I used to get frustrated with the inordinate amount of time it took to set up my router for even the simplest cuts. The main problem was that the distance from the edge of the router base to the bit was always some weird dimension like 2-19/32 in. So recently, while making some new custom router bases out of Lexan, I got an idea. I cut the rectangular base so that each edge of the router base will be exactly 3 in. from the edge of one of my standard bits. For example, if I am using a 1/4-in. bit, the edge marked 1/4 in. will be exactly 3 in. from the edge of the bit. I also made one edge 3 in. from the center of the bit, which is frequently useful (see the drawing). In addition to writing the bit size on each edge, I color-coded the edges with permanent marking pens to help me remember which bit/edge I am using. To make the base, I cut the Lexan slightly oversize, and then, after mounting the router and making test cuts, I ran the base over a jointer to carefully trim each edge to the exact offset needed.

Derek Roff, Albuquerque, N. Mex.

Fine Woodworking Magazine, April 1992 No. 93

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