Hi all. I’m looking to make a prototype project which if it works I will need to repeat so am thinking of making up templates so I can use a bearing guided router bit in future. What material do you recommend to make the templates so they aren’t too heavy, are structurally sound and won’t end up chipping too badly if one gets dropped?
Would 1/8″ or 1/4″ plywood do it and if so do I need to use the expensive stuff or would the cheaper stuff work as well.
Thanks in advance.
Roger
Replies
I think most people use MDF.
I have 1/4" MDF, covered with Melamine foil on both sides. That's my preferred template material. It's not real easy to find; the home centers don't have it. You need to go to a lumberyard with a good selection of sheet goods.
I use 6mm baltic birch ply for most of this type of template work.
Alan
http://www.alanturnerfurnituremaker.com
A couple of factors you might want to consider are how many times the template will be used and how sharp do you keep your router bits? These two factors will have a direct bearing on the amount of wear on the edges of the template. This, in turn, can have a bearing on your choice of material. Assuming you are just duplicating shapes by using a flush trim bit, if you use a thicker material for your template, you can occasionally raise or lower the bit in the router to use a sharper portion of the bit and also transfer the wear on the template edge to a different area. If the shape of the template allows, you could also apply plastic laminate to the edge for increased durability. One more tip - there are bits available with double bearings that would distribute the load on the template edge plus give you some insurance against a faulty bearing.
Lots of choices depending on skill with material, use of templet and number of copies desired. Collar/bush or bearing pilot will play a minor role; the spinning bearing taking its frictional toll more rapidly than collar guide.
Typical material perhaps in descending order of durabilty.
Steel>aluminum>laminate-phenolic>polycarbonate>acrlyic>UHMW-polyethylene>Baltic birch ply>MDF>Masonite>Wood. Wood end grain quite good.
Reading backwards perhaps the latter the easiest to shape, tool steels the most skill required.
Router templet maker
If you need high precision, don't use MDF or Masonite, they will expand or contract with changes in humidity. They will also wear down slowly with repeated use. Baltic birch would be my choice for small production runs, metals and plastics for higher volume work.
John W.
Edited 5/3/2005 9:16 am ET by JohnW
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