Woodhaven 5435 User manual

Additional Hardware:
Identify and verify that you have all of the
hardware shown below prior to assembly.
Tools needed for assembly: #3 Phillips screwdriver
Parts listed are not shown in the hardware drawings
below. Refer to photos in the instructions:
Part Desc ...........................Qty
5435A Fence .......................................2
5435B Base .........................................1
5435C Clamp Pad ...................................2
4206 6" One Track .................................2
Part# Description Qty.
BUSH004 5/8” Spacer 2
Part# Description Qty.
5521 1/4" Knob 4
Part# Description Qty.
5760B Oval Nut 4
Part# Description Qty.
MF020 1-1/4" screw 2
Part# Description Qty.
5775B 5/8" Screw 4
Part# Description Qty.
Spring3 Spring 2
Part# Description Qty.
HB050 1-1/2" Bolt 4
Part# Description Qty.
BUSH050 3/8” Spacer 4
Part# Description Qty.
HB060 3" Bolt 2
Part# Description Qty.
5540 Knob 2
Part# Description Qty.
MP375 3/8” Screw 4
Part# Description Qty.
HB055 2" Bolt 2
Part# Description Qty.
5525 5/16" Knob 2
Shown with optional
toggle clamps
Part# Description Qty.
5590 Knob 2
BEFORE BEGINNING
 Identifyandverifythatyouhaveallthepartslisted.The
Frame&PanelMasterwasdesignedtobeusedwithWoodhaven
StandardDoorTemplatesandrouterbitsonly.Itwillholdparts
between5"and20"long/wideandupto7/8"thick.Ifyoudesire
todothistypeofworkonashaperwithshapercutters,you'llneed
ourHDFrameMaster,HDPanelMasterandHDTemplates.Read
theinstructionscarefullyatleastoncebeforebeginning.
5435 Frame &
Panel Master
Owners Manual
U.S. Patent #5,960,843
Please Read Carefully!
Part# Description Qty.
5548 2” T-Knob 2

 Centerthetemplateside-to-side
onthebaseandinstalltwo1-1/2"bolts
(HB050)throughthebottomofthebase,
intotheholesinslot"A"ofthebasethat
lineupwiththeholesinthetemplate.
Screwa1/4"knob(5521) oneachbolt
andtighten,thenplace aspring
(Spring3)oneachbolt.
1
ASSEMBLY
 Inserttwo5/8"screws(5775B) thrutheholesindicatedin
eachfenceandstartanovalnut(5760B),flatsidefirst,onthe
endofeachscrew.Slidea6"onetrack(4206)ontheovalnuts,
centeredonthefences(thispositioncanbeadjustedlaterif
desired)andtightenthescrews.
 Installtwo1-1/2''bolts(HB050),oneon
eachside,thruthebottomofthebase(5435B)
intoslot"C".Installafenceoneachbolt,
followedbya5/8''spacer(BUSH004)anda
knob(5590).The6"Onetrackoneachfence
shouldbesnugagainsttheedgeofthebase
(5435B).Slidethefencesasfarapartfromeach
otheraspossibleandtightentheknobsfornow.
Attachthefencestothebase(5435B),butfirstdeterminewhetheryou'llbecuttingpanelsorrails:
RAIL WORK:thefencesshouldbeplaced
withtheirnotchededgesfacingeachother.-See Right
PANEL WORK:thefencesshouldbeplaced
withtheirstraightedgesfacingeachother.-See Above
 SelecttheStandard
DoorTemplateyouwish
touse.Note:Youwillnotuse
theindexingfencesorhardware
thatcamewiththe
StandardDoorTemplateSet.
5760 x2
5595 x2
BUSH004 x2
Slot A
Slot B
Slot C
HB050 x2
Selected Template:
Bolt Spacing
5775B x2
5435B
5435A &
4206
SPRING3 x2
5521 x2
HB050 x2

 Inserta3"bolt(HB060)thru
thebottomofthebaseinslot"B",
oneoneachside,andthruthehole
ineachfencenearesttheinsideedge
(closest to the work piece).
 Screwa1/4"knob(5521)on
each1-1/4"screw(MF020)and
installthescrew/knobinthethreaded
holeintheclamppads(5435C).
Adjusttheheightofthescrewhead
tomatchthethicknessofthewood
you'remachiningandtightenthe
knob.Installtheclamppadson
the3"bolts,followedbytwo3/8"
spacers(BUSH050)andknob
(5548).
2
Place rail between & against
notches in fences
CUTTING RAILS
 Placetherailonthebaseandslidethe
fencesinagainsteachendoftherailsoit's
seatedbetweenthenotchesinthefences.

 Placethetemplateon
the1-1/2"bolts/springs.
5435B
 Usingthecentermarkontheback
edgeofthetemplateasaguide,adjustthe
fences/railuntiltherailiscenteredonthe
template.

Usingthetemplateasapattern,drawa
lineontherail.Removetherailandsawit
toshape,stayingapproximately1/8"away
fromthefinishedline.
5548 x2
MF020 x2
5521 x2
BUSH050 x4
HB060 x2
5435C

3
Feed Direction
 Re-installtherailandclampthetemplate/railtothebaseusing
theknobsontheclamppads.
Caution! The knobs are large and easy to tighten, but
overtightening may cause damage to the jig!
Holdthejigbythehandlesandmachinetherailto
shapeusingaflushtrimmingbit.

4
 Removethemachinedrailandinstallanother.Ifyouhavea
secondroutersetupandyourbitwillreachhighenough,youcango
directlytomachiningthepattern(forcutterswitha1/2"deepprofile
max)withouthavingtoremovetherailbetweenoperations.

Forsafety,atleast1/8"ofthebearingshouldrideonthetemplate,
whichalsoactsasastartingpinandprovides
thebestcontrolofthepart.
Dependingonpartthicknessandbitdesign,thismayrequire
anadditionalspacerbetweenthebearingandthe
cutter.Youcanalsousearouterfence,setbackto
accommodatethenarrowestsectionoftherail,
tohelpvacuumawaycuttingdebris.

5
CUTTING PANELS
 Placethepanelonthebaseandslidethefencesup
againsteachsideofthepanelsoit'sbetweenthestraightedges
ofthefences.Placethetemplateonthe1-1/2"bolts/springs.
 
 Usingthecentermarkonthebackedgeofthetemplate
asaguide,adjustthefences/paneltocenterthepanelonthe
template.Usingthetemplateasapattern,drawalineonthe
panel. Removethepanelandroughsawittoshape,staying
approximately1/8"awayfromthefinishedline.

Re-installthepanelandclampthetemplate/
paneltothebaseusingtheknobsontopofthe
clamppads.The knobs are large and easy to
tighten, but overtightening may cause damage
to the jig! Holdthejigbythehandlesand
machinethepaneltoshapeusinga
flushtrimmingbit.
 Removethemachinedpaneland
installanother.Ifyouhaveasecondrouter
setupandyourbitwillreachhighenough,you
cangodirectlyfromshapingthepanelwitha
flushtrimbittomachiningtheraisedpanel
profilewithoutremovingthepartbetween
operations.You'llneedtoslidethepanel
forwardsoitsticksoutpastthe
templateatleast1-5/8"to
preventtheraisedpanelbit
fromcuttingintothebase.
 Forextra
safetyanddust
control,usearouter
fenceforadditional
support.Adjustthe
fencepositionsothatthe
tallestpartofthepanelis
touchingthefence,which
actslikeastartingpinandcan
helpvacuumawaycuttingdebris.
Feed Direction
6

OPTIONAL TOGGLE CLAMPS
Theoptionaltoggleclamps(Woodhaven PN 6305 x2 -
order separetly) attachtothe5435CClampPadsandreplace
thestandardknobsforfasterpartclamping.Weincludethe
additionalhardwareforattachingthetoggleclampswiththe
5435Frame&PanelMasterhardware.Removetheknobs,
spacers,clamppadsand3"boltsfromtheFrame&Panel
Masterandthe1-1/4"screwandknobfromeachclamppad.


 Attacheachtoggleclamptotheclamppadusingthe3/8"
screws(MP375, 2 per clamp).Attachtheclamppads/toggle
clampstotheFrame&PanelMasterusinga2"bolt(HB055
- in place of the 3" bolt),a3/8"spacer(BUSH050)andknob
(5540).Replacethehexnutonthetopofthetoggleclamps
clampingspindlewitha5/16"knob(5525).
At Least 1-5/8"
Overhang
Do not allow
router bit
to strike
jig base!
©Copyright WOODHAVEN INC. 5/15/15
[phone] or WWW.WOODHAVEN.COM
7
6305 x2
5525 x2
MP375 x4
HB055, BUSH050
& 5540 x2