I have an auxilliary base I made out of 1/4 plywood, taking care to
recess the screws sufficiently and sand/wax it smooth.
One thing to do: Remove the mounting screws for your base and flatten
the tops on your bench stone or a file. In my case, bumps on the
screws were the primary culprit for scratches - especially if the
phillips screwdriver has ever slipped.
Go to your local solid surface fabricator, have him give you a
sink-cut-out made out of acrylic 1/2" thick and make a router base out
of it. The stuff cuts on a table saw without causing any damage to your
blade. It is no more agressive than particle board with melamine....in
fact, less so 'cuz melamine is a bitch on blades. Keep the edges of the
base sharp so that small sharp things can't ride under the base as you
move it. (works like a small snow shovel)
Then spray with Bostik TopCoat.
When I make a base like that, I always make one dimension 1/32 narrower.
That way, I make a pass to clean up an edge on a panel, rotate the base
90 degrees and make a fine climb-cutting clean-up pass. I do this a lot
when edgebanding panels.
In the Good ol' days, when cabinet making in a kitchen factory, we used
to adhere laminate to the router and trimmer bases. this eliminated
scratches and made the machines glide more easily over the tops.
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