Woodhaven 204 User manual

204
Router Fence
Owners Manual
Please Read Carefully!
Parts List:
Please identify and verify that you have all of the
parts listed and shown on this page prior to assembly.
Parts listed in this box are shown in photos in the
instructions.
Part Description Quantity
204A 48” Aluminum Fence . . . . . . . . . . . . . . 1
204B 24” Fence faces, pair . . . . . . . . . . . . . . . 1
200C Fence Base, set of 2 pcs. . . . . . . . . . . . . 1
200E End Blocks. . . . . . . . . . . . . . . . . . . . . . . . 2
200D Dust Port Blocks . . . . . . . . . . . . . . . . . . 2
281 Dust Port . . . . . . . . . . . . . . . . . . . . . . . . . 1
200F Dust Port Plate . . . . . . . . . . . . . . . . . . . . 1
202G Guard Insert . . . . . . . . . . . . . . . . . . . . . . 1
3724RL Tapes, L & R. . . . . . . . . . . . . . . . . . . . . . . 1
224 Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
200FS Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
200SC Fence Clamps for 202 & 203, pr.. . . . . 1
240 Hold-Down. . . . . . . . . . . . . . . . . . . . . . . . 1
242 Hold-In. . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Part# Description Qty.
MF015 1” Screw 1
Part# Description Qty.
MF006 5/8” Screw 4
Part# Description Qty.
5793B Barrel Nut 8
Part# Description Qty.
5771B 3/4" Screw 2
Part# Description Qty.
5505 Thumb Screw 2
Part# Description Qty.
5720 2-1/4" T-Bolt 6
Part# Description Qty.
MF010 3/4" Screw 6
Part# Description Qty.
5760B Oval Nut 5
Part# Description Qty.
BUSH004 5/8” Spacer 4
Part# Description Qty.
BUSH002 1/4" Spacer 2
Part# Description Qty.
5540 Knob 6
202 Router Fence
shown

1
FENCE ASSEMBLY
You'll need a #3 Phillips screwdriver for assembly.
Get the two pieces of the Fence Base (200C) and the two
End Blocks (200E).Assemble the Fence Bases and End
Blocks together using four 3/4" screws (MF010) and four
barrel nuts (5793B). Insert the screws through the counter-
sunk holes in the fence base and start a barrel nut on the
end of each screw. Slide each End Block onto the two of
the barrel nuts and tighten the screws. See fig. 1, 2
Attach the Dust Port Blocks (200D) to the base assembly
using two 3/4" screws (MF010) and two barrel nuts (5793B).
Insert the screws through the counter-sunk holes and start a
barrel nut on the end of each screw. Slide a Dust Port Block
on to each barrel nut and tighten the screws. See fig. 3
Attach the Dust Port & Dust Port Plate (281 & 200F)
to the Dust Port Blocks using two 3/4" screws (5771B)
and two barrel nuts (5793B). Insert the screws through the
mounting holes in the Dust Port Plate and start a barrel
nut to the end of each screw. Insert the Dust Port into
the opening of the Dust Port Plate (no need to glue it in
place), insert the barrel nuts in the corresponding holes in
the Dust Port Blocks and tighten the screws. See fig. 3
Insert four 5/8" screws (MF006) through the fence base
and start an oval nut (5760B) on the end of each screw. Slide
the Aluminum Fence (204A) on to the oval nuts until the bit
opening in the Aluminum Fence aligns with the corresponding
opening in the fence base, then tighten the screws. See fig. 4
1
2
34

2
Insert the 1" screw (MF015) through the hole in
the Guard Insert (202G) and start an oval nut (5760B)
on the end of the screw. Slide the oval nut (with Guard
Insert) in the upper T-slot of the Aluminum Fence,
placed in the middle, and tighten the screw. See fig. 5
Insert the six T-bolts (5720) through the four holes in the
face of the Aluminum Fence. Install a 1/4" spacer (BUSH002)
and a Knob (5540) on the ends of the two T-bolts sticking out
on either side of the Dust Port. On the four remaining T-bolts
install a 5/8" Spacer (BUSH004) and a Knob (5540). See fig. 6
Slide the Left and Right Fence Faces (204B) onto the
T-bolts (one fence face from each side) until they cover the
Aluminum Fence. Make sure the fence faces and guard insert
are butted together, then tighten the Knobs. See fig. 6 & 7.
Attach the pair of Left & Right Tapes (3724RL) to the
top edge of these three pieces. The end of each tape (next to
"Woodhaven") must be cut to the zero line first. The tape
numbers should face towards the front of the fence when
installed. Peel back a small part of the paper backing on the tape
and start the tape with the zero mark at the center of the guard
insert, which should be centered on the edge of the fence face.
Press down firmly on the tape, removing the paper backing as
you go. Trim the tape overhanging the ends of the fence faces.
Separate the fence faces from the guard insert with a knife.
Attach the Guard (224) to the Guard Insert
using the two thumb screws (5505).See fig. 9
This completes assembly of the core fence components.
To complete the fence, follow the directions that are included
with the Fence Clamps (200SC), Hold-Down (240), Hold-In
(242) and, if you have the 202T, the Table Saw Brackets (267).
5
8
8
9
6
7

3
USING THE FENCE
It is not necessary for the fence to be clamped parallel
to the table edge, or miter slot, unless you're using a miter
gauge at the same time. Make sure the bit will not strike the
fence before starting the router. The end of a standard shop
vacuum hose (2-1/2") press fits in the dust port. Accessories
are available to adapt to other hose sizes. If you won't be using
a vacuum, remove the dust port and dust port plate so sawdust
doesn’t buildup inside the fence cavity and cause kickback.
The infeed fence (right fence face) can be turned in
to a zero clearance fence that acts as a chip breaker. To do
this, position the fence at the finished cut position, loosen the
infeed fence slightly and slide it into the bit while its turning.
DON'T make the outfeed fence a zero-clearance fence. You'll
reduce the effectiveness of your vacuum, plus there's no chip
breaking benefit on the outfeed side. See fig. 10.Pairs of
replacement fence faces (202B OR 203B) are available.
You can offset the outfeed fence face for jointing
by using the shims (200FS). The shims are 1/32"
thick and fit between the fence face and the aluminum
fence, with the slots of the shims going over the
T-bolts. See fig. 11
ACCESSORIES
The 286 (2-1/2" - 4") Adapter or 285 (2-1/2"
to 3") Adapter, plus a 282 Male Coupler, are
available if you are using a dust collector system
with a 3" or 4" hose. See our website for these.
The 4519 Straight Stop & 4517 Stop Extension provides
a means to control stock travel when cutting stopped flutes, etc.
The 504 Glide Block includes two heads.
One is used as a hold-down/push stick, the other is
used as a push block for cutting tenons, etc.
©Copyright WOODHAVEN INC. 11/5/10
[phone] or WWW.WOODHAVEN.COM
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