sf_basilix

Hello to all,

I am in a bit of a quandary as I recently purchased a Rosseau router table insert for my already existing Bench dog ProMax Cast Iron router table that I have attached to my table saw. I had to purchase a new router plate as the one that comes shipped with the bench dog model is not flexible enough to insert bushings or open wide to accept larger router bits. I saw that the Rosseau has inner rings that you can remove to adjust to the size of the bits and so I purchased it. It is black phenolic (?) with a grey outer ring and a red inner ring which can be removed.

The problem I have is now that I opened the Rosseau packaging and tried to insert it into the cast iron table, it doesn't fit. The Rosseau is too big by about 1/4" on two sides and about 1/2" on the other two sides.

So first, I'm really annoyed that either Rosseau or ProMax didn't conform to any type of standard sizing. Now I'm even more annoyed because I need this router plate to finish my routing and I am stuck as to what I should do.

My thought that I need advice on is this:

Since I know I cannot re-mill the cast iron router top, I am forced to resize the router plate. But I have never milled a router plate before and am nervous in doing so. I don't feel comfortable enough using my table-saw to cut the edges down to size, so I figure I'll probably use my band-saw. But is this OK? Has anyone done this and is there anything I should worry about? I am hoping this is something I can mill, otherwise I'm really outta luck here....

So I need some advice from some veteran router folks - has anyone attempted this before? Any tips?

Many Thanks to all!!

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bobj3

Hi sf_basilix

It's duck soup,,, You're right on about the band saw,,, use some double sided carpet tape and stick the two plates up as one, trim some of the over size plate on the band saw (with in a 1/8" of the edge) then drop in a trim bit in the router table and remove the rest of the plate... this will make the plate just the right size...

You will need to get the plates on dead center with each other, you can use your brass guides for that job or cut one out with a hole saw,(plug) to line up both plates ,then once you have them set press it down to the other then just trim the plate off on the band saw..


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sf_basilix

Thanks Bobj3 - I will see if I can try that tonight. You don't think I will have any issues with a straight bit up against that material? Do you think it will chip out at all?

bobj3

HI sf_basilix

Should be fine, just turn the speed up on the router to 24,000 rpms.,if you have a skew angle trim bit use it but if not it should be fine..

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DAUTTERGUY

Bob J3 No way I would have ever thought that I could ever cut Aluminum with a router bit. Safety Glasses are a MUST I TAKE IT?

bobj3

Hi DAUTTERGUY

Because Alum. is a nonferrous material router bits will cut it just like brass..or hardwood..

I will gull up the bit and must be cleaned out of the bit from time to time but it will do it..carb.over Alum..

Safety Glasses,,, always is a must with the router all the time..chips are coming out all over the place, dust is one thing but metal chips is something else...........

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DAUTTERGUY

Safety Glasses ALWAYS, Just remembering my work at North American Avation. HOT ALUMINUM CHIPS

tmiller

A little kerosene on the cutter will stop most galling from happening, as long as you keep amount of revs down! The faster you cut aluminum the more chance there is of actually melting the stuff and sticking it to the cutter. It's surprising how easy it is to make 1200 degree temps cutting metals.
If you wanna make a real nice finish pass it'd be OK to spin it up, at a small depth of cut.. I hope I haven't put in my 2 cents too late or ruffled any feathers, but now you're talkin' bout what I do for a living!