Making Router Table Insert and Cutting opening for same - Questions

[Hoosierpopi]

Another post about rectangular vs round router base plates contained a suggestion that the rectangular approach would also serve as a/the router table insert. Good idea, thought I. And, adding a router to my RAS/Miter Saw work table became a new "thought-stage" project.

I've actually done this before, but thought to ask here for ideas on how to cut the recess for the router plate (should I go the purchase route and buy a "professional plate/base and how to cut the base plate should I decide to build my own.

I was thinking of some sort of jig that would allow me to do both (cut the plate & the recess) so that the one fit precisely into the other.

I have seen articles on the task over the years, but have none bookmarked at the moment and the pile of woodworking magazines I've save are too deeply store for ready access.

So, if anyone happens to have a suggestion or a URL that would prove helpful, please response.

Thank you

[-MIKE-]

This is the easiest technique I found, when I was looking... and it worked flawlessly and accurately.

[D'ohBoy]

Set of 3/8" and 5/8" bearing collars and a 1/8" straight bit. Attach the plate to the template stock and rout around it with the smaller bearing collar. Now you have a reuseable template. Attach the template to the table surface and using the other bearing collar, rout the dado (or all the way through if using levelers) to support the insert.

Bob's yer uncle.

D'ohBoy

[D'ohBoy]

Oh, yeah. Ummmm.... very similar to that link. But mine leaves you with a reuseable template.

D'ohBoy

[Hoosierpopi]

=BC" (for example, a =BC" bit and a =BE" collar,"

That is a good URL / Page - Thanks

[Hoosierpopi]

=A0Now you have a reuseable template. =A0

Thanks, Your approach offers an added "bonus"

The eight-inch bit seems a bit flimsy. What if I used a larger diameter bit (I have quarter and half-inch bits)?

template bushing and straight cutting bit combination that nets =BC" (for example, a =BC" bit and a =BE" collar,

[D'ohBoy]

As my calc prof used to say, I'll leave the math up to you ;) Do the math, draw it if necessary. It is a seemingly easy task to do, but once I tried to do it in my head, I found myself reaching for a piece of paper. When I was younger, that wouldn't have been necessary ;)

D'ohBoy

[dadiOH]

Cut some strips of ply or hardboard about 2-3" wide and 4-6" longer than the proposed router plate. If the proposed router plate is to be 1/4" use 1/8" thick ply or hardboard; if the proposed router plate is to be thicker than1/4" you can use 1/4" ply or hardboard.

A. If you already have a router plate, use it to make a template...

1. Butt two strips of ply/hardboard against the two long sides of plate.
2. Hold those two together by by gluing two more strips on top of them; they are butted to the plate also
3. Glue filler pieces onto the two long pieces of ply/hardboard; they need not be the exact length needed, just close enough to fit
4. Flip the template over and glue two filler pieces on top of the short pieces. You now have a rigid template with half lapped joints.
5. Use the template to cut the router plate recess in the table top. Stick it to the table top with carpet tape and use a bit with the cutting diameter equal to the shank diameter guiding the shank on the template.

This will work for any rectilinear router plate, the corners need not be 90 degrees. The plate will be easier to insert in the table recess if you taper the sides of the template slightly at the bottoms.

--------------------------- B. If you don't have a router plate...

1. Cut one out on a saw and go to A-1. Note: file or sand edges reasonably smooth first.

- OR -

1. Make a template to the size you want the plate to be plus 1/2"
2. Stick template to plate material with carpet tape and cut out plate with 1/4" bit with a 1/4" shank. Guide shank on template.
3. To make the cut in the table top you need to offset the bit by 1/2"; use a 3/4" bushing or extend the edges of the template by adding material that is precisely 1/4" (assuming the router bit you used was precisely

1/4").

[WD]

In mid August I completed a router table using Rocklers discontinue aluminum

9X11" router insert plate. You might wanna see pics. I will reduce the sizes and post one at a time, so to make sure all the pics show up in abpw.