FASTER THROUGHPUT
MARKLESS INDEXING SYSTEM
DEDICATED JOINERY WORKSTATION
EXCHANGEABLE & VARIABLE INDEXING

Front View

Rear View

 

The Safety Clamp Spacer is used, and is essential, when milling one panel at a time, and that panel is less than 22" wide. The Spacer is used to balance the drop of the pressure bar when the air clamp is activated. Without balancing the drop, the pressure bar will over-drop on one side and jam, and maybe damage, the air pistons. The spacer must match the about-to-be-milled panel in height, meaning thickness. You might need a number of spacers of varying thicknesses. Your MEGA-ncw comes standard with a .75" high Safety Clamp Spacer. We offer one as an accessory, because we're taking a wild guess that at some point you'll lose the original one. 

When you double or multiple mill, you do not need this, but if you single mill, which we do here frequently, you MUST balance the pressure bar of the clamping system with a spacer like this. All it needs to be is a piece of scrapwood that is equal in height, meaning thickness, to the piece you're milling, and measures about 8" long and 4" wide or so. You don't even really need handles.

So why do we have two handles on ours? It's because we have a nasty habit of taking the safety spacer out and forgetting to put it back. Then we mess up the clamping system when we forget to use one and it's unbalanced. The second, or rear, handle locks the spacer under the crosspanel so that it stays on the platform template throughout a particular run when you need it.

Your inscribed vertical template has two short, black marks at its bottom edge. These indicate the locations of the air pistons on the backside of the crosspanel. You should put your spacer at the further "away" mark, as shown in the left-hand photo, depending on which fence is being used for your single panel milling.

The standard thickness or height is .75", but your others will be different if you mill thinner or thicker materials. We only make the .75" thick ones at this point, but you can use it as a pattern for making your own of different thicknesses.

#SCS        $ 29 + shipping

This layout/inking arc is not required, it just makes the inscribing look nice. The arcing line gives you a good stopping point when inking the indexing lines. Offsetting the red and black arcs helps reduce confusion among the lines. See the results photo. White melamine on MDF. Beveled edges reduce chances of ink smear. This is a nice little accessory.

#TA          $ 24 ea. + shipping

These extras are not required, but if your template library expands beyond the 6-array limit of your standard, included 3-pack, you'll need more. You can make your own, using one of these as a pattern, or make rectangular ones very quickly. These white ones, however, are beautiful when installed with the way they surround the centered decal. White melamine-on-MDF, sold as a 3-pack, these are NOT inscribed. They are reversible, however, and so there are 6-inkable surfaces (for arrays) per pack of 3 templates.

#CVTT          $ 49/ 3-pack + shipping

These stops are of a tough, red molded polymer, with a knurled tightening nut. They flip down in use, and up and out of the way when not needed to allow panels to pass by. The Flip-Stops are used to set a panel’s specified location when inserted into the Versidex MEGA, usually for mid-panel-face cuts. They can also be used to keep the Platform Riser in place against the crosspanel spacers when that is being used (see that item below, #9). These are sold in pairs because singles are not useful with the Versidex MEGA.

#WFS          $ 23/ pair + free shipping within the US 48

The Extension Table is not always required, but is necessary when a cabinet has multiple fixed shelves or vertical mid-partitions or dividers, and the panel receiving those mortises is longer than the MEGA’s standard fences can accommodate. The maximum length you can process with one flip-stop set-up is determined by the panel length and your shelf spacing, which together will give various maximum results. Your MEGA comes standard with only 2 Flip-Stops. For milling efficiency, you’ll need 2 more Flip-Stops (see this Accessory above, #7) for EACH additional fixed shelf in your cabinet, so that all of the shelf locations can be set up for double-milling without having to reposition any of the Stops.

The .75" thick Extension Table has a 1" thick build-up cleat that mounts onto the rear of the MEGA using a biscuit array and joining plates. The resulting TOP surface is even with the TOP surface of the MEGA's fixed rear Platform Template half. The butting ends of the Platform template and the Extension Table are both beveled to accommodate any slight height difference.

You will need to SUPPORT the Extension Table's end on a stand or a sawhorse and then make the panel level. Failure to support them properly, will surely DAMAGE them, the connectors, and maybe the platform edge as well.

Your MEGA now comes standard with a pre-biscuited Platform End Cap that fits into the biscuit mortises on the Platform's end when you're not using the Extension Table. Its top edge sits 1/8" lower than the Platform surface, and it is held by a single hex drive connector. If your older MEGA came not so equipped, we'll send you one with the Extension Table, along with Instructions for retro-fitting the rear edge of the MEGA's Platform to accept both the Extension Table and the End Cap.

The Extension Table includes two 44" double T-track rails and their mounting bolts, washers and nuts, the extension panel itself, its pre-biscuited build-up cleat, and two joining plates with their 4 bolts, acorn cap nuts, and washers for each plate. All MEGAs have a serial number stamped into the Left Front corner of the unit. Include this number on your Request Quote form, and we'll supply the End Cap if your unit didn't have one.

For instructions on how to attach the Extension Table to your MEGA, click on this link: Instructions are here.

#XTNT           $ 235 + oversize shipping & remember to order additional Flip-Stops above.

The Platform Riser is NOT required UNLESS your cabinet design uses an integral notched toe-kick. This accessory is an adjustable, flexible, Indexing Platform Riser, elevating your joiner to the exact height necessary to position your cabinet bottom flush with the toe-kick notch. It has 4 mounted levelers, so you can perfectly adjust the platform's height to each run of cabinet sides (the notch is likely to be just slightly different each time). The height range is about 3.75" to 4.5". For cabinets with a face frame front rail drop of another .75" or more, you can add a shim plate UNDER the  Platform Riser, and make your adjustments from there using your particularly calculated gauge bock, vs the supplied one that matches the template thickness.

The Platform Riser accepts mini-templates, laid out to match a given regular Vertical Template, giving you markless mortise-indexing for this type of cabinet. Three blank templates are included for you to lay out as needed.

If you can fit this item into your budget, it's very nice to have around when you need it. The Platform Riser comes with instructions on its set-up & use, for both framed and frameless cabinets, and there is a still-shot video under Videos on the Menu bar. 

#PRw4LV          $ 197 + shipping

These panel carts are not required, but we STRONGLY recommend them as part of the Versidex Transfer System. Because the Versidex MEGA works by you feeding panels into it, having a fast, efficient transfer system is essential to your saving time during the milling process. We do not make the carts. The freight on them is frightening, but you can source your preferred materials locally, do your own labor, and come out way ahead.

Plans come separately, and then you can order the number of wheels you will need. The wheels are 6” maroon polyurethane treads over polyolefin wheels, are non-locking, and are full-swiveling. They have grease fittings for easier maintenance. 

Your cart will have an elevated floor, which puts the uprightly-stored panels at a perfect height so you're not bending over to pick them up. Most carts you can find online have a very low floor, which can lead to back strain, but the low floor does keep the cart's center-of-gravity very low. This is a SAFETY issue. A high-floored cart, loaded with panels, will be more likely to tip-over when used carelessly, pushed sideways, or otherwise misused, having a high center-of-gravity. They easily handle a full load of .75" thick melamine-on-PBC kitchen base cabinet sides measuring 24x30.5", BUT that cart will be HEAVY, having a lot of MASS at just under 700lbs. If it runs into something, the impact will be substantial.

If used properly, these carts are the way to go. Since we built our first ones 25 years ago, we have never tipped one over. Then again, we work carefully, with safety first, no fooling around, aware of the carts' limitations, and all of that. These plans will guide you to make a cart body measuring: 50x16x32"h. There are two end platforms each measuring 19x9" that overhang the body on three of their four sides, bringing the final cart dimensions to 52x19x41"h, with 6" wheels providing 7.5" of that total height. The interior panel storage area ends up measuring 32x16x22"h, so the cart will hold about 40 panels that are .75" thick, because we angle the first panel slightly so they'll stay put.

Order one plan set, and choose the number of wheels you need for the number of carts you want to make. We use 4 carts as part of the full Versidex Transfer System set up, but you could start with TWO (at least) and add the others singly over time, having to order just the wheel sets. Order your wheels figuring 4 per cart at: #11. 4 pcs, #12. 8 pcs, or #13. 16 pcs, below

Plan set is:  #P4PC            $ 29 + shipping

Available in March 2015

A set of 4 panel cart wheels. Maroon polyurethane wheels on a grey polyolefin core; 6" diameter x 2" tread; full-swivel, non-locking; 900 lbs capacity per caster. Top plate mounting; plate is 4" x 4.5"; lag bolt slots are .375" wide; mounted height is 7.5"; grease fittings on axle and kingpin.

#PCW4          $ 78 + shipping

NOTE: Be aware that these wheels DO NOT come with mounting lag-screws, because the plans give you flexibility as to what you choose for cart-making materials. You’ll have to determine what lag screw length is best for your material. The mounting plate slot width is .375”, and there are 4 screws per wheel, so 16 screws per cart. You should use the maximum diameter possible, so, .375”, but the length is a variable depending on your material and whether or not you optionally double-plated the bottom where the wheels mount. You should also use a flat washer and a lock washer under the lag screw’s head, and account for those in your chosen length.

A set of 8 panel cart wheels. Maroon polyurethane wheels on a grey polyolefin core; 6" diameter x 2" tread; full-swivel, non-locking; 900 lbs capacity per caster. Top plate mounting; plate is 4" x 4.5"; lag bolt slots are .375" wide; mounted height is 7.5"; grease fittings on axle and kingpin

#PCW8          $ 152 + shipping

NOTE: Be aware that these wheels DO NOT come with mounting lag-screws, because the plans give you flexibility as to what you choose for cart-making materials. You’ll have to determine what lag screw length is best for your material. The mounting plate slot width is .375”, and there are 4 screws per wheel, so 16 screws per cart. You should use the maximum diameter possible, so, .375”, but the length is a variable depending on your material and whether or not you optionally double-plated the bottom where the wheels mount. You should also use a flat washer and a lock washer under the lag screw’s head, and account for those in your chosen length.

A set of 16 panel cart wheels. Maroon polyurethane wheels on a grey polyolefin core; 6" diameter x 2" tread; full-swivel, non-locking; 900 lbs capacity per caster. Top plate mounting; plate is 4" x 4.5"; lag bolt slots are .375" wide; mounted height is 7.5"; grease fittings on axle and kingpin

#PCW16          $ 286 + shipping

NOTE: Be aware that these wheels DO NOT come with mounting lag-screws, because the plans give you flexibility as to what you choose for cart-making materials. You’ll have to determine what lag screw length is best for your material. The mounting plate slot width is .375”, and there are 4 screws per wheel, so 16 screws per cart. You should use the maximum diameter possible, so, .375”, but the length is a variable depending on your material and whether or not you optionally double-plated the bottom where the wheels mount. You should also use a flat washer and a lock washer under the lag screw’s head, and account for those in your chosen length.

This template cart is NOT required, but like the panel carts, it is STRONGLY recommended as part of the Versidex Transfer System. Efficiency is improved, but more importantly, your ever expanding “library” of template sets is safely stored within the mobile cart. If you lean your large, platform templates against the wall and they aren’t moved for some period of time, and if the angle of lean is great enough, they will eventually bend and take that “set”, and that is not good for their doing their very important referencing job. One cart will store 24 unique arrays, far more than any shop should ever need.

We do not make this cart at this time. Plans come with 4 of the 2.5” red polyurethane, non-locking, full-swiveling wheels pictured above. You CAN buy the pre-drilled PLATFORM for the cart (see #15, next) if you order it with your new MEGA (it will ship on the pallet), or make your own, as you wish. The plans are not sold separately.

Plan set with wheels is: #P4TLC/4          $ 89 + shipping

Available in March 2015

Mobile template library cart base platform for #14. No wheels, they come with the plan set. This can only be shipped in the MEGA's pallet container, not separately later. Its width x length make shipping costs prohibitive. Made of .75" white melamine-on-MDF. This is the same platform that the MEGA mounts onto. You would build your template library cart on this platform using the plans in #14.

#MTLC-PL        $ 65 + shipping on the pallet only

The Keeper Bar collects multiple narrow pieces and lifts them to vertical for end-face cuts. It adds some downward pressure to help the stock ends maintain full contact with the referencing template surface. But it also keeps the pieces aligned as they're held only at the ends of the Crosspanel by the spring closers. Essential for multiple-milling, not everyone will use their MEGA this way, so we offer it only as an Accessory.

#KB     $ 37 + shipping

This is a quick, visual gauging chart to help you choose the template indexing array that works best, according to your criteria. It will tell you the two most important things you want to know.

First, according to the chart, you can find the minimum array spacing for the biscuit or connector size you’d like to use. Any array with wider spacing would then work, too, by default. The second thing it will tell you is whether or not the mortise closest to the front edge of the panel will blow out through the front edge, something we usually want to avoid. There is a little scale at one end of the chart, with various setbacks paired with the various biscuit and connector sizes.

There are 9 bands with unique array spacings from 2.5” to 4.5”. You are usually using the DEPTH of your panel to determine your array, but sometimes other edges are the determining factor. You’ll almost always be able to find a good match-up of panel and array. But if not, the instructions tell you how to employ a temporary mark to create the perfect asymmetrical array for that cabinet. Or if it is going to be a production item, you might want to make a new, dedicated template set especially for it.

The chart uses icons within the band that has the minimum array spacing for that size connector. Listed are: #0, #10, #20 & S6 biscuits, Simplex, Duplex, Bisco, and the entire Lamello P-Series of connectors. It measures 10" x 30".

#Chart1          $ 29 + shipping

Available in March 2015

The Lamello Classic X sets the standard for biscuit joiners. Beautifully machined and finished, this joiner pairs perfectly with the Versidex MEGA. In fact the MEGA was optimized in its design for the Lamello footprint and its external fittings. Watch this: Lamello Classic X video   Click here for Warranty details.

#LAMCX          $ 599 + shipping

The Lamello Top 21 is unique in its ability to adjust its cutting blade's REFERENCING height, and do so while retaining "memory" of the previous setting. We find that valuable for slightly off-setting a panel and its edging, or for creating a reveal between two pieces.Watch this: Lamello Top 21 video   Click here for Warranty details

#LAMT21          $ 1199 + shipping

The amazing Zeta P2 is a biscuit joiner and a whole lot more. We thought we would just let their video do the description instead of us rambling on about it. This machine opens up a whole new world of connectors for joining panels together. There are a lot of applications where given panel components will be too big for the Versidex MEGA to accommodate, but within the MEGA's capacity limits, user's will find plenty of appropriate and time-saving ways to pair the MEGA and the Zeta P2. Watch this: Lamello Zeta P2 video  Click here for Warranty details.

#LAMZP2          $ 1650, carbide blade + shipping

This is one of their ultra-quiet air compressors, operating at only 60 dbs. Its output is more than adequate for the pneumatic needs of the MEGA, including the blowgun. If you want to serve other equipment in your shop or factory at the same time, this unit might not be big enough. But for a dedicated, on-board air supply system, this is a top-notch compressor, and the best that we like all-around so far.

This item CAN be purchased later, separately and apart from the MEGA, and if you do so it would be drop-shipped by a 3rd party vendor for free. Click here for Warranty details.

#ROL-JC-10          $ 263 + free shipping within the US 48

This is the most compact, economical, and reasonably-large capacity system that meets the cfm and static pressure requirements for sufficient dust and debris control when used with the Versidex MEGA (175cfm & 60”sp). It has a 10-gal collection capacity, 6.5 Peak HP, 195 cfm, and 60” static pressure rating. The dust control is excellent, and remember, “Dust is the Enemy”. The boxy canister shape stores well on the MEGA's lower shelf, without the wheeled dolly, but the on/off switch is a bit awkward to reach unless you also opt for the iVac Switch Box, which controls the the vac for you with an automatic shut-off delay, #26, below.

You can use either paper collection dust bags, or the standard cartridge filter, which is not HEPA, or you can also order a HEPA cartridge filter, which we recommend, for $ 48. Frankly, the Versidex MEGA is for production use, so we think the bags' cost is a negative. They make for easier clean-out, though, so we'll leave the decision to you.

The vacuum’s dust port will accommodate the Lamello 1” dust hose's cone-shaped port-adapter, #24 below, if you pull off the vac-side screw-off connector from the native hose. It can be easily replaced when needed. You can put the native hose aside. The vac can be easily removed for use elsewhere, by just unplugging it, removing the Lamello dust hose, reconnecting the native fitting to the native hose and putting the vac back on its dolly if you want to wheel it around. Click here for Warranty details.

#SVDUST(#22)          $ 152 + free shipping within the US 48 
#HEPAC(#23)            $ 48 + free shipping within the US 48

We here at Versidex feel that these two devices provide more than the necessary performance to help you do excellent work. We are not tool dealers per se. We have established supply lines with these manufacturers at very small discounts, just so we can provide top-notch Versidex MEGA packages for those customers who really prefer one-stop shopping. Those customers want a well-designed and matched system. We try to provide that convenience at a price that is somewhat close to street prices. We will sell you a MEGA all by itself, if you prefer to crawl the web and track down better deals for these components, or to buy other components you might prefer. We don’t mind. Our main goal is to help you become the owner of a Versidex MEGA.

What is important for you to remember is that the on-board, lower equipment shelf is of limited size, and that to be self-contained, both the compressor and the vacuum will have to fit on there. More capacity can be added, by removing the lower shelf and adhering it to the mobile base. That increases the available height, but not the width. In fact, the width becomes MORE limited, but height might be MORE important in accommodating the tandem you want to use.

See the topic “#8. Alternative position for the lower shelf in the "Assembly Instructions for the 31" Versidex™ MEGA-ncw Rolling Stand" under Instructions on the Menu bar. We believe that self-containment plays a very important part in the overall Versidex experience and environment, and that you really should try to achieve that. Our recommended components do that, but so may other component tandems.

This collection hose from Lamello exactly fits their 1” joiner dust port. This is an excellent, very lightweight hose. The narrow diameter and great flexibility make it very maneuverable, particularly when standing the joiner up on its nose, as you do when making mid-panel face cuts. It may seem a little pricey, but our original one has lasted for 30 years now. We have changed vacuums about 5 times over that span, and the hose has worked perfectly no matter what the vacuum was/is (surely there are exceptions).

Another factor that comes into play is the D-ring hose & power cord controller. The Lamello hose and a joiner's power cord will fit through the D-ring. The Fein and Festool hose ends will not. We haven’t been able to find a larger swiveling D-ring, but those hoses could be hung below the D-ring, from the D-ring. This still leaves you with capacity reduction on the MEGA (see #25/a below), and those hoses are not as flexible, compact, or lightweight.

#LAMVH          $ 59 + shipping

 

The Lamello Top 21 and the Zeta P2 come with this port in their kits. The Classic X does not, for whatever reason. It must be purchased as an option. We regret this as well. It will cost an extra $10 to equip a Classic X, but you really must do it, and then purchase the dust collection hose that fits to it, #24. Read 25/a below for more information.

#LAM1DSTP          $ 10 + shipping

The three Lamello biscuit joiners come with a right angle dust port and a Festool-compatible dust port in addition to the 1” port (except the Classic X, as noted above). The right angle port is not at all compatible with the Versidex MEGA. The Festool-compatible port, can be used, but there are tradeoffs in capacity and 1st mortise cut distances-from-the-fences. The overall width capacity might be reduced from 31" to about 29". Biscuit locations can be adjusted to make this reduction unimportant, but you should be aware of the compromise.

The vacuum end of the hose is cone-shaped, as a variable port fitting. Festool and Fein need a 2.25”>1.5” reducer to accommodate the cone efficiently, and then you can put aside their native hoses and use the 1” Lamello hose. We do believe that buying the 1” Lamello hose and using the 1” Lamello dust port is your best overall solution.

This is their Switch Box model, with two power cords for two separately wired circuits. We sell this model of iVac so that you will always have enough on-board, self-contained control & protection even if you upgrade to higher amp-drawing machines of joiner, compressor, and vacuum, that could, at times, all be running at once and exceeding 15-amps.

If these systems are NOT all on-board, and you’re planning to run air and/or vacuum off of your shop systems, you don’t need this; you would benefit from getting a simpler, one-circuit, delaying iVac, though, if your vacuum system does not have a built-in shut-off delay feature, just to keep dust at a minimum, and to have it handled as well as possible. Remember, Dust is the Enemy. We can’t say that enough. You can’t hear it too much.

The Switch Box can be run on one circuit by plugging the left side cord into the Auxillary Outlet on the bottom right. The joiner plugs in on the top right, and the vacuum into the top left outlet. In this case, your air compressor plugs into a separate power source. Click here for Warranty details.

#iVAC15/20          $ 65 + shipping

This item is standard equipment on the MEGA-ncw. You don't have to buy another one, but you might find that you could use a second one, or maybe you've lost yours, so we've put it here just in case.

This small panel slides in under the Crosspanel from the rear of the MEGA to fill that gap during certain procedures. There are also two small blocks of unfinished MDF included that you use upright against the Vertical template, flushing up the Gap Filler with the surface of that template. You then activate the air clamp to hold it in place. The gap filler gives you a positive stop to push against, which comes in handy when you want to multiple mill and have to lift the pieces upright from the Platform template. It also supports narrow pieces when you make end-face cuts during multiple milling.

The panel is also used as a squaring block at the infeed side when multiple milling end-edge cuts. It's very helpful.

The panel measures 11 x 30.75 x 1.5", and has a nicely sized "D" handle that is off-set to what would be the rear when used. It is finished in "Acorn" like the pressure bar and lower shelf.

#PLCPGF          $ 78 + shipping

If your delivery address is within 60 miles of Hatfield, MA 01038, we will white glove deliver a Versidex as a fully assembled Rolling Stand and a fully assembled MEGA-ncw. We'll connect the two, and give about an hour-long introduction and demonstration of the working MEGA and its components. There are a number of variables, such as which brand joiner you have, what your air & vacuum systems will be, and what products you typically are making. We will email you for these details once we have received your Request Quote form. These details affect our preparations here and our on-site time, and affect what we'll charge for this service.

In figuring your true costs, you can deduct about three-quarters of this delivery and set up charge against what the cost of assembling it yourself would be, about 4-6 hours, and all of what your freight charge would be if you choose that delivery method instead. We will quote you both types of delivery to help you decide. Having us deliver will cost a fair amount, but it does get offset some. The hour of introduction and demonstrating is a stand alone charge and is an excellent value because we're already there and can provide that service without any additional costs like transportation. It's a pretty cheap way to get off to a good start with your new Versidex MEGA-ncw.

#D/SU          Calculated on your returned quote, after details are provided.