Small cut-out in thin template - Page 2 - Router Forums
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post #11 of 14 (permalink) Old 11-05-2018, 04:02 AM
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Originally Posted by DesertRatTom View Post
I'd probably start with laying out the cutout, finding center then use a large Forstner bit to hog out the center. Then some smaller bits in the four corners, then chisels for the rest. I'd probably leave it a little proud then some sandpaper on a block to perfect the sides and corners. But the best way to do this would depend a lot on your tools. If I used a chisel in the corners, i'd sharpen the heck out of it first, and I'd scribe the line so it didn't splinter.

I also might choose to use four guide boards as Harry suggests to rough cut the center opening. Cut the outside dimension with the table saw, then lay four boards close around it to define the opening and use a bottom bearing trim bit to cut the inner opening, and use sandpaper to perfect the opening. This would only work if you have your bit perfectly centered. I'd use a trim router because it's smaller and more manageable. You'd have to place the guide boards so the inside cut was accurate, or a little proud so you can sand it flat.

This is definitely going to depend on what tools you have. Or, take it to a local CNC shop and get it done quick and easy.

Lots of ways to skin this cat.
Tom, the four pieces ARE the template. As shown in one of the shots, the simple formula to calculate the size of opening in the template is: dia. of template guide minus diameter of the bit plus the size of the finished project.


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Last edited by harrysin; 11-05-2018 at 04:19 AM.
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post #12 of 14 (permalink) Old 11-07-2018, 09:01 PM
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I agree with harrysin's suggestion. I used this technique on jigs that require square corners as in the attached photo of a band saw jig for cutting an inside radius.
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post #13 of 14 (permalink) Old 11-08-2018, 01:04 AM
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I vote for Harry's idea. I use that very idea for lots of things. If concerned about joining the 4 pieces, just fasten another overlapping layer on top. Masonite or MDF is perfect. I use 23ga headless pinner to fab jigs and such. With this method, you could have a template in 10 minutes flat...cheers, guys
Jim Pearson
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post #14 of 14 (permalink) Old 11-08-2018, 07:48 AM
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Needing to cut some slots of the legs for my adjustable workbench, I made this jig from 1/2" MDF - as said, takes about 10 minutes (plus drying time). I made extra length of the center block once I had the perfect fit on the guide bushing so I can make more in the future.
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