Homemade insert - Router Forums
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post #1 of 5 (permalink) Old 02-25-2011, 10:37 AM Thread Starter
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Default Homemade insert

Good morning,

I asked a question the other day about inserts for router plates and the replys I received were very helpful, thanks. I thought the ones I located were a bit expensive for just a plastic ring, so I measured one and made my own using a circle cutting jig on my bandsaw. I used 1/8 inch acrylic that I purchased from a glass shop, it was very inexpensive, in fact if he had a piece in the scrap pile he would have given it to me, but he had to cut me a small piece.

It is sold as 1/8 inch, but it really is a bit smaller, perfect thickness. I cut a 4 inch circle then sanded it just a bit and used a hole saw to cut a 2 inch circle and I was in business. I was able to use my 1/2 inch round over bit and the dust collection seems to work better I think because the relief around the cutter is smaller.

Anyway, ir works great and I will be making more inserts as needed.
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post #2 of 5 (permalink) Old 02-27-2011, 12:08 AM
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Good for you ... no reason why someone with a bit of innovation and talent cannot make items like this. Well Done !!
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post #3 of 5 (permalink) Old 02-27-2011, 01:03 AM
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Use Acrylic, it's hard and machines easy. Use your router with a circle jig to cut several 4"circles. Make them with a 1/4" hole in the center, then open them to fit what you need for a zero clearance bottom supporting insert. Finish the edges with a tool bit in your drill press then polish or sand fine with something like alum.polish. If you don't have a drill press then just use an arbor bolt thru the 1/4 hole and carefully spin them against some sand paper on a square block.
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post #4 of 5 (permalink) Old 02-27-2011, 01:16 AM
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awesome! how about some pics, thanks
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post #5 of 5 (permalink) Old 02-27-2011, 09:09 AM
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Just another approach. On an old router/shaper I used to have I made a disc template out of 3/4" stock then for subsequent inserts all I had to do was cut the plastic into squares and double face tape the template to the plastic and use a flush cut bit on the table to make the insert.

John Schaben

The problem with experience is I usually get it immediately after I need it.
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