Bench Dog Pro Plate and Zero Clearance Insert problem
I'm having real trouble getting my Bench Dog Pro Plate and Bench Dog Zero clearance ring to work with my Makita 3612C. I've been in contact with BenchDog several times, however they haven't provided a solution.
The issue is that once the zero clearance insert is attached to the 2" reduction ring (which is bolted into the pro plate), the flange on the underside of the zero clearance ring bumps into the router's base (subbase removed of course!) and prevents the router's base sitting flush with the underside of the pro plate.
I took some measurements with my digital calipers:
• external diameter of flange of zero clearance insert : 76.21mm, 3"
• maximum diameter of aperture in router's base : 68mm, 2 2/3"
• minimum diameter of aperture in router's base : 62.11mm, 2.5"
The reason for there being two measurements for the diameter of the aperture in the router's base : there are two 'tabs' into which template collars screw when they're in use. These two 'tabs' sit opposite each other, and reduce the diameter of the aperture at that point. Even if those tabs weren't there, the flange of the zero clearance ring is still too large to fit into the aperture of the router's base.
As I see it, there's no way that the zero clearance insert can attach to the 2" reduction ring and permit the router base to sit flush on the underside of the pro plate. If the nuts of the bolts used to secure the insert are installed, the situation is even worse.
As you can see from the diagram, the dotted lines represent the aperture in the router's base - and the flange is of greater diameter than this aperture. I assume the flange is supposed to be of lesser diameter than this aperture - which would allow the flange and nuts to sit in the aperture, and not hinder the router's base from sitting flush with the underside of the pro plate? If this assumption is incorrect, how is one supposed to get the router base and pro plate to sit flush? I was under the impression that the Makita 3612C has a large aperture in the base - how on earth would this flange go with router's that have a smaller aperture!!
I'm unable to cut the flange down as in order for it to sit within the aperture in the router's base, I'd have to cut so much off it, that the 3 holes that secure it would be removed too.
I'd really like to find a solution to this as I really need to reduce the aperture of the 2" ring for safety reasons -there's simply too much space around the bit when using a 1/2" bit, for example.