Woodhaven 3000 User manual

3000, 3002 & 3004
Planing Sled
Owners Manual
Please Read Carefully!
Part# Description Qty.
5521 1/4" Knob 2
Part# Description Qty.
5760B Oval Nut 12
Part# Description Qty.
5590 Knob 2
Part# Description Qty.
BUSH050 3/8” Spacer 10
Parts List:
Please identify and verify that you have all of
the hardware shown. Please refer to photos in the
instructions for the parts listed below:
Part Description Quantity
3000B Brackets, 4 pc. set (2 pairs). . . . . . . . . . . . . 1
3000P NoDrill Plate . . . . . . . . . . . . . . . . . . . . . . . . . 1
4973 NoDrill Plate Hdw. . . . . . . . . . . . . . . . . . . . . 1
4406 6" Ultra Track . . . . . . . . . . . . . . . . . . . . . . . . 2
Model 3000 also includes the parts below:
4436 36" Ultra Track . . . . . . . . . . . . . . . . . . . . . . . 2
4016 16" Double Track . . . . . . . . . . . . . . . . . . . . . 2
Model 3002 also includes the parts below:
4448 48" Ultra Track . . . . . . . . . . . . . . . . . . . . . . . 2
4024 24" Double Track . . . . . . . . . . . . . . . . . . . . . 2
Model 3004 also includes the parts below:
4460 60" Ultra Track . . . . . . . . . . . . . . . . . . . . . . . 2
4032 32" Double Track . . . . . . . . . . . . . . . . . . . . . 2
Part# Description Qty.
WB002 Washer 18
Part# Description Qty.
5860 Ratchet Handle 4
Part# Description Qty.
NUT006 Acorn Nut 4
Part# Description Qty.
HB020 3/4" Bolt 10
Part# Description Qty.
CAB015 Angle Bracket 8
Part# Description Qty.
STP004 1/2" Screw 16
Part# Description Qty.
PAD1 Glide Pad 8
Part# Description Qty.
HB030 1” Bolt 10
Part# Description Qty.
MF006 5/8" screw 4

BEFORE BEGINNING
The Planing Sled must be setup and used on a flat surface.
Identify and verify that you have all the parts listed. You'll need
a 7/16" wrench for assembly. Read the instructions carefully at
least once before beginning.
ASSEMBLY - ROUTER SLED
Follow the directions in the 4973 Plate Hardware and
attach your router to the Router Plate (3000P). The router does
not need to be perfectly centered on the plate. Position your
router on the plate so the router handles (if you haven't removed
them) are parallel to one of the router plate edges and position
the router to take the best advantage of the plates mounting slots
and router control locations. Mark the position of the router on
the router plate (timing mark) so you can return it to the same
location, then temporarily remove the router. See fig. 1.
An optional drill style plate (PN 3000PD) is available for
semi-permanent mounting of your router, but it requires drilling
mounting holes in the plate.
Insert the 5/8" screws (MF006) from the underside of the
router plate through the countersunk holes. Start an oval nut
(5760B), flat side first, on the end of each screw. Slide a 6"
Ultra Track (4406) on to two of the oval nuts, position it even
with the plate at it's ends and edge, then tighten the screws.
Repeat for the second Ultra Track on the opposite side of the
router plate. See fig. 2.
Remove the paper backing and install the glide pads
(PAD1 - 2 on each track, 4 extras provided) where shown on
the outsides of each Ultra Track, next to where the plate attaches
to the track. On a 1" bolt (HB030), place two 3/8" spacers
(BUSH050) and start a knob (5590) on the end of the bolt. Slide
the bolt head in the top side T-slot of the Ultra Track. Center the
bolt in the track and lightly tighten the knob for now. Repeat
this step on the opposite Ultra Track. On four of the 3/4" bolts
(HB020), install a 3/8" spacer (BUSH050), washer (WB002)
and acorn nut (NUT006). Slide two of the bolt heads in to the
top T-slot of the Ultra Track, one on either side of the knob.
Position the spacers flush with each end of the Ultra Track and
lightly tighten the acorn nuts for now. Repeat this step on the
opposite Ultra Track, then set the Router Sled aside for now.
See fig. 3.
ASSEMBLY - BRACKETS & RAILS
Install a washer (WB002) on eight of the 1" bolts
(HB030). From the ribbed side of the Sled Bracket, insert the
bolts through the holes in the Sled Brackets (3000B - 4 pieces,
2 pairs) and start an oval nut (5760B), flat side first, on the end
of each bolt. Sliding the oval nuts into the T-slot of the Double
Track, mount a pair of Sled Brackets to both Double Tracks
(4216, 4224 or 4232 depending on model purchased). Position
the pair of brackets so they are 3-5/8" apart (measured from the
inside ends - this gap will be adjusted later), flush with the edge
of the Double Track and centered on it, then tighten the bolts.
Insert a 3/4" bolt (HB020) through the hole in the rib on each
Sled Bracket and install a washer (WB002) and ratchet handle
(5860) on the end of each bolt. See fig. 4.
1
1
2
4
Space brackets
3-5/8" apart.
One 3/4" bolt, washer
and ratchet handle
per bracket.
Two 1" bolts, washers & oval
nuts per bracket.
3
Place a glide pad on
the lower corners of
each 6" track - 4x.
Router Sled
5/8" screw and oval nut, 4 places.
Slide 6" Ultra Track onto oval nuts.

Set the Ultra Tracks on a flat surface, making sure they are
on the same plane. Install the Sled Brackets/Double Track on
the Ultra Tracks (4436, 4448 or 4460 depending on model pur-
chased) by sliding the bolt head/rib of the bracket into the T-slot
of each Ultra Track. For now, position the Sled Brackets so they
are 2" from the ends of the Ultra Tracks and tighten the ratchet
handles. See fig. 5.
Take the Router Sled (router should not be installed yet)
and place it as shown on the top of the two Ultra Track rails.
Loosen the knobs and four acorn nuts, dropping the Router Sled
slightly downward between the Ultra Tracks, then tighten the
acorn nuts. This adjustment should allow the four spacers of the
Router Sled to sit evenly on the Ultra Track rails. See fig. 6.
Flip the Router Sled over between the Ultra Tracks and
tighten the two knobs on the Router Sled so those spacers are
not touching the Ultra Track rail. Double check that the Router
Sled does not rock on the Ultra Track rails. See fig. 7.
Loosen one of the Ultra Track rails by loosing the Sled
Brackets where they attach to the Double Tracks. Adjust the
Ultra Track rail against the Router Sled so it moves freely, but
with very little side-to-side of slop between the Ultra Track
rails, then retighten the Sled Brackets. See fig. 7 & 8.
Install a spacer (BUSH050), washer (WB002) and knob
(5521) on a 3/4" bolt (HB020) and insert the head of each bolt
in the upper side T-slot of one of the Ultra Tracks. These act as
stops to control the front-to-back movement of the Router Sled
on the Ultra Track rails. See fig. 7 & 8.
OPTION "A" - PARTS THINNER THAN 3"
This option is designed for best portability. Maximum
depth of cut is approximately 1/4" without readjusting the part
height in relation to the rails. Make two "L" shaped wood rails
out of 1-1/2" x 2-1/4" and 3/4" x 3-1/2" material. These "L"
rails will be screwed to the underside of the part to be planed.
The rails must be straight and longer than the part length by at
least 12" (for the 3000 Planing Sled) or 16-20" (for the 3002 &
3004 Planing Sleds). See fig. 9 & 10 (on next page).
The part must have parallel edges. Set the part face down,
shimming if necessary so it won't rock from corner-to-corner
or side-to-side. Place 1" to 1-1/8" thick spacers you provide
between the "L" rails and the flat workbench to insure both rails
are on the same plane. Line up the inside of the rails so they're
in line with the edges of the part and parallel to one another.
Using four to eight angle brackets (CAB015) and 1/2" screws
(STP004), attach the rails to the underside of the part. The
brackets bend to conform to the angle between the part and the
rail so the rails remain flat on the workbench. See fig. 9 & 10
(on next page).
Router Sled
2
8
7
6
5
1" to 1-1/8"
spacer (x 4)
Stops
Position the Sled Brackets so
they are 2" from the ends of
the Ultra Tracks and tighten
the ratchet handles.
Tighten knobs, making sure the spacers
are not touching the track.
Tighten sled brackets after checking that Router
Sled moves freely between rails.
9

Workbench
Part Support
Part
Wood
Rail
Wood
Rail
OPTION "B" - PARTS THINNER THAN 3"
This option is designed to be semi-permanent setup and
functions as a planing workbench in your shop. This setup is a
good choice for odd shaped parts that do not have parallel sides.
Maximum depth of cut without repositioning the part is approxi-
mately 1/4". It may require more part mounting hardware than
what we provide. These rails will be permanently mounted to
a flat workbench and the part will attached independently to
the workbench for planing. This way the part can be raised or
lowered independently (see part support) of the wood rails to
optimize the parts height. Make two "L" shaped wood rails out
of 1-1/2" x 2-1/4", 3/4" x 3-1/2" and 1/2" x 3-1/2" material. The
rails must be straight and longer than the part length by at least
12" (for the 3000 Planing Sled) or 16-20" (for the 3002 & 3004
Planing Sleds). See fig. 11.
OPTION "C" - PARTS 3" OR THICKER
This method (not shown) works well for resurfacing
butcher blocks, thick workbenches and more. Maximum depth
of cut without repositioning the rails is approximately 1/4".
Make two rectangular rails out of 1-1/2" x 3" material. The part
edges must be parallel, or the rails must be shimmed as neces-
sary so they're parallel, for this method to work. Fasten the rails
to the sides of the part using bar clamps or screws, making sure
both rails are on the same plane. The rails should be positioned
approximately 1" to 1-1/8" below the surface of the part. Or you
may want to measure up from the bottom of the part, especially
if it's surface is uneven, to insure the part will be an even thick-
ness. The rails must be straight and longer than the part length
by at least 12" (for the 3000 Planing Sled) or 16-20" (for the
3002 & 3004 Planing Sleds).
PLANING
Here we describe how to plane a part using Option A
described earlier. Make adjustments as necessary if using
Option B, or Option C. Loosen the two rear ratchet handles and
adjust the rear Double Track so the part is sandwiched between
(with a small gap) the front and rear Double Tracks.
Before using, make sure the Planing Sled moves freely
from side-to-side on the wood rails and the Router Sled moves
freely (but without excessive slop) between the Ultra Tracks
from front-to-back. Never allow the center of the Router Sled
to go past the center of the wood rails or the Planing Sled could
tip off the wood rails. When planing narrow parts, verify that
the weight of the overhanging Ultra Track rails will not tip the
Planing Sled off the wood rails. If necessary, you may need to
make an additional wood rail to support the outer ends of the
Ultra Track rails.
Install the necessary bit (must have at least a 2-1/2" over-
all length) in your router and attach the router to the Router
Sled. Set the depth of cut to 1/8" or less. Set the stops on the
Ultra Track rail to control the front-to-back movement of the
Router Sled. Wide parts may require you to complete one side
of the part before doing the opposite side. Never try to reach
beyond a comfortable and safe distance. Always work against
the rotation of the bit - never climb cut! Always take appropriate
safety precautions. See fig. 12 &13.
©Copyright WOODHAVEN INC. 1/18/12
[phone] or WWW.WOODHAVEN.COM
12
"L" shaped
wood rail
1-1/2" x
2-1/4"
part
1-1/2" x
2-1/4" part
3/4" x 3-1/2" part
3/4" x 3-1/2" part
1/2" x 3-1/2" part
11
13
10
3
12