A. With a Vi" straight bit in a table-mounted router, plow a groove H" deep.
B. Switch to a W keyhole bit. Raise the bit flush with the botton of the groove. Adjust the fence so the bit cuts a notch in the sidewall farthest from the fence. Make the cut into both sidewalls.
C. Lower the bit V\f>" and make a second pass on each side, increasing the height of the notch.
o n is pencil and straightedge, lay out the tangents and the slot.
2. Drill the holes for the router. Using the holes in the factory baseplate as drill guides, drill holes for the mounting screws. Mark the location of the bit opening. Remove the factor)' baseplate from the blank. Then countersink the mounting-screw holes, and bore a large-diameter hole (about 2 inches) for the bit opening.
The T-nut for the slide-lock sits in a counterbored hole drilled in the baseplate near the tail end of the slot. To seat the T-nut's prongs, thread a bolt into the T-nut, as shown, and tap on the bolt head with a hammer. (Note that the necessary hole is larger than the slot.)
3. Rout the T-slot. This is a good router table operation. Begin by routing a Vtinch-widc X ^«-inch-deep groove at the position shown in the layout drawings. Switch to either a T-slot bit or a '/2-inch keyhole bit. Adjust the fence so this bit will be cutting into the outside sidewall of the groove (the sidewall farthest from the fence).The neck of this bit should be flush with the groove's sidewall. so its wing can cap the T. Make a cut into each sidewall of the groove. The proper feed direction, by the way, is right to left. For one side, plow from end to bit opening; for the other, from bit opening to edge.
4. Drill for and install the T-nut. As noted, the slide is fixed in position by a thumbscrew that's run through a T-nut. The tip of the screw presses against the slide, jamming it. You have to drill a pilot for the T-nut, plus a counterbore for the T-nut flange. Work very carefully, since you don't have much thickness with which to work.
Set the baseplate on the drill press table, with the slot up. Align it for drilling the T-nut pilot, and clamp it to the table. Drill the appropriately sized pilot hole. Switch to a "¿-inch Forsincr bit. and drill a counterbore deep enough for the T-nut flange Test the depth by setting the T-nut into it. upside down, and seeing if the flange is flush with the bottom of the slot.
Tap the T-nut carefully into place. Turn the thumbscrew into the T-nut.
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