TerryRFC

To answer a couple of comments:

Yes I am creating chip displays that will hang on the wall. One chip per hole. The 40mm bit is way too big for this and leaves a large gap at the top.

I am mostly concerned with easily creating 25 to 40 chip holes in a single display and repeating that process over and over with a wide variety of shapes of the display. Some will be rectangular. Some hexagonal. some in the shape of the card suit:Spades or Clubs or hearts or Diamonds. Repeatability and ease of working are my main concerns. That is why I came up with the idea of the turn table.

I will be creating 2 hole templates that can be used for any display. One will be a 4 rows of 5 holes in a rectangular pattern and the other will be 4 rows by 5 holes in a hex pattern.

I will then be creating many templates for a wide variey of outside shapes of the displays.

In creating a display I will first route the outside shape with a template. Then I will use one of the 2 Hole templates to populate the display with recesses that hold a single chip. I may only make 6 recesses or I may make 40, all depending on the size and shape of the display.

I figure using a turn-table will make the process repeatable and accurate.

;-)

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Terry L. Pinotti
Mpls, MN

Slow and easy does it.

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harrysin

Terry, you obviously have the methodology all worked out without outside help, but the thing which still puzzles me is why accuracy to three decimal places is required, does it really matter if 1.5" instead of 1.575" is used and a dab of adhesive applied to the rear of the chip considering it's for display purposes only. Is that extra 75thou. really that important? As a matter of interest, if you take a peep at these shots, you will see that 1.575" is in fact a smidgeon under 40mm, the actual conversion shows the 1.575" to be 40.03mm.

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Harry

Charles M

If you use template guides and center them properly you don't need to worry about keeping one part in contact with the template for accuracy. More importantly, it seems to me, you will need some way to accommodate the varying sizes of chips so I think you will need a lot of different sized templates. Or one of these:

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Charles M
Freud America, Inc.

TerryRFC

I will add some shots of my sample tries. I think you will see the big difference in the fit of a chip in a 40mm hole versus a chip in a hole that I did with the router and a collar guide.

I will also try and make some photos of my sketches and see if you think this is going to work. I know I can make one and have it look good. It might take me 8 hours but I know I can do that. I would love to be able to roll one out in under 30 minutes. We shall see.

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Terry L. Pinotti
Mpls, MN

Slow and easy does it.