[routafinger]

I haven't been on here for a while....quite a while.
I decided to take my router skills to another level, and have made repeated attempts to try to get acceptable results in template routing. I'm trying to mount an aluminum car club plaque, approx 5" x 7", 1/4" thick, into a 2" x (?) board in a picnic table top. Please critique my steps, and make suggestions to make this go easier.

First off, I needed a inlay set with the correct size bushing and bit. I couldn't bring myself to spend $40 at a big name woodworking supplier, so I settled on the Harbor Freight set, #99552 for $8.99. Only 22.5% of the specialty store. Made of brass, and mates perfectly with my router template set. I'm using 1/4" hardboard, and I wasn't happy with the supplied spiral up bit as it didn't clear the sawdust very well. Changed to a 1/8" 2 flute CMT carbide #81103211 with much better results. The instructions with the kit outlined steps to make the recess first, then the inlay. Backwards for me, so I used this tutorial that I found online. https://www.busybeetools.com/pages/Perfect-inlays-with-your-Router.html Exactly what I needed, and the pictured kit has pieces that look identical to the HF one.

I followed the outlined steps with pretty good results; the plaque fits OK. The trouble I'm having should be the easiest part of the process; cleaning out the recess. Since the bit only leaves a 1/8" outline, extreme care must be used to clean out the recess near the edge. Any suggestions? I'm thinking about using the template, modifying a template bushing and use a narrow diameter bit to stay away from the edge until I get a some of the edge cleared away, then freehand. Or simply use a fence, and guide on the router base. Which leaves only the round corners to freehand. I know that somebody here has done this before, and has some tips. Thanks.

 

[routafinger]

Thanks for the quick reply Mark. One of my issues is the router. The only plunge router I have is the Freud FT3000VCE monster. It was a ridiculous Black Friday deal at Woodcraft a bunch of years ago, and I just had to have it, and unfortunately it's my one and only plunge router. I have wrecked a couple of plastic templates with my fixed base Craftsman routers, so I mostly use this one for template routing with larger and heavier custom made templates.

My biggest issue is cleaning out the recess, and the small 1/8" groove doesn't leave much room around the edge. I've got 2 ideas to solve that. Simply clamp a guide for the router base to guide on, and carefully freehand the round corners. Or modify a large router bushing, (shorten the bottom to 1/4" for the thickness of the template) use a smaller bit, and use the inlay template to get a larger margin before freehanding the middle portion. I'm guessing that router choice isn't critical for that step, but like you said, smaller and lighter is better. We all know that the outside edge of the recess has to be perfect, and you only get one shot at achieving that.

 

[routafinger]

Thanks for the suggestion Harry. I tried that method first with not so perfect results. That's why I switched to a different way that used the approx 5" x 7" & 1/4" thick inlay to create the template, and that resulted in a near perfect sized recess.

 

[routafinger]

I have a much smaller Craftsman fixed base I'll try, and I'll start away from the edge where the plunge would be so critical. I'll just try to tell myself concentrate and control. Thanks for the replies. F

 

[routafinger]

Did you make your template to fit the aluminum plaque or did you allow for the bushings and bit when you made your template?

I followed the instructions I found online, and used the bushing, so the template is slightly larger than the plaque. After some thought, to do what I wanted, I'd have to fabricate a slightly larger bushing to to put on the insert to push the bit a little farther away from the template. If that makes any sense. Thanks for the reply.

 

[routafinger]

Thanks for all of the replies. I think I've finally got the basics figured out. I made the first perimeter cut in the recess with the supplied bushing, then made a 2nd pass with a little larger bushing I fabbed up which increases the groove to about 3/16". I nicked the outside of the recess with the surfacing bit (bad eyes), so tomorrow I'll make another practice run and set up a fence to keep me away from that outside edge. I'm finding new ways to make sawdust.

 

[routafinger]

Thanks for the reply Mickeyfolse. You've got the plan correct. I'm planning to mount the plaque in a wider 2 x 8 center board. I'd have to go look, but I picked up a tube of some heavy duty exterior construction adhesive that should work with both metal and wood. I planned to make the recess about 1/16" or so deeper than the plaque and use the adhesive to level it, and cleaning out what might be forced out the sides. So the bottom finish isn't critical. Then leveling and clamping it flush with the top surface until the adhesive sets up.

I did try your method without the template first, but had an issue with the round corners. I even tried establishing the corners with a forstner bit first, but after many failures, I moved up to the template idea thinking I could get an exact copy much easier. If I got paid by the hour, I might be up to a quarter. Thanks.

 

[routafinger]

My thanks to all who volunteered their opinions on my template question. I have played with this long enough to find the system that works for me, and I managed to rout a recess that I am happy with and claim as mine. Thanks again everybody.

 

[routafinger]

It didn't occur to me at the time I was asking for help with this, that I should have included a pic of my finished project. So, hopefully better late is better than never. Thanks again for all of those replies. F