Assembling the all-metal pantorouterThis is an older version of the guide from 2014. For how to assemble the current (2015) version please see here
For how to buy an all metal pantorouter, See here
Assembling the base frameYou can see a cool animation of assembling the pantorouter,
part of one of Frank Howarth's videos
When assembling the base frame, make sure the thin washers go inside the slots in the rails, not outside. I used a small screwdriver to push the washers against the screw's head while sliding the rails together.
It's best to add the shaft holders and the angle braces to the double-wide crosspiece in the middle before joining it with the rails on either side.
Assembling the plunge carriageThe plunge carriage comes mostly pre-assembled. However, you will need to assemble and install the template holder on the carriage.
Mount the vertical parts of the template holder to the metal base with four screws. Be careful inserting these screws, it's easy to get them cross threaded. It's advisable to use a regular screwdriver so you can tell if they are cross-threaded.
The cross piece has two fasteners on each end for attaching to the rail. You may need to use a screwdriver to lightly push them outwards as you slide the crosspiece in. You may also need to loosen the screws holding these fasteners to get them in.
lock the cross piece in place by tightening the screws in the side of the crosspiece with an Allen key.
There are some springs in the pantograph mechanism to help hold up the router. It's easiest if you leave these unhooked until the rest of the machine is assembled so that the pantograph lies flat and does not push itself upwards.
Mating the sled with the framePlunge sled and frame ready for mating.
Start by inserting one of the shafts in the linear bearings under the plunge sled. Also note that the tension springs in the pantograph have not yet been hooked up. This keeps the pantograph nice and flat.
With the shaft in place, lift the plunge sled onto the frame. Be sure to hold the shaft while lifting the pantograph so it won't slide out. Slide the shaft forward through the front shaft holder. Slide it about 8 cm (3") beyond the shaft holder
The screws on all shaft holders should be loose during these steps.
Once the shaft is in the linear bearings, slide the front shaft holder in place to line up with the shaft and push the shaft through it.
Please note: Earlier versions had the table further back, but mounting it this way allows the router to move further from the table, allowing for more plunge depth.
I made a made a short video on this
The feet are attached with small M4 screws to the bottom of the rails. The screws screw directly into pre drilled and tapped holes in the bottom of the frame, about 8 cm (3") from the ends of the long rails.
For a video on assembling the machine, see:
If you would like to buy an all metal pantorouter