Routing a perfect insert rebate.

[Steely Stan]

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?

Regards

[JackD]

How about stacking the old insert and the new insert and running a straight bit with a roller?

[George M. Kazaka]

Depending on the size you are looking doe try a hole saw and then a spindle sander

[Mark Jerde]

He needs to cut the hole for the insert, not make another insert.

I'm lurking because I need to do the same, moving my drill press sanding drum table to a new, bigger DP.

-- Mark

[JackD]

Nevermind...

-Jack

[George]

You've got the right idea. Rout a female from the male, small collar to bit distance. Use female with greater collar to bit distance to make the opening.

[Shawn]

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.

Shawn

[Erik Ahrens]

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?

Erik

[George M. Kazaka]

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.

[Sprog]

[Adam White]

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 want.

If you have a template guide for your router base, the circle jig is easy to make -- or you can buy one.

Adam

[may]

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 sanding.

[Mark Ohlund]

My additions below.

Set the router bit depth by placing the table insert across two of the pieces of timber. Then place your router on top of the insert (which is on top of the timber) and set the bit depth to just touch the table top. This will set the router depth to be exactly the thickness of insert plus the templates and the resulting routing to be exactly the depth of the insert.

~Mark.