Ski jig's are very usefull items to have. Keep in mind that a plunge router is the best choice for maximum utility. Since you own a Bosch 1604 I built this jig to give you a way to get started. I used a 1601 which is in effect the same router. Start by removing the wooden knobs and place them in a Zip lock bag for safe keeping. Since I often do this I mark the bag with the routers model number. Remove the sub base plate and keep it handy; you will use this to mark the hole locations on the mounting plate. I built this jig from scraps on hand and only purchased the hardware for less than $10.
Parts required: (From any good hardware store)
8 each: 1/4" - 20 x 2" hanger bolts
8 each: 1/4" - 20 solid wing nuts (Do not use the stamped kind as they do not last)
8 each: 1/4" flat washers
2 each: 1/4" - 20 nuts (For installing the hanger bolts)
6 each: #8 x 3/4" flat head wood screws
1 each: 6" x 7" Lexan 1/4" thick. (The hardware store will cut this for you)
Note: I used an old piece of used Plexiglas for my mounting plate. One of the corners chipped off and this is not important because 4 screws will hold the router. The extra hole in the plate was from another jig and does not effect performance.
Note: I used an old piece of Plexiglas for the mounting plate. One corner chipped off when mounting it to the rails; this really doesn't matter because 4 screws are enough to hold the router.
Baltic birch plywood parts, do not substitute other types of plywood:
2 short rails: 1-1/4" x 6" x 1/2" thick
2 long rails: 1-1/2" x 18" x 1/2" thick
2 Risers: 5" x 8" x 3/4" thick
This job requires a 5/16" straight or spiral bit and a 1/4" roundover bit.
Set up your router table with the 5/16" straight bit and adjust it so the center is 3/4" from your fence. Cut the slots in the long rails leaving 1-1/2" on each end. Cut the slots in the Risers leaving 1/2" on each end. Next install your 1/4" roundover bit and round over the two top corners of the risers then roundover the ends and top on both sides of the risers.
Drill/countersink the 6 holes and attach the short rails to the ends of the Lexan mounting plate with the #8 screws. Center your drill bit on the ends of all the rails and drill the holes for the hanger bolts. Install the hanger bolts by jambing the two nuts on the end of the bolt and turning them in.
Drill the center hole in the mounting plate using a 1-3/4" Forstner bit or hole saw. Assemble the H frame with the washers and wing nuts. Your sub base plate will fit into the frame; Mark the mounting hole locations with a Sharpie marker, remove the plate and drill/countersink the holes from the bottom side of the plate.
Adjusting the ski jig:
With the H frame sitting on a level surface tighten the wing nuts on the short rails. Set the H frame on two spacers known to be square. (I use 1,2,3 blocks for this) Add the risers, washers and wing nuts on the ends and tighten. It is important to do this EVERY time you set up the jig. Attach your routers base to the mounting plate and drop in the motor.
"Living in the D" (this means Detroit!)
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Last edited by Mike; 09-26-2012 at 06:27 PM.