Mike

Yesterday forum member BrianS and I built a couple of replacement sub base plates for his Craftsman router so it could use PC style guide bushings. The material used was an old plastic sign. Here is the process we followed:
Remove the sub base plate from the router and apply double sided carpet tape. Press it firmly on the material and rough cut to shape with a band saw. Using a pattern bit we cut the final outside shape. The next step was to drill the mounting holes. We used the large diameter hole saw to drill the recess just deep enough for the guide bushing to sit flush with the surface, then the smaller hole saw for the through hole. There is a small amount of material left around the through hole and we used a Forstner bit to clean this up. While you can use Forstner bits instead of hole saws I feel it is easier to align the holes using the pilot bit of the hole saws and this is critical for a good fit. Separate the sub base from your original sub base and countersink the mounting screw holes using a Forstner bit. Since this countersunk area is non critical we used a 1/2" bit as opposed to the factory 7/16" size. (If your router uses flat head screws then use a countersinking bit.)
The sizes of the center holes vary between PC style and the Router Worksop style from Oak Park. The large hole saw will be the overall OD and the small hole saw will be the through hole size for your bushings.

Attached Thumbnails

         

   

__________________
Mike

Advertising

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Router Forums

mountain monkey

Awesome guys! I just may do this myself since I just can't decide which replacement base to buy for either of my two "stock" routers. And I love how you salvaged an old sign for the material. The possibilities are endless!

Josh

cbsjoez1935

Mike,

I like the idea of using the hole saw instead of the forstner bit, because of the advantage of the pilot hole bit. My problem is that the hole saws I have are for door locks and are way off size. Where did you obtain the 1-3/16" and 1-3/8" hole saws? I just wish some manufacturer (are you listning PC?) would make those size router bits and then cutting the holes would be a snap. My 2 bits worth (inflation you know).

Joe Z.

__________________
JoeZ If you never made a mistake, you never tried anything

bobj3

Hi Joe

Here's a set for 8.oo dollars and it has the sizes you need, I use them all the time and they work great...
Just clamp the stock to the drill base table, drill a 1/8" hole then use the 1 3/8" bit then the 1 3/16" bit to drill the center hole out all the way..it's a very fast way and it works every time...and I'm sure once you do it a time or two it will be the last time you buy any base plates for the router or the router table..

Just a note,,, a square sub base plates are the best....then they can be used in many more ways, for a strait edge,to hold bearings on the corners for M & T sloting, etc.


http://cgi.ebay.com/5-pc-Set-of-Fors...742.m153.l1262

Attached Thumbnails

   

__________________
Router Tables plans FREE, plus more
http://www.absolutelyfreeplans.com/W...p_projects.htm

Router Tip Archive
http://www.routerworkshop.com/router_tip_glossary.html

Calculators
http://www.routerforums.com/dynamic-calculators/

cbsjoez1935

Bob,

Thanks for your help. I already have the proper size forstner bits. I felt it would be much simpler to do it with the right size hole saw. That's why I asked where Mike obtained those sizes.

Joe Z.

__________________
JoeZ If you never made a mistake, you never tried anything

bobj3

Hi Joe

The Hole saws are the hard way to do it . it can cut the 1 3/16" hole easy but when it comes to the 1 3/8 hole (recess hole it can't do it right,) it must be flat and true to hold the brass guide just right..

I also use a fly cutter that works well but a good set of forstner bits is the way to get the job done right plus you can make your own base plates to hold the big guides ( 1 1/2" x 1 3/4" ) Oak-Park/Lee Valley type and they do come in handy when you need to use a bigger bit ,like a 1" for just one of many...

http://www.leevalley.com/wood/page.a...000,51208&ap=1
http://us.oak-park.com/catalogue.htm...&product=BG034
http://grizzly.com/products/Round-Fl...et-3-pc-/H7537

========

__________________
Router Tables plans FREE, plus more
http://www.absolutelyfreeplans.com/W...p_projects.htm

Router Tip Archive
http://www.routerworkshop.com/router_tip_glossary.html

Calculators
http://www.routerforums.com/dynamic-calculators/

cbsjoez1935

Bob,

Thanks again for your help and good advice

Joe Z.

__________________
JoeZ If you never made a mistake, you never tried anything

bobj3

You'er Welcome Joe

I have made so many base plates I have lost track of how many...
I think it's one every week for the pass 2 years or so.. I now want to make one more now for the new router I just got, so I can drop it in one of the router tables>>>> ..

========

==========

__________________
Router Tables plans FREE, plus more
http://www.absolutelyfreeplans.com/W...p_projects.htm

Router Tip Archive
http://www.routerworkshop.com/router_tip_glossary.html

Calculators
http://www.routerforums.com/dynamic-calculators/

Mike

For some reason my tagging of new postings is not working right and I missed this. Joe, I have a Lenox set of hole saws and most sizes are available from HD or Lowes. The advantage of using the hole saw is you chuck the 1/4" bit and plunge for a perfect center. Following with the hole saws is easy with this pilot hole. The larger saw is used first for the part way through cut and the through cut with the smaller saw cleans out the hole.

__________________
Mike

jw2170

Thanks Mike,

You have saved me some dollars......

I will still go to Carba-Tec (Sydney) this weekend to get the bushing set.

(and I will have to check the sizes of my hole saws (probably metric


James