Woodhaven 5432 User manual

5432
HD Panel Master
Owners Manual
U.S. Patent #5,960,843
Please Read Carefully!
Additional Hardware:
Parts listed below are not shown in the hardware
drawings. Refer to photos in the instructions:
Part Desc ........................Qty
5432B Base .....................................1
5432S 5-7/8" One Track . . . . . . . . . . . . . . . . . . . . . . . . .2
5432T 6-3/4" Ultra Track Fence . . . . . . . . . . . . . . . . . .2
6305 Toggle Clamps ...........................2
Part# Description Qty.
5525 Knob 2
Part# Description Qty.
5765B Oval Nut 8
Part# Description Qty.
MP375 3/8" Screw 4
Part# Description Qty.
HB040 1-1/4" Bolt 4
Part# Description Qty.
HB030 1" Bolt 2
Part# Description Qty.
HB060 3" Bolt 2
Part# Description Qty.
WFN002 1" Washer 4
Part# Description Qty.
BUSH1250 1/4" Spacer 8
Part# Description Qty.
BUSH1125 1/8" Spacer 8
Part# Description Qty.
BUSH004 5/8" Spacer 2
Part# Description Qty.
WS002 Washer 4
Part# Description Qty.
5760B Oval Nut 4
Part# Description Qty.
MF006 5/8" screw 4
Part# Description Qty.
5590 Knob 2
BEFORE BEGINNING
 Identifyandverifythatyouhaveallthepartslisted.The
HDPanelMasterwasdesignedtobeusedwithWoodhaven
HDDoorTemplateswiththehardwareincluded.Itcanalso
beusedwithourStandardDoorTemplatesbypurchasingthe
5431HardwareKit.Itcanbeusedonashaperorarouter
tableusingtheHDDoorTemplatesandonaroutertable
onlyifusingtheStandardDoorTemplates.You'llneeda#3
Phillipsscrewdriveranda7/16"wrenchforassembly.Read
theinstructionscarefullyatleastoncebeforebeginning.
Part# Description Qty.
5548 2” T-Knob 2

1
Holes/bolts in Tracks
face each other
 Installa5/8"screw(MF006)thruthecountersunk
holesineachofthe5-7/8"OneTracks(5432S)and
startanovalnut(5765B - smooth side first)onthe
endofeachscrew.Therearetwoholesineachof
the6-3/4"UltraTrackFences(5432T).One
holeis3/4"fromtheendoftheFence
andtheotherholeis1-1/2"from
theoppositeendoftheFence.
 Placethelongedgesofthetwo
Fencesagainsteachothersotheholesareclosest
toandacrossfromeachothertoinsureyouhave
mirrorimagesofthetwoFencesafterassembly.
AttheendofeachFence,wheretheholeis1-1/2"
fromtheend,installaOneTrack.Insertthetwooval
nutsontheOneTrackintheT-slotsoftheFence,butt
thelongedgeoftheOneTrackagainsttheendofthe
Fence,checkitforsquareandtightenthescrews.
 Installawasher(WS002)oneachof
the1-1/4"bolts(HB040).Placethe6-3/4"
UltraTrackFence(5432T)ontheBase
(5432B)withtwoholesineachFence
alignedwiththetwoslotsintheBaseand
theOneTracksbuttedagainsttherearedge
oftheBase.ThetwoholesintheFences
shouldfacetowardsthecenteroftheBase.
 Insertthe1-1/4"boltsthrutheholes
intheFence/slotsinBaseand,fromthe
undersideoftheBase,startanoval
nut(5760B - smooth side first),
ontheendeachbolt.Position
theFencesabout12"apartfor
nowandsnugthebolts.
 Inserttwo3/8"screws(MP375)thru
thetwofrontholesofeachToggleClamp
(6305)andstartanovalnut(5765B -
raised side first)ontheendofeachscrew.
SlideoneToggleClampontoeachFence,
withtheovalnutsengagedinthecenter
T-slot.PositiontheToggleClampswhere
desiredandtightenthescrews.Forquicker
spindleadjustments,replacethetopnuton
thespindlewiththethumbnut(5525).
 Inserta5/8"spacer(BUSH004 on
thetwo1"bolts(HB030)andstartaknob
(5590)ontheendofeachbolt.Slidethe
boltheadintoaT-slotofthefence,
positioningtheknobwheredesired
forbestcontrol,andtighten.
5765B x2
MF006 x2
HB040 x2
WS002 x2
5760B x2
5590 x1
5525 x1
BUSH004 x1
MP375 x2
5765B x2
HB030
x1
5432S &
5432T
5432B

 Theheightofthespacerstackoneachboltshouldbemorethenthe
thicknessofthepanelanditshouldalsoplacethetemplateatthe
optimumheightforyourshapercutterbearingtoridefirmlyon
theedgeofthetemplate.Adjustthenumberof1/4"and
1/8"spacersasnecessarytoachievethebesttemplate
height.Makesuretheshapercutterwillnothitthe
template.

 Slidethepanelblank(one end should
be finished cut square)inthePanelMaster,
betweentheFences,Baseandtemplate.
Positiontheuncutendofthepanelatthe
desiredfinishedlength,usingthehigh
pointofthetemplateasareference.
Tracetheoutlineofthetemplate
onthepanelblank,removethe
panelandroughcutittoshape,
staying1/8"orlessfromtheline.
2
SETUP THE HD PANEL MASTER
 Insertthepanelbetweenthe
FencesontheBaseoftheHD
PanelMaster.Slidethe
Fencesupagainsteach
sideofthepaneland
centertheFences/panel
side-to-sideontheBase,
keepingtheOneTrack
ofeachFenceagainst
theedgeoftheBaseto
insurethepanelis
squaretotheBase.
Tightenthe
Fencebolts
usinga
7/16"
wrench.
 Selectthepaneltemplateyouwish
tousefromtheHDDoorTemplate
set.Centerthetemplateside-to-
sideontheBase,usingthe
centernotchontheedgeof
thetemplateasareference.
SelecttheholesintheBasethat
lineupwiththeholesinthe
template.

 Installtwo3"bolts
(HB060)thruthe
recessedslotin
thebottomof
thebaseand
thrutheholesinthe
Basethatlineupwith
theholesinthetemplate.
WFN002 x2
BUSH1250 x6
HB030 x2
5548 x2
WFN002 x2
 Placethree1/4"spacersoneachbolt.
The number of spacers may need adjustment
depending on your shaper cutter configuration.
Placea1"washer(WFN002)oneachbolt/spacer
stack.Installthetemplateontheboltsandanother
1"washeroneachbolt,ontopofthetemplate.
Placeaknob(5548)oneachboltandtighten.
Center Fences &
Panel Stock on Base and
tighten bolts
Center Template on Base
and install hardware
Trace template
outline on panel
and remove waste

3
RAISED PANEL CUT WITH A ROUTER
Thedoortemplatecanberemovedsincethebearing
onthepanelbitwillfollowtheedgeofthepanel,notthe
template.Makesureyouhaveatleast1"ofthebitshank
intherouter.Ifextrabitheightisneededtocutthefull
profiledepth,youmayneedtousearouterliftor
colletextension.You'llneedtomakesurethe
panelsticksoutpasttheBaseatleast
1-5/8"topreventtheraisedpanel
bitfromcuttingintotheBase.
 ClampthepanelintheHD
PanelMasterwiththetoggle
clamps,holdthehandles
andmakeincremental
passestomachine
theraisedpanel
profileonthepanel.
RAISED PANEL CUT WITH A SHAPER
 Ifpossible(depends on raised panel cutter & bearing set up),keepthe
HDDoorTemplateontheHDPanelMasterwhenmachiningtheraisedpanel
profile.Thetemplatesareextralongsothebearingcanmakecontactwith
thetemplatebeforethecuttermakescontactwiththepanel.This
providesgreatercontrolandincreasesthemarginofsafety.
 Theheightofthespacerstacksunderthe
templateshouldplacethetemplateattheoptimum
heightforyourshapercutterbearingtoridefirmly
ontheedgeofthetemplate.Adjustthenumberof
1/4"and1/8"spacersasnecessarytoachieve
thebesttemplateheight.Makesurethe
shapercutterwillnothitthetemplate.
 Makesurethetemplateisinline
withtheraisedpanelcutterbearing.Clamp
thepanelintheHDPanelMasterwiththe
toggleclamps,holdthehandlesandmakeincremental
passestomachinetheraisedpanelprofileonthepanel. ©Copyright WOODHAVEN INC. 5/20/15
[phone] or WOODHAVEN.COM
FLUSH TRIM PANEL TO SHAPE
ClampthepanelblankintheHD
PanelMaster,holdthehandlesand
flushtrimthepaneltoshape
usingaflushtrimcutter
onyourrouteror
shaper.The
bearingofthe
flushtrimbit
willfollowthe
paneltemplate
andcutthepanel
toitsfinished
shape.
You
canuse
theHD
PanelMaster
toholdthe
panelfor
theraised
panelcut
onthepanel
endjustshaped(see below).
Aftermakingtheraised
panelcut,thepaneltonguewill
fitintothegrooveinthematingrail.
Feed Direction
At Least 1-5/8"
Overhang
Do not allow
router bit to
strike jig
base!