How to cut a template / LONG and Short Version - Page 2 - Router Forums
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post #11 of 16 (permalink) Old 05-12-2019, 12:21 PM
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Originally Posted by Danny H View Post
Thank You for letting me in on that. It makes it much easier.

This is the image of what I'm doing. ALL of the white areas are cutout. Including everything outside the circle.

w/ that much to remove.. use a jigsaw to hog out the waste and finish/clean w/ up your router...

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post #12 of 16 (permalink) Old 05-12-2019, 02:15 PM
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You should still be able to adjust your router for height ,even in the box. Just release the lock and adjust it up or down, it is not fast,in your set up, but can be done.

I agree with Stick, take the bulk out with a jig saw and finish cut with the router, it works best.
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post #13 of 16 (permalink) Old 05-12-2019, 02:46 PM
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OK, took a couple of reads to get what you were talking about.

I would call the aluminum a pattern. I use mainly 1/2" plywood for almost everything. So I would trace the aluminum pattern onto a piece of plywood. Then like the others said, cut out what you don't want, leaving preferably a bit less than 1/8". With straight lines like that I would normally tack down a straight strip, route one are, move the straight strip. I use nails because they are easy to use, no cleanup, and can reuse. And they work. Can cut the corners or sand square. Once I get that piece done exactly the way I want it, I trace it onto another piece of plywood, rough cut that piece, then glue the finished piece to it. Then I rout that, which gives me a master 1" thick. I normally make masters because there are few things I do not make more than one of. I drill pilot holes thru, trace around it onto my finish piece. Be sure to tack the master to the back of your finish piece, so no holes will be visible. Then you can square the corners. If you want more copies, repeat.

I do it a bit different that the other guys, do use a flush trim bit, but I also tend to make different things than the others. Works for me. Oh yes, I also put a drop or three of Marvel Mystery Oil on my bearing before I start, don't try to hog with my bit, and don't tray to rout too fast. Works for me.
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post #14 of 16 (permalink) Old 05-12-2019, 03:14 PM
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Having been burned by photo hosting services before I can tell you that uploading photos to this site will ensure they're always available. I switched a while back, maybe two years ago, and it's so easy to just upload the photos here and be done with it.

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post #15 of 16 (permalink) Old 05-12-2019, 05:13 PM
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The picture makes it clearer to me. Jigsaw and router cleanup for me too.
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post #16 of 16 (permalink) Old 05-13-2019, 07:56 AM
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It’s been said that the router is a great finishing tool but a poor one for for removing large amounts of waste so one more vote for the jigsaw. For cutting the outside of the ring I might agree with doing it on the table. For the inside parts I think I would be more inclined to go handheld and plunge or make sure the holes are large enough to make sure I’m not going to touch a side on entering. There’s no reason you can’t use 2 methods when routing that.
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