Bravo's Pantorouter - by BRAVOGOLFTANGO at LumberJocks - Com Woodworking Community

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...
http://lumberjocks.com/projects/78763
Bravo's Pantorouter
Project by BRAVOGOLFTANGO posted 26 days ago 4790 views 9 times favorited 47 comments
image image image image image The journey of a 1000 Mortise & Tenons, begins with a single Pantorouter
Drop the pebble in the pond they said, the ripple will reach far they told me, ahh, yes but when building an ark like Noah, I must use them, keep your chisels and wood mallets.
Fact is I really do love handmade mortise & tenon joinery, or Noah woodworking as I like to call it. But while I enjoy the old-schoo approach to a point, Im not out to compete with Noah, fact is I like to build my projects accurate, unique and brutally strong. Yes, I everything Im told.
So after quite a bit of researching several venues for accomplishing M/T joinery, I couldnt quite find what I wanted. I wanted the ab M/T joinery, Leigh (great), Trend (blah, mediocre reviews), EZ-Pro (typical General Tools junk in my opinion), Jessem Slot-Mortise handrill?), few others, but you get my point. Leigh came out on top but they nickel & dime you for the little plastic templates, etc an limited to workpiece height for tenons to your benchof course the room and step-ladder was an option and with the roof pitch..an lol..kidding.
Finally came across the pantorouter created by Matthias Wandell, procured the plans and got started. Gathered all the hardware an journey began. In his own words (its just cool). My goal was to build this in a couple weeks in the evenings cradle to grave.
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Day-1 Progress Sun-Jan 20th all hardware procured, all wood pieces cut
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Day-2 Progress Router assemblies completely built and ready for router assembly base setup.
NOTE: The router hold-down caps are specified to build from plywood (anti-warping, etc), at least use good plywood, better than th Home Depot plywood that I used. Im going rebuild mine from plywood, using hardwood. I noticed on one of my plywood router ca spreading slightly on tightening near the screw hole on one end, so rebuilding both of them from hardwood (take about 30 mins top
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Fits like a glove and perfectly 1/4 pin alignment
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Haha can you say clamp overkill?
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Day-3 Progress Pantorouter sub-assembly built this evening
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Day-4 Progress (in progress today 1/31) DRAWER SLIDE BEARINGS
Major progress today, Lowes carrys the bearing guides in the pic below, $5 ea. Returned the full extension type I original show in t they will not work due to the necessity to have a flush mounted bearing base that the bearing guides do not hit, those would have ne due to that. They have no play and the best part is buy a total of 4, pull the bearing rack & bearings from the 2nd set, cut the pieces p (inner/outer guides), add the second rack which is 28cm (plans call for about 30cm) and it makes it even more stable.
UPDATE: If anyone does use the same guides, while it says 35 lbs, the steel framing is the same as the double-tiered and its about 1 additionally the bearing cages and bearings are identical and with the full 29cm of bearing guides in this puppy now itll hold 100 lb double-tiered + some.
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This is about how far the guides will extend (roughly 4) and there was no play with this set out of the pkg, adding the new bearing g 2nd set make it even more stable and there is no cutting required for the bearing guides, just a tiny bit on the inner/outer guide plat stuff).
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All cut & laid out per the plans, you can see the 2nd set of bearing guides (no cutting required) ready to slide in. There is just one (1) guide you knock down with a hammer & punch to slide out the bearings to work on everything.
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Each guide required just one (1) hole along with the other 3 holes that were already in place, drilled out the holes for the 3/4 machi to fasten and used my carbide rounder to make the flush bevels.
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Finally smooth down all the worked areas for burs
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Now back to mounting the main fulcrum pieces to the pantorouter base plate and adding the main router assembly, getting closer.
Well color me purple & call me Prince, made some major progress (yesterday technically, but never went to bed, off work today Fr
Plunge base is completely done, everything lined up fantastic and feels smooth. Guides are all mounted on both pieces. Feeding the was pretty fun, albeit tedious. Few pics below.
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Figured out a cool way to hold the router table @an angle to feed the bearings into the cages using my Erwins.
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On my dry-run fit of both table sections with the guides, everything feels smooth so far, adding the dust shields right now.
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Day-5 Progress Mucho progress today,
~Modified the dust guards for the guides in the back to somewhat follow the guides without hitting them. The dimensions in the pla guides and their placement with the dust guards in place hit the guides, so they needed modificaiton. Maybe Im expecting too much was fine, has plenty of travel now I guess.
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Semi-completed
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I couldnt find the springs at the dimensions required (4-7/8), but found the right thickness and had to cut them, wow cutting sprin first cut a piece grenaded 30 miles an hour through the shop, after that cut I decided to suit up for warfare, fun making the springs.
A NOTE on springs: With my router in place on the assembly the springs still lift the entire assembly. Now this is explained in the p lift the router assembly (without) the router, but it should rest down with the router in place and springs attached later on. So I may too much spring pressure, although it works fine.
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Dry fit of the template holder & workpiece tabletop. Decent fitup of the finger joints for a rookie, but I should have built my Advanc Jig with the plans I procured. Thats my next project after I build a rolling stand for the pantorouter.
A NOTE on finger-joints: For the experts out there, you will notice (especially with the nicer pics) that I do not ha finger joints and also Im leaving the plans top piece off the template holder exposing the top-edge of those finger
Thats intentional and the reason is I love exposed joinery and these imperfect finger-joints serve as a reminder o humbly started with expanding my woodworking knowledge through the years. Kind of a battlescar if you will.
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Doggone mortises kick my butt every time! The template base, table-top and router base guide stops all require slots. I setup a jig on drill-press which works perfect, there is barely a tiny bit of sanding required. Ironic the pantorouter will do these slots easily and Im to build the pantorouter. I oh, and he sloppy mortise piece in the pic is just scrap, actually used Lowes General Tools dowel jig expe piece of junk obviously.
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Slots came out decent, little bit of filing and those are done.
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Decided to woodfill Lowes Birch plywood pieces (the edges) with wood filler in order to apply oak edging & their subpar plywood h times. Figured itd look pretty nice. Debating once I build it, tearing down the router assembly (just pull the pins which are several) sanding everything followed by hand rubbing Cherry Danish Oil and maybe the hand rubbed poly.
Update! Screw handrubbing danish oil, too impatient for that nonsense and this high-end tool throws too many router shavings eve love that by the way. Yeah so I stained it English Chestnut and clear coated it. Look forward to making the custom plunge handle vs the straight one and a custom (non-lathed) router assembly handle. Finally, should be checking alignment tomorrow hopefully, maybe make a mortise template for starters. Day-5 or 6, I lost track haha!
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I cant decide whether or not to leave the top piece on over the finger jointed template holder, I like that the box joints/finger joints looks cool and no further strength is needed. The piece isnt really needed in fact. Its just a 7/16 hardwood top-cap is all, will decid but I like exposed box joints.
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All thats left is dismantle and staining, well need to check alignment first. Still have to make a template for trying it out, but that wo at all, hour tops.
The table feed handle has to go, interferes with the router motion handle, I had the pieces already cut when I came across Lees (aka here on LJ) version whereby he changed it to a curved version, nearly hits the other handle at points in certain position, so Im still a modified extension for that, 30 min job. The full sized router handle is something else I need to finish, albeit it has the little tiny o the plans called for.
The springs need attaching but thats a 30 min job, Im not using the string, have stainless 1/16 cable cut & ready. Finally Im still d clamping methodology, I dont care much for the homemade clamp, albeit works, probably going with some Bessey jig clamps. Day-7 Progress
Mounted the router in, fits like a glove, springs are on, the stainless cable for the cam springs worked ok, but the string was easier to going back with the cable once I determine final sting length which is easier to tweak, but the springs work as the plans state very w router mechanism and router weight. I ended up using a cut 1 coarse wood screw, the string stays centered perfectly in the slot
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Nice router fitup
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Workpiece top mounted, still need to drill the fence holes in it, but the fence is done. Very nice design on the fence plans, it doubles design as a squred-edge pre-set fence to use on any of the four corners.
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I recommend countersinking the two 5/16 bolts on the underside of the adjustable router base slide stop section, you can use the s benchtop that way without the carriage bolt smooth head protruding causing wobble, etc. Im going to build a stand for my panto bu this tool to build that stand with mortise & tenon joinery, so needed it wobble free for my workbench while building the stand. !http://i36.photobucket.com/albums/e50/BrettGabriel2006/Home%20Projects/Bravos%20Pantorouter/20130203144501
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Power went out @superbowl, so I had 20 mins to play a bit more. All thats left is applying the oak-stripping on the plywood, final a check, stain, clear-coat, apply my standard brass Handcrafted By plaque and build a tenon & mortise template then time for Navy Few progress pics from Sun evening.
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The new table-sled feed handle works much better than the stick I called it.
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Took a big solid oak table leg from a dining room table given to me from our church, cut a 4 piece, it started out as a 3x3 piece. H bandsaw, squared it, octagoned it, thew it on the drill press (bluecollar lathe haha), then started with 80 grit, stepped down up to 10 320, double tapered 4 handle was the goalaccomplished!
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Looks nice!
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Compared to the original from the plans.
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. . . Mon 2/5 ~ PROJECT COMPLETE
Had to bring it inside for some good shots with the Nikon, shop lighting is subpar @night. My wife suggested just using my custom table when needing to make joinery with this tool, pretty good idea vs building yet another roll-around cart for it. So I slid off the ro fence and it fits rather well. My 2-car garage is filling quick with rollable tables.
The jig clamps are just sitting on the fence, for ideas, may or may not mount them there. Thinking of a movable separate clamp bloc auto-adjust version of these I just ordered. Also, the string from the guide-bearing to the router was just to hold the assembly down spring tension to take the photos.
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. . . . Bravos Pantorouter Build Review
Plans & Drawings (4 of 5 starts). Pretty thorough drawings for $18, only found one (1) dimension on the cut-list which needed som for thicknesses, but no real complaints for a humble $18. This dimension anomaly was communicated with the designer who has sin change in the plans. Drawing Review
- The cut-list dimension finding I came across was on the cut-list-Hardwood Cutting Diagram. It states to use 1.5 (36mm) thick har you will find later that the 2mm difference affects the box-joints (finger style) fitup due to the 1:1 printable templates in the plans ar exactly at 36mm. If it stated to plane your hardwood to 36mm or add 2mm to the finger joint depth if using 1.5 thick material, th things easier up front, minor drawing fix which has been taken care of by the designer.
- I like to lay everything out as you can see in the pics, its just how my brain works I guess. I made my own Cut-List parts drawing r mapped pieces to the assembly plans, this made it so much easier for me and bit closer to how we did things in the Navy & presently Aerospace industry.
Assembly Review - The plans are pretty detailed here and overall get the job done. Alignment is the BIGGEST thing with the router mount sub-assem made very clear in the plans.
- I read through the entire plan pkg but didnt follow the assembly methodology completely. For example, I used 1/4 rod vs 1/8 fir
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custom fit the router pieces to my particular router, which is mentioned in the instructions albeit the 1:1 templates are at best a (get approach).
- During assembly of these critical alignment sub-assemblies, I used either 1/4-20 nuts/bolts to align said assemblies or the 1/4 ro perfectly aligned. The instructions will get you there to alignment, but I used a simpler equally accurate method. - The fence system for this tool and the plans for it were well thought out and its a multi-use capability tool actually. Pantorouter Use Review Im going through my learning-curve with the templates at the moment, but it seems to be a small curve, its new is all. My first stab with doing 3/4 stock with a through-tenon (love these)
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First stab with a blind M&T, the cuts are incredibly clean and not too tight to prevent a glue surface, yet it still makes the nice little p sound (nominal fit)
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Almost midnight Thur 2/7 & I have a fully functional 1 mortise & tenon template that works fantastic. Thanks to Mathias & Luv2le on LJ for the tips.
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My first Pantorouter quick project. Sea-Trials went well for this little picture frame. Once you setup your templates and mark them
I took the 1 M/T template I made last night and threw it on the panto, just wanted to see how close itd be without micro measuring do initially to build templates). Very satisfied with the results. Its western red cedar scraps, handrubbed with cherry Danish oil. Nothing fancy, but a cool test run.
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The possibilities are near limitless with the panto. Whats really cool is I now have a super fast and simple way to make slotting vs th system I used to build this rig. -- "Damn the torpedoes, full speed ahead"
47 comments so far
I wish I had room for one of these They look like they do a great job Bill_N
163 posts in 361 days #1 posted 26 days ago
-- I have the Saw Dust Fever
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Oh man I barely have room in my 2-car garage, but its a dedicated woodworking shop, our trucks are ou vehicles now haha. BRAVOGOLFTANGO
-- "Damn the torpedoes, full speed ahead"
Im jealous, this is awesome!
Ben Simms
-- I played with Legos as a kid and I never had the part I thought I needed, so I learned to improvise. Now engineer with a woodworking hobby.
Looking forward to see how this turns out. I would build several of Matthias inventions but my garage is and my wife wants to park her car inside. Julian
-- Julian
What do you think it cost you total (minus the router)?
Zinderin
Ben dont be jealous, its just a guy-toy, you know the drill lol
BRAVOGOLFTANGO
Julian I hear you on the garage thing, we gave up on the garage parking once we sold our Jeeps. 4-dr JK Wrangler RUBICON and I had a 2-dr JK RUBICON I built myself for rock-crawling that c garage top by 3/8 Haha37 BOGGERS take up some room. She was scared of rock-crawling any it, we got tired of fixing mine, ditched them both and her Yukon and my crewcab do NOT fit in the anyway unless it was empty all the way up to the sheetrockscrew that! :). On the bright side ~ wo is cheaper than JEEPING ~, well waitno no..Im incorrect..those fancy wood planes for $8,000 I yesterday indeed compete with JEEP upgrade costs.
Zinder Im roughly $100 $120 in hardware parts & lumber. I bought a Porter Cable 9690LR F 1-3/4hp router ($129) from Lowes, its body dia measured 3.5 (89mm) which is exactly what the called for.
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-- "Damn the torpedoes, full speed ahead"
RCT
Im looking forward to see how this turns out as well. I have had the drawings for some time been waiting insperation. Thanks -- "Ya but what does he know anyhow?"
BRAVOGOLFTANGO
RCT its a fun project thats for sure. Its intimidating looking at first, but Ive built other complex thing up there mind you, but its no more complicated, albeit more complex than the wooden-router-lift I built more parts! -- "Damn the torpedoes, full speed ahead"
I forgot Mathias loves to use metric I dont want to convert and am lacking metric measures Bill_N
-- I have the Saw Dust Fever
You are going to like this tool. How do I know? I built one. Be prepared to figure out some kind of chip an collection. I am still working on that part myself. luv2learn
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-- "If the women don't find you handsome, at least they ought to find you handy" Red Green
Bill kind of thought the same at first, $6 android ap Measure Master pro from Calculated Industries mad conversion simple really, but I understand what youre saying. BRAVOGOLFTANGO
Luv2learn, thanks for sharing that bit of intel, inspiring to get me back in the shop, taking a break and bu handle right now, thinking of changing it from straight though to curvatured like someone else who built who).
Still debating whether to build the clamps, just not sure Im crazy about them, was considering some auto jig clamps. I first thought all the 3/8 holes were bench dog type holes for the clamp plans, but see its no -- "Damn the torpedoes, full speed ahead"
Thanks for the info I will check it out -- I have the Saw Dust Fever Bill_N
Hey Brett the curved handle modification was me. After I had it all together and put it though its first tria didnt like how close the two handles were. luv2learn
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-- "If the women don't find you handsome, at least they ought to find you handy" Red Green
BRAVOGOLFTANGO
Ahh ok thank you sir, well I have some scrap oak dining table legs scrap Im considering building a two-p handle out of, figured Id get it all assembled first though then go back, didnt care for the closeness of the either. Nor do I care for the tiny little 1 dowel handle thats being changed out to something oak and may long. -- "Damn the torpedoes, full speed ahead"
trasner
With that device, who needs a CNC machine. This is probably the best review I have read of one of Mr. W plans. The guy is extraordinary, albeit probably a little eccentric. I mean, who builds a wooden bandsaw? reminds me of a woodworking version of Dr. Emmett Brown (Back to the Future). I love his website. Plea some picture of some of your creations with your pantorouter. -- Todd
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Bravo's Pantorouter - by BRAVOGOLFTANGO at LumberJocks - Com Woodworking Community

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Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Fits like a glove and perfectly 1/4 pin alignment

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Haha can you say clamp overkill?

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Day-3 Progress Pantorouter sub-assembly built this evening

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Day-4 Progress (in progress today 1/31) DRAWER SLIDE BEARINGS

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Finally smooth down all the worked areas for burs

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Day-5 Progress Mucho progress today,

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Nice router fitup

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Compared to the original from the plans.

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

. . . Mon 2/5 ~ PROJECT COMPLETE

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...

. . . . Bravos Pantorouter Build Review

Bravo's Pantorouter - by BRAVOGOLFTANGO @ LumberJocks.com ~...