Greetings folks. First post in quite some time.
Anyone else out there have trouble with Bosch template guides breaking?
Here’s what happened: I was routing a 4 3/4″ round hole through 3/4 MDF topped with formica. My template was 1/4 MDF. I was using a 1/4 solid carbide up spiral bit in a 17/64 ID x 5/16 OD guide. This was the first plunge and was 1/4 deep or thereabouts. About 1/3 of the way around (clockwise and slowly), the cylinder broke away from the mounting plate, with catastrophic results. Countertop and template both ruined, to say nothing of the guide itself. Fortunately, the bit seems to have survived.
Now, had this been the first occurrance, one could write it off to a single defective guide, but the exact same thing happened (on the underside, fortunately) when I was routing out the countertop connector bolt recesses. I just happened to have another guide of the same configuration, and finished the underside with it, but it didn’t even make it through the first of 5 through holes working from the top. Fool me twice…….
I took some photos of the offending SOB, had them emailed to me at home, but can’t open them for some reason, so can’t post them for your edification +/or amusement. What I see (and I’ll try to post the photos soon) is that the shoulder of the guide cylinder is attached to the mounting plate through some kind of magic, or maybe a wish and a prayer, and the miracle is that it lasted as long as it did.
This could be extremely dangerous, as the condition of the surviving cylinder gives evidence of flying shrapnel (yes, I was wearing safety glasses). Unless someone can point out to me something I was doing wrong, I would urge all of you NOT TO USE THESE DAMNED THINGS!
The Bosch system does include a PC system adapter, and come Monday, I will have another go using it and a PC guide.
Does anyone make a decent (and safe) set of Bosch system template guides?
Awaiting your responses.
Replies
OK, I think i've got the pic files posted.
Wouldn't yet put the blame on the guide.
At 17/64 ID and a 1/4" cutter you have to have near perfect centricity of both.
Extend a lot of cutter, put <3/4" of the shank in the collet, and that cutter can hit the inside wall of the collar and rip it right out of the plate. In my view you did not have enough room for chip clearance between the cutter and the collar.
Moreover, (& another reason spiral cutters are risky) an up spiral pulls the GD chip right up into the collar and jams/wedges itself between cutter and collar extension. A severe outcome, but not unexpected x this observer.
A legal issue: Maybe but I think you have to share part of the blame.
Routers
Thanks for the reply. Point well taken. If I seemed to be laying all the blame on the manufacturer, I can only plead temporary insanity - I was just a bit het up.....and witness my plea for correction, which you have provided in spades.
Great web site! Speaking as a (so far) indifferently talented jig maker, you may well get a bit of my business one of these days.
& I won't hold tha agin' ya.
Somewhat of a similar circumstance happened to me with a Bosch router template guide.
I was using the guide with a plunging base and I happened to plunge too far into the work. The collet nut hit the backside of the template guide and burned where the bushing was fastened. The bushing broke loose and things started whirling around very quickly; fortunately I wasn't hurt.
The Bosch router guide template system has always seemed pretty flimsy to me. It's made largely of stamped metal and doesn't really fasten in place very securely. You can move the bushing plate around with your fingers even after it has been snapped in. Despite the obviously low-cost materials, the bushings are pretty pricey.
I also question the wisdom of having the bushing and plate that it's attached to made of separate pieces. As you and I have both discovered, that's not a permanent solution; the pieces can break apart from one another.
Glad to hear you weren't hurt. I'm going to look up that adapter to which you referred. I've got a bunch of Porter Cable bushings and never had the slightest problem with those...
Zolton
If you see a possum running around in here, kill it. It's not a pet. - Jackie Moon
I agree with you re: the wisdom, or lack thereof of a two piece unit. Probably less expensive to produce, certainly cheaper. Haven't noticed any movement after installation, but will certainly check for same, as I plan on using the PC adapter and PC guides tomorrow AM.
Thanks for the reply.
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