Circle/Radius Cutting Jig - Page 5 - Router Forums
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post #41 of 46 (permalink) Old 01-13-2020, 12:09 AM
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I am wondering ... for a dust collector for hand routing, could you mount a router into a modified 2 gallon paint bucket?

Imagine a router with the base mounted to the lid of a paint bucket that rides on the lid. Popping the bucket off of the top would allow you to change out bits with wrenches. A front window could be made by pop riveting a sheet of Lexan over a square hole. Lights could be put inside around middle. The handles could be mounted to the bucket itself, and a remote switch is easy enough to install. The bottom (now the top) could be fitted with a standard shop vac outlet for the hose to suck chips out through the top of the housing. The LARGE lid base of the bucket would slide over material and keep the router flat and level. The recess in the lid could be filled with a 1/2" sheet of Teflon or whatever. Small holes through the sides covered by screen material would allow air to be sucked into the bucket to carry out the chips. For plunge routers, two buckets nested, the top half with the hose telescoping over the bottom half with the lid?

Hmmm ... That might be worth a Saturday afternoon experiment!

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post #42 of 46 (permalink) Old 01-13-2020, 12:34 AM Thread Starter
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Default Routing Rabbets for Ladder Rungs

Although the design for this ships ladder that I was generally following used rabbets to locate the treads/rungs, I initially was not going to do it this way. I was going to use a 2x4 block underneath and screw the rungs in from two directions. Then I realized I could probably use the jig that I made for sawing the center waste sections of the handholds for routing such rabbets. And I definitely liked the thought of cleaner lines.

So, I started checking it out. I had to widen the jig for the rabbets because the saw jig was designed so the saw cuts would be about 1/8" inside of the final dimension, 1 1/2". That was easy as it it amounted to simply moving one side only. Doing that and applying a fence at the 20 angle the treads needed to be, a trial run showed that it worked very nicely. Nice to be able to reuse that jig.

I had dismantled the taped up dust hood, so I made this trial without any dust hood and of course dust went everywhere. The hoods I ordered are supposed to arrive tomorrow but tracking it via UPS they may not arrive until Thurs. I don't want to wait, but I do not want to proceed without the hoods and I don't have a clue how effective they will actually be. Decisions. Patience. Ugh!

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post #43 of 46 (permalink) Old 01-13-2020, 12:44 AM Thread Starter
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Quote:
Originally Posted by The Hobbyist View Post
I am wondering ... for a dust collector for hand routing, could you mount a router into a modified 2 gallon paint bucket?...snip...

Joe
I couldn't quite follow your description. Sounds really complicated. Let us know how it goes if you give it a try. Photos would really help.

I did try clamping a cardboard box to the underside of the handhold cutouts, with two things in mind. First, I was hoping it would catch much of the dust that was falling down through the slots. Second, I was hoping it would allow the dust hood to be more effective, by keeping dust up close so it could be sucked away. Didn't work. I'm not if my shopvac is not working up to snuff. So, I gave up on it and just swept it all up afterward.

Rick

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post #44 of 46 (permalink) Old 01-13-2020, 06:34 AM
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Rick,

Double ouch a couple of replies ago. The base below has an opening that's too large.

Circle/Radius Cutting Jig-circle-jig-spans-handhold-gap-640.jpg

The first point is removing all that material in the middle leaves less support for the router, esp. for narrower stock. And the MDF itself could use some more support. Secondly, the max dia of a bit for handheld router use is 1.75". This is Pat's number and I agree w/him. Besides preventing the use of panel raising bits in an under powered router, it precludes one from using a 3 wing slot cutter, the next stupidest thing . Slotting in the middle of stock is a trapped cut and if the stock is not flat or the router wiggles, all hell will break loose.

I don't have anything against Bosch routers, but I think a different router would result in less fighting the tool. Craigs List usually has a good selection of used ones and you do need more than one router. I'm 80% serious and 20% joking. For hand held use, Pat's choice is the Dewalt 621, which features a built-in dust collection port. It's not perfect, but he designed all his jigs and bases to work with it. I've had my hands on one in a store and think that it has lots to offer, but some annoyances too.

My Milwaukee 5616 (?) and PC 690 (1992 vintage) plunge bases were both miserable until I reduced the spring tension. Simple process to reduce the OD by 5% using a bench grinder. Adjusted the preload by cutting off 1/2 a coil.

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Last edited by difalkner; 01-13-2020 at 08:20 AM. Reason: missing 'read' in last sentence
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post #45 of 46 (permalink) Old 01-15-2020, 12:35 AM Thread Starter
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Rick,

Double ouch a couple of replies ago. The base below has an opening that's too large

...snip...

The first point is removing all that material in the middle leaves less support for the router, esp. for narrower stock. And the MDF itself could use some more support. Secondly, the max dia of a bit for handheld router use is 1.75". This is Pat's number and I agree w/him. ...snip...

For hand held use, Pat's choice is the Dewalt 621, which features a built-in dust collection port. It's not perfect, but he designed all his jigs and bases to work with it. I've had my hands on one in a store and think that it has lots to offer, but some annoyances too.
...snip...
Thank you DG. I had no idea on either point. I made the opening that size to match the router base. I sure had no intention of using bits anywhere near as large as the opening, but it is good to get this cautionary information.

Easy to make another with a smaller opening. I wonder if that would also make for better chip extraction by a dust hood.

BTW, the dust hoods did not arrive on Monday. UPS showed them arriving Thurs. I've been making good use of the time, working on other aspects of the ladder, playing with my granddaugther after school and shoveling snow at my daughter's during school.

Rick

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post #46 of 46 (permalink) Old 02-25-2020, 01:47 AM
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Good thinking
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