For the router table
Start with some 1/2" MDF or Plastic stock,put a 1/4" slot down the right side,about 2 1/2" from the edge, put in a 1/4"wide slot 3/8" deep,then cut a spline from some 1/4" MDF or plastic (1/4" x 1/2" tall ) and glue it in the jig,sand down the edge so the stock can move free over the spline,but not to free.
For the Free Hand Plunge router.
This is a real hard one to make because it needs to be dead on.
This will take a band saw or a good jig saw.
To make the template use some 1/2" MDF or plastic, the slots will need to be 1/2" wide so you can use a brass guide or a bit with a bearing on the bit.
This will let you use the template over and over without turning the template into firewood.
Now ask a mate if you can use his 1/4" template as a pattern to make yours,it can be a Alum.one or the plastic type from PC,HF,Rockler,etc. just about any of them will work to make yours.
You can try a make one from sq.1 but it will not turn out right because it needs to be DEAD ON ,once you have the pattern cut it out (WITH CARE ) again it must be dead on, one miss cut and it's junk, .010 is a big deal when it comes to box joints because they must match when you try to put them together.
Once you have the template made mount it to some 2" x 6" stock so you clamp it to the bench top ( L type bracket made with 2ea. 2" X 6" stock)
Then drop in a bit in you plunge router and make a pass on two boards and test fit them after you make them.
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