Can anyone offer advice to the best way to make a perfect inside cut from
and outside template? Specifically, how to make a perfect hole to recieve a
router table insert.
All I can think of is using a small guide bushing to make a secondary
template with a bigger hole than the insert (or I guess I could just use a
trimmer/template follower), and then a bigger bushing to make the final hole
exactly the right size for the original insert.
I guess this would work OK but it sounds elaborate. Is there a better way?
I would use a template bit (i.e bearing on top) to make a template with
a hole bigger than the insert, then use a bushing to offset a straight
bit by the width of the template bit to create the desired hole.
What if you used the template you have and make another "inside" template
from it. Then using the new template use a straight trim bit with an
oversize bearing. eg if you use a 1/4" bit to cut the new template the new
template is going to be 1/2" to big. Use a 1/4" trim bit with a 1/2" guide
bearing to make the final. Does this make any sense?
Your all missing something, When you use the insert to make the female hole
at some point towards the end of the cut the peice falls out creating an
imperfect hole, the entire concept is correct if he has drawer full of
bearing, collars and feelers etc.etc.
Quite an elaborate undertaking for a little insert.
Put your router table insert on your router table in the position you want it
Using double sided tape fix 4 pieces of timber, MDF, etc (wide enough to
support the router - about 4") tightly around the insert. The length of the
timber should be the length of your insert plus about 4", thickness depends on
length of the router bit you are going to use.
Butt the end of one piece against the side of the other piece.
Remove the router insert.
You have now created an inside template.
Using a 1/2" straight bit with a top bearing the same size as the bit, rout
out the hole to the depth of the insert.
Change to a larger bearing or use a template guide bush or jigsaw/sabre saw to
remove the rest of the waste material.
Measure the inside diameter of the hole in your router table. Then use
a circle-cutting jig for the router to cut a hole of the size you
If you have a template guide for your router base, the circle jig is
easy to make -- or you can buy one.
I recently made mine table top with a circular insert. To make the
table top hole, I make a template with 1/4 plywood that fit the insert
and use the template and pattern bit to route the hole on the table
top. The thin plywood allow you to test and adjust the fit by hand
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