Let me elaborate some of my ideas.
I've been inspired by Jim Topin's jigs in his table saw book. He
drills holes in the metal body of his fence, and attaches his
"Universal Rip Fence" to that. And when he wants a different fence,
he attaches a second fence to his rip fence, which is attached to the
It seems to me that a single fence would be preferable to two fences.
So I'm trying to use the quick mount/dismount feature to hold the
fence in place.
A friend says I should just rough cut the holes, eyeball the location
of the clips, and slot the holes on the clips to make them adjustable.
The problem is aligning the 4 clips so the fence face fits onto the
metal fence body. Getting all 4 perfectly aligned seems like it would
be difficult. I don't want to have to struggle with the fences every
time I swap one for another.
So this is what my ideas are.
I first tried to place a piece of paper over the existing fence and
did a rubbing to locate the holes. I tried to transfer that onto a
thin metal template, but was a PITA using sheet metal cutters, files,
a nibbler, etc. There has to be a better way, I thought.
My next thought was to take a panel pilot bit, and grind off the
point, so the bottom of the bit is smooth, and using the original
fence with the clips removed, make a duplicate of the holes using the
original as a guide. I'd make some rough holes for a started cut, and
place a piece of 1/4 plywood over the fence, and make an exact
duplicate of the holes.
But then if I use this as a guide, the router bits with the bearing on
top are too deep. And if I use a bushing, the hole cut won't be the
exact size as my pattern.
I'm thinking of using a keyhole router bit with a bushing guide to
make a copy of that pattern that is slightly larger, and then using
this second guide to cut the holes. I think I found a combination that
may work, but I have to test this.
Another idea is to take the existing plastic fence face, with the
clips removed, and drill through the fence where the clip holes are,
and use these to mark the pilot holes for the clips. I still have to
cut out the holes for the clips, but that should solve the alignment
issue. Then roughtcut the openings.
Am I making this way too complicated?
As I said - my freehand skils with a router are limited.
I'd rather have a solution that lets me make several custom fences.
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