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There's alot of router tables on this web site but no mention about routing out for the plate to get a perfectly tight fit… Norm's router table video tells you he made a templet from mdf but doesn't show you how… 3/4" guide bushing 1/2 bit [norm just says straight bit] from a templet made 1/8" bigger then router plate. How are the corners done on the templet with a 3/4" GB so it fits right…
 

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I cut acouple before on a smaller top using a pattern bit with an MDF router plate template, the corners didn't come out perfect, I didn't care for the results. I had to trace them & free hand route them, I think I'd get better results with a guide bushing and a straight bit. How can I cut a template 1/8" bigger than the plate so I can use the router with a G. bushing, straight bit and cut out the grove as good/easy as norm did on his…
 

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I wanted a one piece template big enough edges to clamp. If rockler didn't discontinue this template I'd just order another one… That sound like a good idea… the strips to make it bigger… the bearing did a numder on the MDF template thats why I though using a G.Bushing would work better…
 

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Does this help?

1) Make pre-template:





2) Use pre-template to make actual template:




3) Rout "shelf" for the plate and then cut out the middle with a jigsaw:




The rest is on MY BLOG along with a full description and bigger photos.
 

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This came up before and I did it a similar way. I posted this in another thread so I cut-n-pasted it here but I added the pictures. Hopefully they will be of help.

When I did mine it was a three step process to make the template, time consuming yes, but I wanted a perfect fit with no slop no gap. I tried a similar method on my first router table, clamping the boards instead with double sided tape with not good enough results.

This time I double sided taped a piece of MDF to the actual router plate and used my old router table and bearing bit to machine the MDF to be a replica of the plate.



I then took that piece of MDF and screwed it to two other pieces of MDF so I had a 3 layer MDF sandwich. I used a top bearing bit to cut the middle piece of MDF, the bearing running on the copy piece of MDF of the plate.



When that was done I removed the copy piece of MDF of the plate and the piece in the middle layer of MDF.



I then used a collect and straight bit to cut a hole in the bottom layer of MDF running the collet around the hole in the middle piece of MDF. I sized the collet and straight bit so that the hole in in the bottom MDF piece was then the exact size of the router plate.



That bottom piece of MDF was now the template to cut the hole in the router table.



This picture shows the perfect tight fit.



I then put the template in place (don't have a picture of that) and used a short straight top bearing bit (CMT I think, shortest I could find) on the table, only cutting down the thickness of the router plate, this then became the rabbit that the router plate rests on. I think a made two passes to get the rabbit wider because the bit was only a 1/2" diameter. So I first put a 7/16" spacer board again the inside edge of the template and did the inner cut, then ran the bearing against the template. I also put a piece of MDF in the center for the router to ride on so that it wouldn't tip while I was routing.



I removed the template and using a jigsaw then cut out the hole following the inner edge of the rabbit.
Thus a perfect, zero gap zero slop fit.



Time consuming, as I said but when I dropped that router plate in place there was no gap, no slop, and no height adjustment needed.

The complete process can be seen here, unfortunately without narration but with more and larger pictures.

I may have to Project or Blog this.
 

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With the time I put into this table top I want it done right [it looks to good to cut, it wood make a perfect top for a table] I pick'd up a can of danish oil medium walnut at HD 1.90 [thanks Lisa] One coat the oak trim looks like golden oak. I wonder if I give it another coat will it make it look too dark?? Thanks blankman thats just what I was looking for…
 

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I've seen this version [BlankMan's] done in a W.mag before, I can't remember which one, at that time I didn't plan on getting any guide bushings plus they were stating that you could get just as good results with a plate template or placing pieces of MDF to fit around the plate. I've tried both, not happy with either..

This is a 3 piece 4 step process provided you use the right bit & guide bushing for each step…
That's my problem…

1- bottom bearing bit any size
2- pattern bit 3/8 or 1/2
3- straight bit? / g. bushing?
4- straight bit? / g. bushing?
 

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I tried that way on a small table that I made and wasn't that pleased with the out come…
It wasn't a nice tight fit… It was alittle better than when I used a template from Rockler…
I tried to keep it as level as possible, Maybe if I put another bearing on the bit I might get
better results …
 
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