Don't follow the installation instructions step by step. The 3" dimension in Fig. 1 is wrong. Do the math at the bottom of the next page and then subtract 3/8" from that figure for the set-back on the homemade guides.
viz: ((diameter of base minus 1/2") divided by 2) minus 3/8" = setback for template.
DAMHIKT
Am responding to my own post with a follow-up to report that Paul at Rousseau responded very positively and in a reasonable amount of time.
When things go well it is easy to recommend just about any company. They all have some virtue or other that makes them worth dealing with for someone under some circumstances.
However, when the chips are down the story often changes.
Paul opted to lose more than he could possibly have made rather than lose a customer. All he asked from me in return was help in re-wording the directions so that others would not be confused by them.
The cleats mentioned above are oak, glued on with polyurethane glue and will be (sometime this weekend) reinforced with several 1/8" dowel pins glued in place. I suppose I could also just use common nails glued in place, too. The point being that I am going to try to make the repair I had already started suffice instead of just reflexively reaching into someone else's wallet.
The fact that Paul responded quickly and favorably plays a large part in this decision. As things stand now, we are agreed that if the repair holds, he is off the hook. If it doesn't, I'll have to repeat the work of making the table but I won't get stuck with the expense.
Until his revised directions end up in packages, keep in mind that the outline you are directed to make is 3/8" too large. Use that outline, but subtract the 3/8" from the 3" dimension given in Figure 1 to get the proper setback. Also keep in mind that the setback figure will vary with the size of your router base and you will have to adjust your numbers if your router base varies from 6 1/2". Don't assume. Measure.
Bill
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