Routing a flush-fit cover for an existing opening.

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Forum topic by Adam posted 01-25-2021 01:37 PM 327 views 0 times favorited 2 replies Add to Favorites Watch
View Adam's profile


42 posts in 3569 days

01-25-2021 01:37 PM

Hey all. I have a need to replace a missing ice box lid, but I can’t figure out how to pattern it. The lid needs to fit flush inside the existing opening, which is in an existing countertop. I figured to make a pattern and then use a flush-trim bit, but I can’t figure out how to make the pattern, as using the opening will just give me another opening. Thoughts?

2 replies so far

View Walker's profile


470 posts in 1812 days

#1 posted 01-25-2021 06:38 PM

Pictures would help.

You could use cardboard, styrofoam, piece of paper etc to mock up the lid, then transfer that to a pattern. Or use a cheap piece of particle board, cut it larger than the opening, then sneak up on the cuts until it is a perfect fit and use that as your pattern. Or do the same thing with the actual workpiece if you’re brave.

-- ~Walker

View CaptainKlutz's profile


5167 posts in 2834 days

#2 posted 01-25-2021 07:30 PM

+1 pictures?

Offsetting cut from template is easy.
Use a 3/4” template guide on router with 1/2” spiral bit, instead of flush trim. The final cut will be 1/8” larger/smaller than template OD (depending on outside/inside cut of template). HF sells a cheapo template guide set for $16.
Can use smaller or larger guide for different cut offsets.

Best Luck.

-- If it wasn't for bad luck, I wouldn't have no luck at all, Doom, despair, agony on me… - Albert King - Born Under a Bad Sign released 1967

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