I made a template from 1/4" Baltic Birch and used my DeWalt 611 with a router bushing and up spiral bit to make the hand holes in the tote bins in the attached photo. I made 12 of these bins, 24 total hand holes. The template was made by cutting the hole using my scroll saw, but two Forstner bit holes and cutting out between them works too. It was cut 1/4" larger all the way around (1/2" total width) than the holes to be cut in the tote bin ends. This accounted for the router bushing to bit difference in size. I added square pieces of 3/8 Baltic Birch to the bottom of each to act as feet and also to make them stackable and interlocking.
This template is now in my jig storage area, because I know I'll be using it again. I wrote the bit and bushing sizes on it, as I do with all of my jigs, so I can remember how I did it for the next time. My jig and template storage area is hooks in the 8' high ceiling beams of my shop. Larger jigs get hooked above benches, so my taller friends don't hit their heads. I'm 5'8" and have no problem moving and working under the shorter jigs, but I have one friend that needs most of the jigs moved from over the aisles when he comes to visit.
Central North Carolina
Last edited by CharleyL; 01-19-2020 at 11:01 AM.