I've had the need to to recess a male part into a work piece. Kinda like inlay only less ornamental and more utilitarian like mounting a mounting plate to a router table. I know the math but I thought a table would be helpful.
[IMG] Inlay-Insert xref
by pat w1
, on Flickr[/IMG] Theoretical at this time - Check on scrap first
The table is two sections. The top section is for creating a female template from the master part that needs to be recessed. The bottom is for cutting the recess for the master using the female template just created. Various bit diameters are listed across the top and the guide bushing sizes are listed along the left side. (sorry - no millimeter sizes). The object is to use the table to obtain a number (in green) that corresponds to a particular bit-bushing pair and then obtain a matching number in the other table with another bit-bushing pair. The red shaded numbers have no match in the other table and the purple numbers are no fit/too tight bit-bushing pairs.
Let's say I have a odd sized router mounting plate that I need to install in my brand new router table. I need a female template so I pick a bit-bushing pair from the top table. I'll go with a 1/8" bit and a 3/8" bushing. That crosses to an '8' in the top table. I attach the mounting plate to the template material and cut the template. Then I chose a suitable bit-bushing pair from the bottom table. For '8' I have three choices:
If I used the last one I could get the recess and hog out enough room to get the 1" bushing into the groove I just cut and then use the edge of the recess to directly cut the opening below leaving a 1/4" mounting lip.
I did this on Excel without having the actual parts in front of me to back check my math for fit so if there are more combo's that fall out please let me know.
Also, if anyone sees that I've hosed this up in any way please sing out - I'd hate to be responsible for someone's trashed project.