Replies

1. 
   YesMaam27577 | Aug 18, 2003 01:08am | #1

   Go ahead and make your template. Then attach it to a piece of scrap plywood. Cut the scrap, and try the insert. If it fits, then you just need to duplicate the effort with the table top. If not, then you can make adjustments, and try in another scrap.

   But like a good experimenter, be sure you're taking some notes concerning the critical elements of each attempt. That way, when you get it right, you have a written procedure for duplicating it.

   Vast projects should not be founded on half vast ideas.
1. 
   BG | Aug 18, 2003 02:41am | #3

   YesMa'am,

   I have made a couple of templates and tested it on some 1/2" plywood scrap...the second template is pretty much right on the mark.(good notes) 

   What I don't like is the 1/2" rabbit in the second step.  First of all only half the router base is supported on the cut....making it a bit unsteady.  Secondly, the arc of a 1/2" rabbit bit will not fit the arc of the plastic...could look messy.  Third, a 1/2" of support around the plastic is probably enough but I wouldn't mind having 3/4"...but the rabbit cant go that large.

   I'm kinda thinking of using a 1/2" (or maybe 1/4" straight bit for the arc issue)straight bit with a collar and a straight edge with stops. Make successive cuts to 3/4x3/8" deep by moving the straight edge and then just attach a 1/4" bit and go all the way through around the template.

   what ya think? 

1. 
   YesMaam27577 | Aug 18, 2003 05:18am | #5

   I had a number of the same fears when I cut my router table top. But I now know that I was worried for no reason.

   My top is made from 3/4 thick MDF. So is my insert (I did'nt buy somebody's table top, and I didn't even buy the insert. I made it all myself.) The rabbet at the edge of mine is 3/8 by 3/8 deep.

   And for what it's worth, I have one of the heaviest routers available (M12, 3HP). It's been in the table for over a year, and I've run a few hundred boards through it. No signs of weakening, sagging, or any such nonsense.

   Vast projects should not be founded on half vast ideas.

1. 
   Sancho | Aug 18, 2003 05:50pm | #6

   I didnt route a recess for the insert. I cut the hole to fit the insert then made some levelers I mounted to the bottom of the table to level the plate. you can buy them cheap or make the but using small bolts holes drilled through wood with nuts to hold them on place and loosen for adj. I know there are many ways to do something. That is how I did mine. 

   Darkworks:  No Guns No Butter squilla and the bling bling.

2. 
   BG | Aug 18, 2003 08:37pm | #7

   YesMa'am,

   I re-thought the whole thing as I went to sleep last night, got up at 5 and did it..it came out great.  I wanted to make sure that if the router got away from me it would be to the waste side.  Thanks

2. 
   RANGERP75R | Aug 18, 2003 01:20am | #2

   BG

      Ditto Yes'Maam. Make the test cut on scrap ply or 1/2 MDG. Whatever you got. Test the water before taking the dip.

   sage..jt

1. 
   BG | Aug 18, 2003 02:46am | #4

   Sarge,

   When you built your router table..is that the way you did it?....or did they not have electricity back then....he,he

1. 
   RANGERP75R | Aug 19, 2003 07:42am | #8

   BG

      I built the template then cut a square hole smaller than the template for the router to drop through. Double taped the template down an used an overhead bearing pattern cutting bit to rout out the 3/4" wide an 7/16" deep ledge the insert rests on. I cut the ledge 1/16" deeper so the template sits 1/16" low intentionally. The leveling screws on the insert take it up to table height.

      From the post you have already got there with success. Well done, as there are several ways to skin a cat. The bottom line is getting to the finish line.

   Enjoy......

   sarge..jt

1. 
   BG | Aug 19, 2003 01:05pm | #9

   Sarge,

   Thanks for the comments, it never occurred to me to use a bit with the bearing on the top..I don't have any of those...got plenty of space for bits now...wife gets nervous when she sees all the empty bit holders...lol.

   Half way through the process Woodcraft put a combo Bosch router, Jessem lift system and router table top for TS mounting on sale...all for $350....as you all have said, many ways to skin a cat. thanks

1. 
   RANGERP75R | Aug 19, 2003 06:34pm | #10

   BG

      Regarding the WoodCraft sale. Story of my life, a day late an a dollar short. An I still manage to have fun. ha..ha..

   sarge.jt

3. 
   RoyinMD | Aug 19, 2003 08:08pm | #11

   All great suggestions so far.

   The last router job I did, about two weeks ago, took 45 minutes to set up and test and about one minute to do the router cut.

   Nothing beats a good plan.

   Enjoy, Roy