I need a little help here guys, I'm not sure where my thinking went wrong and I'm still not really sure why this didn't work. Somebody enlighten me.
In order to inlay a router plate, rather than taking the normal plans of attack, I decided to try a trick that I'm sure I've used before with success.
Here's the process.
1.) lay a plate blank on a piece of 3/8 BB while using 1/4" bit with a 1/2" O.D. guide bushing, route an opening around the outside of the plate.
2.) take the template with the opening, lay that on router top (in this case a test piece of 3/8 BB, THANK GOD), switch the guide bushing out to a 1" O.D. while keeping the same 1/4" bit and route around the inside of the template.
3.) My mind tells me that this should essentially allow me to have a perfect inlay for the blank that I started with.
I'm sure I've done this same procedure at least once before inlaying a rectangular plate with success. This is a Jessem router plate and has rounded corners and the finished hole is CLOSE ... VERY VERY close, but the plate just won't fit (possibly the rounded corners being a problem?) . I'm not sure where I went wrong but was hoping one of you could whack me in the head and get me thinkin' straight
BTW: I'm familiar with all the ways of mounting a router plate, but I saw other uses for this 'inlay' type of process and specifically want to know why this procedure isn't working