mount the scales. Use of the Pins is not required, however, and might not be desirable if you are working with highly figured scales or prefer a solid effect.

To Mount Without Pins:1. Apply a thin coat of CA glue or epoxy to the inside face of one scale and press it against one side of the Tool Body. Clamp in place and allow glue to cure.

2. Apply a thin coat of CA glue or epoxy to the inside face of the other scale and press against the other side of the Tool Body. Clamp in place and allow glue to cure.

To Mount With Pins:1. Apply a thin coat of CA glue or epoxy to the inside face of one scale and press against one side of the Tool Body. Clamp in place and allow glue to cure.

2. Using the holes in the Tool Body as a guide, drill 1/8" holes through the scale to accommodate the Pin. Place a sacrificial backer board under the scale to avoid tear-out. Fig. 1.

To avoid problems when installing the pins, it is important to drill holes as close as possible to perfectly vertical.

3. Apply a thin coat of CA glue or epoxy to the inside face of the other scale and press against the right side of the Tool Body. Clamp in place and allow glue to cure.

4. Using the holes you drilled in the first scale as a guide, extend the 1/8" holes through the second scale. Fig. 2.

5. Apply a drop of CA glue to the Pin and press it into one of the holes you drilled in the scales, making sure that the Pin goes all the way through to the outside face of the other scale.

If the fit is snug, a Spring Tool nail set (12394, sold separately) makes it easy to carefully tap the pin into place.

6. Use a hacksaw to cut the excess Pin material just above the scale. (You’ll file or sand it flush during final shaping.)

7. Repeat Steps 5-6 to install the Pin in the other hole you drilled in the scales.

Shape, Sand and Finish the Scales1. Using flat and round files, a power sander or handheld sandpaper, shape the outer edges of the scales flush with the Tool Body and refine the thickness and profile of the handle until the desired contour is achieved.

2. Sand the scales and Pins through progressive grits, up to 600.

3. Apply the finish of your choice to the scales, keeping in mind that, as the Opener is handled, the handle will come in regular contact with oils that could degrade the finish.

4. Polish as desired.

Check Rockler.com for updates. If you have further questions, pleasecontact our Technical Support Department at 1-800-260-9663 or support@rockler.com

Fig. 1

Fig. 2

Sacrificial backer board

Scales

4 Distributed by Rockler Companies, Inc. ©2016 Rockler Woodworking and Hardware55391Rev 11/16

Shop Drawing