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post #1 of 9 (permalink) Old 03-12-2012, 01:39 AM Thread Starter
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Default Rousseau Installation Kit

I used the Rousseau install kit to install the Rousseau mounting plate that I bought. Everything went well until I went to remove the template. The template snapped and left my laminated top with sticky residue from the double sided tape. Is the install kit a "one shot" deal? I figured I would be able to use the template to install other plates. Has anyone else had this problem?

Thanks for your input,

Keith
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post #2 of 9 (permalink) Old 03-12-2012, 07:47 PM
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I normally pry (carefully) a template off with a putty knife after sticking down for use.

I did repair a broken one, don't recall what brand but it was mdf, just glued it back together sanded back to profile.

Goof-off or similar solvent will take care of the residue.
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post #3 of 9 (permalink) Old 03-12-2012, 10:34 PM
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Sorry but too late to help you, what's done is done and all that...

For others coming along, you DON'T NEED TO BUY a fancy template to rout out an opening for your plate or lift. All you need are four relatively straight sticks, some clamps, plastic wrap, a short top-bearing flush trim bit(which you need anyway foir the template) and some Bondo.

Here's the procedure(nothing new, Google is your friend): First, clamp one of the sticks parallel to one side of the table wherever you want your plate to sit. Front, back, side it makes no difference. Set your plate or lift down on the table against that piece wherever you want it to live, centered, offset, whatever.

Now clamp the other three pieces around it, tight to the plate. Before you start routing check your flush trim bit with a caliper, if the bearing is wider than the bit, add a piece of blue tape or two to the plate to match half the difference. Add another layer so the opening you rout will be ever so slightly larger.

Next step is to check the radius on the corners of the plate. If you have a short flush-trim bit that matches you're good to go. Chances are you don't, lift and plate manufacturers seem to pick corner radiuses out of their [email protected], sorry, hip pockets...

Now the plastic wrap and Bondo come into play: rip off some wrap and stretch it over the corners of the plate so the Bondo won't stick to it. Mix up a little of the Bondo, it won't take much, set the plate down between your sticks and pack the Bondo into the corners between your sticks and the plate. Don't let it get up higher than your plate.

After it's cured, yank the plate, use the sticks and the Bondo and the sticks as a template for your flush-trim bit and rout your opening to depth. Easy-peasy... It took longer to write this reply than to do it.

A small can of Bondo from your local auto parts store will cost you $5-10 and you'll have a lot left over when you're done for more patterns(use your imagination). We all have sticks laying around and plastic wrap.

You buy a fancy template, it's only good for one particular plate. How many of those plates are you going to use? How many table tops are you going to rout for that plate? Maybe you decide to buy another plate, are you going to spend the money for another template? How many templates do you want hanging around your shop taking up space just in case you decide to make a new table for that particular plate?

Save yourself some money and have a little fun, isn't this what it's all about?

HTH,
Bill
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post #4 of 9 (permalink) Old 03-13-2012, 12:51 AM
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Keith, I have been using my template for about 11 years now with no problems. Did you perhaps go overboard on the double sided tape?

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post #5 of 9 (permalink) Old 03-13-2012, 01:21 AM Thread Starter
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Quote:
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Keith, I have been using my template for about 11 years now with no problems. Did you perhaps go overboard on the double sided tape?
I followed the directions that were supplied with the kit. I used Goof Off to remove the sticky residue. I called the Rousseau Customer Hotline today and explained the situation. The guy on the other end said they would take care of the broken template. I am expecting a call from them on Wednesday.

I am pleased with the install of the plate. I think in the future, I would use very little tape.


Keith
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post #6 of 9 (permalink) Old 03-13-2012, 11:58 PM
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Bill,
there's nothing fancy about most of these templates, they're either supplied with the plates, you get directions on how to setup for the cut or they are cheap enough to merit purchase without the hassle of DIY and with the right size cutter, you match the corner radii of most plates I've installed.

I do like that pattern making thing with the bondo, can see many a use for it down the road, thanks for the tip.
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post #7 of 9 (permalink) Old 04-20-2012, 08:43 PM
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Quote:
Originally Posted by billg71 View Post
Next step is to check the radius on the corners of the plate. If you have a short flush-trim bit that matches you're good to go. Chances are you don't, lift and plate manufacturers seem to pick corner radiuses out of their [email protected], sorry, hip pockets...

Now the plastic wrap and Bondo come into play: rip off some wrap and stretch it over the corners of the plate so the Bondo won't stick to it. Mix up a little of the Bondo, it won't take much, set the plate down between your sticks and pack the Bondo into the corners between your sticks and the plate. Don't let it get up higher than your plate.

After it's cured, yank the plate, use the sticks and the Bondo and the sticks as a template for your flush-trim bit and rout your opening to depth. Easy-peasy... It took longer to write this reply than to do it.
You could also start with a round sub-base,1/4" bit, and some 1/4" MDF.

Run the router counter-clockwise around the plate making a female template that's 1/2 the sub base diameter + 1/8" over-sized.

Run the router clockwise around that template making a female template that's original size + 1/2 sub base diameter + 1/8" - (1/2 sub base diameter - 1/8") where the sub-base dimensions cancel out and you end up with a female template 1/4" over-sized.

Install a 3/4" guide bushing, center with a centering cone, and run the 1/4" bit clockwise around your last female template. The resulting hole will be 1/4" over-sized - 1/4" offset = exactly like the plate.

Of course, aesthetics aside any tighter radius in corners will work fine with the plate positively located by its sides.

Last edited by Drew Eckhardt; 04-23-2012 at 01:55 AM.
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post #8 of 9 (permalink) Old 04-20-2012, 09:37 PM
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post #9 of 9 (permalink) Old 04-23-2012, 06:41 PM
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Thanks for the video
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