PantoRouter PR-PPWR How-To Manual

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How-To Guide

Mortise & Tenon, Box Joints

Dovetails, and Much More!

Manufactured and Distributed by

WoodCraft Solutions LLC

www.PantoRouter.com

Info@PantoRouter.com

+1-877-333-7150

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Summary of Contents for PantoRouter PR-PPWR

Page 1 How-To Guide Mortise & Tenon, Box Joints Dovetails, and Much More! Manufactured and Distributed by WoodCraft Solutions LLC www.PantoRouter.com Info@PantoRouter.com +1-877-333-7150 Copyright January 2024 - WoodCraft Solutions LLC...
Page 2 Some of these hazards are discussed below. Use common sense when operating the PantoRouter® and all woodworking tools, and use this tool in accor- dance with the instructions. You are responsible for your own safety.
Page 3 TABLE OF CONTENTS SAFETY MORTISE AND TENON JOINERY Terminology Mortise and tenon template systems Essential mortise and tenon template selection Cutting a mortise and tenon joint Segmented mortise and tenon template set Slot mortise and tenon template set Floating tenons and bridle joints DOVETAILS ON THE PANTOROUTER® Setting up and cutting dovetails Dovetails wider than 8” Keeping track of dovetail pieces Tips for successful dovetails BOX JOINTS DOWEL TEMPLATES SPECIALTY TEMPLATES UNIVERSAL CLAMPS CALIBRATING THE TEMPLATE HOLDER REFERENCE MATERIALS AND VIDEO LINKS...
Page 4 While there are many ways to cut mortise and tenon joints, the PantoRouter® offers a repeatable and accurate solution to creating both sides of the joint using a single template and setup.
Page 5 Anatomy and Terminology of a Mortise and Tenon Joint Mortise Tenon A. Tenon Width A. Mortise Width B. Tenon Length B. Mortise Depth C. Tenon Thickness C. Mortise Thickness D. Shoulder D. Face E. Tenon cheek E. Mortise Wall F. End F.
Page 6 Mortise and tenon template systems Over the years, we have developed several template systems to cut mortise and tenon joints, each with their ap- propriate applications. This section covers each template system, their advantages, and how to select the correct template system for any given project.
Page 7 The Basic PantoRouter® Package includes an array of templates for various joint sizes and orientations, the Pro- Pack and All-In Packages have even more, and all are available à la carte from our on-line store.
Page 8 You can get more in- formation about this process by reading our How-to guide for 2017 models & older at: www.pantorouter. com/getting-started/#how-to-guides Center the template vertically. This step is just as easy.
Page 9 Example mortise and tenon joint. For this simple example, our stock is 3” wide and 1-1/4” thick. The two identical workpieces are joined at a 90 degree angle, flush on both faces as well as the edge as seen below. 3”...
Page 10 Setting the Centering Scale Fence. To set the fence in the correct location on the table, simply measure the width of your workpiece using the full scale ruler on the fence and align the corresponding mea- surement on the 1/2-scale ruler to the cen- Centering Bar ter line of the table.
Page 11 Avoid clamping directly over the area to be mor- tised, since the clamp could deform the mortise wall as the mortise material is cut away. Alternatively, you can use the Pantorouter® rotating clamps which are available separately from our on-line store. Learn more on page 53.
Page 12 Set the depth of cut. Simply touch the bit to the workpiece and set the depth stop just past the length of the tenon you’ll cut next. About 1/16”- 1/8” of room for excess glue at the bot- tom of the mortise is plenty. Dust shroud brush goes back on.
Page 13 Tenons after mortises Trace the outside of the template for tenons. We recommend using a 1/2” spiral up-cut bit for all tenon cuts except those cut using the diamond and bow tie templates. Consult the chart at the bottom of this page to deter- mine the correct guide bearing for the desired tenon thickness.
Page 14 The colors in the chart and on the guide bearing shafts in the photo are for clarifying the sizes, but we do not color-code the guide bearings for the PantoRouter® woodworking machine. The chart below lists actual measurements of mortise and tenon widths when using the Essential Set of mortise and tenon templates, Segmented mortise and tenon widths are discussed later in this guide.
Page 15 Guide bearing starts at back of template Reset the depth stop. Touch the tip of the router bit Set the guide bearing. Push the guide bearing to the to the end of the workpiece then set the depth stop as thickest part of the template closest to the template before but the tenon must be slightly shorter than the holder for your first tenon attempt.
Page 16 Longer tenons take multiple passes. The Spiral up-cut bits provided with the PantoRouter® have 2 cutting flutes. Depending on the bit, the length of these flutes vary. When cutting tenons, be sure to note the length of the flutes. The cutting flute length Cutting flute length 1-1/4”...
Page 17 Multiple tenons are just as easy. For wide workpieces, combine templates. Use a square and the scale on top of the template holder to align the templates. When two templates are used, they are usually spaced equidistant from center. Make sure to leave room between them for the guide bearing to pass through.
Page 18 You can also mount the B-V and D-V templates horizontally which allows variable spacing between templates. Angled Mortise and tenon joinery The PantoRouter® makes single angle or compound angle joinery easy by using the auxiliary fence and the tilting table. Auxiliary Fence Compound angles are made much easier using the PantoRouter®...
Page 19 The Essential mortise and tenon templates used in the previous section can cut 35 sizes of mortise and tenon joints in minutes. The Segmented mortise and tenon set allows PantoRouter® users to cut 154 different sizes of round-end mortise and tenon joints and another 77 sizes of square-end tenons. Using the provided chart, it is easy to select the desired size M&T joint based on the project and quickly mount the correct pieces on the tem-...
Page 20 Hundreds of possibilities from eleven segments. After consulting the provided chart, select the correct segments from your segmented template set. Note: The square end templates are for making the tenon ends square. The mortise still needs to be squared with a chisel, but at least we get you half way there! Scan the QR code for an in-depth Tech-Tip on square-ended tenons.
Page 21 Slot Mortise Template The Slot Mortise Template is a fast and easy way to cut any width slot and can be set up for either inch or metric sizes. This flexible template system is a great choice for cutting mortises for floating tenons, bridle joints, hand holds, finger grooves, and more! Simply align the bit size with the desired mortise width to cut a perfect mor- tise.
Page 22 Double mortises. For double mortises, align the bit-diameter mark on the two sliding stops closest to the centerline with the desired dis- tance between the two mortises. In this case the 1/2” thick mortises are set to be 2” apart. Use the centering ruler to space the mortise widths for each side.
Page 23 ” bit makes a nice snug fit for the 8mm float- ing tenon in this mitered joint example. on the PantoRouter® joinery machine took only a couple of minutes longer. Note: Some metric router bits have metric shafts and others have inch scale shafts. Make sure the collet you are using is designed to work with the router bit shaft that you are using.
Page 24 Dovetails are fast and foolproof Your PantoRouter® package comes with 2-in-1 dovetail templates to cut both pins and tails with the same templates, just like the templates for mortises and tenons. The template for each pin/tail is a separate unit and they can be attached along the template holder in any array to create a pleasing layout.
Page 25 Template selection and placement The dovetail templates provided with the PantoRouter® can be used to make fixed-space dovetails by pushing the templates tight to one another on the template holder, or the templates can be spaced apart on the template holder to cut variably-spaced dovetails.
Page 26 Centering ribs on the back. Each dovetail template has a centering rib molded into the back to use in con- junction with the centering scale printed on the top of the template holder. Use these ribs to make sure the templates are laid out in a symmetrical pattern.
Page 27 Set the depth. Load the high-quality dovetail bit supplied with your PantoRouter® or an 8° bit of your own, touch the end of the bit to your workpiece and set the rear depth stop. Make sure enough of the board is overhanging the table so the bit doesn’t...
Page 28 Cut stacks of tails Tails are fast and easy. You can machine stacks of boards in minutes, with the PantoRouter’s dust shroud grabbing every bit of waste. The bearing goes in the template’s center slots for cutting tails. Follow gently along each side of that slot to be sure you are making full cuts, and slow down when breaking through the bottom of the board to prevent tear-out.
Page 29 The secret to Dovetail Success Cut two sample boards about 6” long and milled to the same dimensions as your workpieces; one will be a test board for the tails and the other will be for pins. Cut tails in this board as you cut the rest of your workpieces. This sample tails board will be used to dial-in your fit for perfect pins.
Page 30 Change to a spiral up-cut bit. Most dovetail op- erations use the 1/4” or 3/8” straight spiral up-cut 10mm guide bear- ing against sloped bit for the pins. When using the 1/2” dovetail bit side of dovetail provided with the machine for tails, we recommend template cutting the pins with the 3/8”...
Page 31 The bit still needs to be able to clear the top and bottom of the workpiece while remaining engaged against the template sides. Do a quick safety check by running the bearing up and down the side of the template with the router off to make sure you have proper clearance.
Page 32 Tip: As mentioned before, the PantoRouter® does not require a heavy hand. When cutting your test pins, note the amount of pressure you are applying to the template with the guide bearing and how many times you are going up and down each template side. For the most accurate results, try to replicate that pressure and procedure on all of your cuts.
Page 33 Dovetails wider than 8” The PantoRouter ® has a cutting window of approximately 8” wide by 4” tall. In most furniture making applica- tions this is adequate, however occasionally there is a need to cut joinery on boards wider than 8”. One of the most common situations is when making large drawer boxes, case pieces or chests.
Page 34 Guide bearing shaft in center hole of template. Place the board against the Centering Scale Fence and overhang the table about an inch. Bring the Panto- graph forward until the Split-Shaft Centering Jig is past the workpiece but not contacting the table, then lock the front and back depth stops so the pantograph cannot move.
Page 35 Slide the reference block in the back T-slot of the table until it contacts the end of the centering scale fence and tighten it into place. Make sure the top edge of the reference block is lower than the top surface of the table.
Page 36 Skip this template Place the workpiece on the table and against the Remove the Split-Shaft Centering Jig from the rout- Centering Scale Fence. Use a scrap piece of wood er and insert the 1/2” dovetail bit provided with the approximately 1” wide to reference how far the machine.
Page 37 Use the same 1” strip of wood to locate the overhang of the workpiece and clamp it down. Once the workpiece is clamped down, run the guide bearing in the center slot of the template farthest from the operator. At full plunge depth, it should pass through the dovetail slot that was previously cut.
Page 38 Before un-clamping and indexing the workpiece over, test the fit of the joint and adjust the size of the pins as needed by raising the Template Holder using the Template Holder Micro-Adjust as described on page 31. Once the first section of pins has been cut on all “pins boards”...
Page 39 Keeping track of dovetail pieces on a 4-sided box for V3 dovetail templates When making a 4-sided dovetail box, it is import- ant to keep track of the reference faces and edges to ensure all components are aligned when assem- bled.
Page 40 Start with the tails. As described earlier in this section of the How-To guide, always start by cutting tails first. The tails board is cut with the outside of the workpiece facing UP and the inside face is against the table surface. After cutting one end of the tails board, rotate the workpiece to cut the oth-...
Page 41 Cleaner cuts on large dovetails and dense woods When working with dense woods or large router bits on the PantoRouter®, we like to take light passes and make incremental cuts to remove material. This reduces stress on the rout- er bit and produces a cleaner and safer cut.
Page 42 Tip Works the same with V3 A 1/4” spacer was used to account for the 1/8” blade since most everything on the PantoRouter® is 2:1. Once the lid was separated from the body, the dovetails are evenly spaced. The Strength of a Through Dovetail with the Look of a Half-Blind Half-Blind dovetails are a timeless joint seen in many furniture periods and styles.
Page 43 Great trick for asymmetrical dovetails For some boxes and drawers, you’ll want an asymmetrical array, which will need to be reversed for opposite corners of the box. Here’s how to reverse any template array. Record it. Get the templates where you want them for one of the joints, and use a long fold- ed piece of paper as a story stick for marking the centers of the templates as well as the center...
Page 44 Box joints in minutes, with no fitting Even easier than it cranks out mortise and tenon and dovetails, the PantoRouter® uses segmented templates to make immaculate box joints in two sizes, with perfect joints right off the machine—no sample boards or fitting required.
Page 45 There’s another way to do this more quickly and still as accurately on the PantoRouter®. Step 1 - Clamp the workpiece far enough forward of the table that your bit will clear, then bump the bit gently to the front of your workpiece.
Page 46 Check your clearance. Adjust the height of the template so at least half the bit clears the bottom of the workpiece before the bearing exits or bottoms out in the slot. Make sure the router doesn’t hit the bottom of the templates and adjust so the guide bearing reaches all slots.
Page 47 Another dust-free process. Paired with a power- ful vac or dust extractor, the PantoRouter’s dust extractor system grabs every chip. Measure the bit with dial calipers and rip or plane a spacer to the exact same width. The spacer goes between the workpiece and the fence, offsetting this half of the joint so the edges of the workpieces will line up.
Page 48 Dowel Templates These seemingly simple templates are incredibly versatile and have many applications in the shop. Dowels can be cut from the same wood as your workpiece and used as floating dowels (traditional method) or as integral dowels or round tenons. The dowel templates use the 10mm guide bearing on the inside to make the dowel mor- tise, hole or pocket, and the same bit and guide bearing sizes as our mortise and tenon templates for the integral dowels or round tenons.
Page 49 Another method for accurately locating the dowel tem- 10mm guide bearing inside loose template plates is to use the split shaft centering jig, the 10mm guide bearing, and the centering bar. Slide the dowel templates onto the template holder and partially tighten the mounting screw leaving it just loose enough for the template to be able to move side to side.
Page 50 Perfect Fit for Round Tenons Round through tenons can add a nice decorative detail to a piece and can be a great choice when you might need to rotate the orientation of a piece when the mortise and tenon are assembled. Add a contrasting wedge for an accent and a perfectly tight joint.
Page 51 Slide the drilling guides onto the round tenons. The plywood drilling guides make locating the Place the tenons in the desired location, then Forstner bit easy, no measuring or math necessary. simply slide them down the tenon until the double stick tape contacts the mating piece.
Page 52 Specialty Templates and Accessories Same Bit and Guide Bearing Inside and Out. The Diamond and Bow Tie templates use the same 10mm guide bearing and 3/8” bit for the mortise and tenon. Diamond Finished diamond shaped mortise and tenon is about 3/4” X 2-1/2” Diamond shown with a wedge and dowel adorn- ment.
Page 53 Universal Lever and Air Clamps for the PantoRouter® Simple yet powerful, our Universal clamps can rotate 360° on the table and can have either the familiar lever clamp arms or pneumatic or air clamp arms. • Both start with a very high-quality cast stainless-steel base.
Page 54 Calibrate the Template Holder in Under 3-Minutes Alignment of the template to the pantograph and table is critical for accurate joinery. The template holder must be perfectly aligned to the frame and must slide freely on the posts. Adjusting it is quick and easy using the following method.
Page 56 Get the most out of your PantoRouter® with Jigs and Fixtures Auxiliary Table To learn more about when and how to use the Auxiliary table, scan the code and watch this video. Build your own Auxiliary Table by downloading the free plans...
Page 57 See the assembly guide for more detailed photos and descriptions of the PantoRouter® components...
Page 58 YouTube Video Links Scan the code with your phone or tablet to go directly to these videos. Dialing-In the Segmented Slot Mortise Variably Spaced PantoRouter Mortise and Tenon Dovetails Joinery Machine Dowel Templates Guide Bearing Angled Tenons Intersecting Mortise Collars...

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