Hi Tom . Are you asking someone to come up with a way to do it on a table? At first look I might not use a router at all for some of it, then using the table for the rest may be simpler.
I think any project can be accomplished on the table, whether it is simpler or worth the set up to make it safe is another question.
People who visit this forum are left with the impression that more than 90% of all routing processes can be achieved on the router table. What you have submitted saying you think any project can be accomplished in the table is adding fuel to the fire. I am not saying that the project I have submitted which was done in the plunge mode with the aid of the template guides could not be achieved in the table mode. You hit it right on the nose "is it worth the set up to make it Safer". I have to say yes it is.
When I do make any postings regarding the method I have developed, I usually have tried and had success producing the item with the plunge router in the plunge mode. I have given consideration to the safety factor before I proceed, whether it is to be produced in the table or plunge. (I have three routers set up permanently in the router table). I have looked at the challenge given me and made the decision on safety. Under no circumstances would I have submitted the project until I had completed it. For interest sake only, this actual clock was made by one of my blind students when I went back teaching for a year at the Association for the blind.
I was only asking some router enthusiast to consider if this could be done in the table and submit some procedures used, in the same way as I submitted drawings of my Jigs and templates. Personally I do not think I would attempt to use the table but I would always be interested when someone actually produces the item.
In the near future I will be doing a 'film shoot' when producing this item on DVD showing more clearly step by step the procedure I have developed.
I suppose what I am trying to get over to members is, there are other ways of using the router and do not be led to believe that it should be done in the table.
I have many processes that in my opinion should not be attempted in the router table and people have to 'think outside the square' when considering their next project.
I have decided to try and get into our colleges and senior schools this year to illustrate use of the guides. I did attend a couple of schools just before they broke up for the Christmas holidays and I had a good response to what I had presented hence the reason to make the effort to attend others.
Enclosed Joint of a (mortice)
oops should have read Tenon
incorporated on a mitre and the Cabinet handle are two more examples that should not me made on the router table.