Using a Guide Bushing Template

I like this approach, as I said, because there's less opportunity for error to creep in. If you work carefully, you are sure to get a perfect fit.

1. Rout an internal template guided by the mounting plate. Use a piece of /¿-inch plywood, MDF, or particlcboard for the template. There's no Layout work to perform, but some preparation is ncccssary.

First bond the mounting plate to the template stock with carpet tape. Use die carpet tape also to bond the template stock—particularly die section beneath the mounting plate-to a piece of ex|>endablc material. Do this even though you damp the template stock to the workbench.Tlie expendable material protects the workbench top. The carpet tape between it and die template keeps the waste, whidi supports the muter, from shifting as it is cut free of the template.

Outfit a plunge router with a Vk-inch-O.l). template guide and a '/4-inch straight bit. Set the plunge depth stop so the bit will, when bottomed against the stop, just break through the template stock into the waste beneath.

Keeping the template guide tight against the mounting plate, rout around it in the direction indicated in the drawing Routing Tabletop Opening with Guide-Hushing Template. Make several passes, plunging a little deeper for each circuit, until the waste is cut free. IJnciamp the work-piece. Pry the plate from the waste.

To make a guide-bushing template, use the mounting plate itself as a template. Bond it to the template stock, and rout counterclockwise around it. as shown here. Keep the template guide tight against the mounting plate because the template will be ruined if the guide drifts away from the plate.

2. Rout the plate-support rabbet in the tabletop. Position the template on the router table top. Clamp it. being sure to position the clamps where they won't interfere with the router as you feed it around the inside edge of the template.

Change the plunge router setup. Chuck a %-inch straight bit in the collet, and install a 1 '/i-inch-O.l). template-guide in the baseplate. Porter-Cable makes this guide: it's part number -12021. (You can also use a -8-inch straight bit in a 1-inch-O.D. template guide.This combination, obviously, will yield a narrower groove.)

Set the plungL- depth carefully.The depth of the groove you are about to rout should exactly match the thickness of the mounting plate.You also must account for the thickness of the template.To do Uiis. set die router on the template, and gently bottom the bit against the workpiccc. Now rest a corner of the mounting plate on the turret, and drop the depth rod onto it Lock the rod. You are ready to rout.

Keeping the template guide tight against the template, rout around the inner perimeter in the direction indicated in the drawing. Make several passes, plunging a little deeper for each circuit, until the maximum depth is achieved Uncianip the template, and clear the chips from the groove.

Use the mounting plate to set the plunge stop.

After bottoming the bit against the work (stand the router on the template and plunge it 'til the bit touches the tabletop) and locking the plunge, hold the plate between the router's turret and the depth stop rod, as shown. With the plate against the turret, seat the rod on the plate and lock it. Now the router will cut a groove as deep as the plate is thick.

Grooving the tabletop is a less ticklish operation than routing the template. Set the router on the template, with the guide collar tight against the template's guiding edge. Plunge the bit, and guide the router clockwise. If you do let the rcuter drift away from the guiding edge, you'll merely be cutting into the waste area.

ROUTING TABLETOP OPENING with Guide-Bushing Template


H"-O.D. guide bushing


Scrap to protect work surface

Mounting plate







Waste IA" straight bit

Template blank -


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Mounting plate




Template ,




Vfc" straight bit



Saber saw blade



Saber saw blade




3. Cut the waste out of the tabletop opening. I 'se a saber saw for this operation, cutting roughly along the inner shoulder of the groove. YouTI get the cleanest job if you drill /Vinch-diameter holes at cach corner, as shown in the drawing and photo. This way, you can insert the blade into the hole and make a straight cut from one comer to another.

The placement of the saw cut will determine how wide the plate-support rabbet is. If you do cut right at the groove's shoulder, the rabbet will be just under >8 inch wide, which is a bit much. A good widdi for the rabbet is % inch.

With the waste removed, the mounting plate should lit perfectly, which is to say, just a bit hard. You will be able to set it into the opening, but you'll probably have to smack it with your fist to seat it.

Cut out the block of waste with a saber saw. If you drill a large-diameter hole at each corner, as shown, you simply have to make straight cuts from corner to corner. Guide the saw along the inner edge of the groove so a rabbet is left to support the mounting plate.

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Woodworking Tools and Installation Tips

Woodworking Tools and Installation Tips

There are a lot of things that either needs to be repaired, or put together when youre a homeowner. If youre a new homeowner, and have just gotten out of apartment style living, you might want to take this list with you to the hardware store. From remolding jobs to putting together furniture you can use these 5 power tools to get your stuff together. Dont forget too that youll need a few extra tools for other jobs around the house.

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