I haven't been on here for a while....quite a while.
I decided to take my router skills to another level, and have made repeated attempts to try to get acceptable results in template routing. I'm trying to mount an aluminum car club plaque, approx 5" x 7", 1/4" thick, into a 2" x (?) board in a picnic table top. Please critique my steps, and make suggestions to make this go easier.
First off, I needed a inlay set with the correct size bushing and bit. I couldn't bring myself to spend $40 at a big name woodworking supplier, so I settled on the Harbor Freight set, #99552 for $8.99. Only 22.5% of the specialty store. Made of brass, and mates perfectly with my router template set. I'm using 1/4" hardboard, and I wasn't happy with the supplied spiral up bit as it didn't clear the sawdust very well. Changed to a 1/8" 2 flute CMT carbide #81103211 with much better results. The instructions with the kit outlined steps to make the recess first, then the inlay. Backwards for me, so I used this tutorial that I found online. https://www.busybeetools.com/pages/P...ur-Router.html
Exactly what I needed, and the pictured kit has pieces that look identical to the HF one.
I followed the outlined steps with pretty good results; the plaque fits OK. The trouble I'm having should be the easiest part of the process; cleaning out the recess. Since the bit only leaves a 1/8" outline, extreme care must be used to clean out the recess near the edge. Any suggestions? I'm thinking about using the template, modifying a template bushing and use a narrow diameter bit to stay away from the edge until I get a some of the edge cleared away, then freehand. Or simply use a fence, and guide on the router base. Which leaves only the round corners to freehand. I know that somebody here has done this before, and has some tips. Thanks.