Rounding corners of table insert - Page 2 - Router Forums
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post #11 of 18 (permalink) Old 12-24-2017, 10:47 PM
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Originally Posted by DesertRatTom View Post
The thing about a simple, shop made plate is that you will find it hard to use inserts, which can be changed to fit your different sized bits. Having the insert fit close to the bit size helps with above table dust collection. Suggestion on cutting the plate opening is good. As to cutting the opening for the bit, it needs to be a little bigger than the biggest bit you expect to use, which means for all smaller bits, you'll have way to large an opening. This is why most of us use commercial plates, some of which now have twist lock inserts instead of the 3-screw (where'd that darn screw go?) veriety of old. Kreg makes some nice aluminum plates for reasonable prices. And they have already rounded corners.
Didn't know that when I made my router plates. All I use are 1/2" bits, and I think the hole in my plates are 1 1/2". Works fine for me. But it would actually be no biggie to make different size inserts if I ever decide to. I don't know if I would enlarge the hole or not, likely not, but would make inserts to fit the hole, with different size holes in them, and glue some support pieces on the bottom of the plate, to support the inserts. As my top is 1/2" plywood, inserts of 1/2" plywood should be able to go into place and be right on. Possibly use magnets to hold the inserts in place if need be. Any reason why that shouldn't work?

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post #12 of 18 (permalink) Old 12-26-2017, 09:32 AM
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When making the jig for routing the hole, decide the diameter of the bit that you will use, also the outside diameter of your chosen template guide then use this simple formula: guide dia. - bit dia. + size of the finished hole. For example, a 1/2" bit and a 1.5" guide + 2 1/2" finished hole: 1.5 - 1/2" + 2.5 = 3.5".
The simple corner jig shown takes just minutes to make and you decide on the radius. I saw the corners off first. The shot was of a quick set-up for a member several years ago.
The pdf shows how to make a very simple circle routing jig.
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post #13 of 18 (permalink) Old 12-26-2017, 08:45 PM Thread Starter
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Thanks for the photos Harry. Do you coat the edges of the template? If so, what with?
By attaching a template to the under side of a work piece and using a bottom bearing bit....... is that so the template can be attached without damaging the top side (the good side) of the material you are working on?
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post #14 of 18 (permalink) Old 12-27-2017, 09:14 AM
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Originally Posted by ranman View Post
Thanks for the photos Harry. Do you coat the edges of the template? If so, what with?
By attaching a template to the under side of a work piece and using a bottom bearing bit....... is that so the template can be attached without damaging the top side (the good side) of the material you are working on?
No, I've never found it necessary to coat the edges, just keep the router pressed firmly against the template. Regarding whether to have the template on the top or bottom is just a matter of choice, also on what bit you have, top or bottom bearing.
Whilst the photos show wood being routed, Aluminium routs quite easily, I find that slowing the router is the best, too fast and it tends to melt the Aluminium and bits stick to the cutting edge requiring repeated stops to remove.
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post #15 of 18 (permalink) Old 12-29-2017, 01:52 PM Thread Starter
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I can't slow my router electrically, so I used a 1/4 inch bit instead of a 1/2 inch bit and used wax on the bit and the aluminum and routed slowly.
In rounding the corners, I can do 98% of the corner cut with a jigsaw and a final cut with the router
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post #16 of 18 (permalink) Old 12-29-2017, 02:00 PM Thread Starter
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I can't slow my router electrically, so I used a 1/4 inch bit instead of a 1/2 inch bit and used wax on the bit and the aluminum and routed slowly.
In rounding the corners, I can do 98% of the corner cut with a jigsaw and a finish cut with the router. I still haven't decided on the radius. I don't think it's important. I just want to remove the sharp edge for a cleaner look.
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post #17 of 18 (permalink) Old 12-29-2017, 02:33 PM
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Randy if your router doesn't have speed control or soft start you can use an after market speed controller. I think Rockler has them.

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post #18 of 18 (permalink) Old 12-30-2017, 01:59 AM Thread Starter
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Not in the budget Chuck. Still gots to make me a table. I could probably just file the corners, but then they wouldn't match the finely machined finish of the rest of the plate.
A speed control is a ways down the road.
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