The Router book A complete guide to the router and its accesories - Pat WarnerThe Router Book
Transcript of The Router book A complete guide to the router and its accesories - Pat WarnerThe Router Book
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THE
BOOK
-
A Complete Guide to the Router and Its Accessories
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The RouterBook
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Te Router Book
Pat Warner
The Taunton Press
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Text © by Pat Warner
Photograp hs © by The Taunton Press Inc.
Ilustrations © by The Taunton Press, Inc
Al rights reserved
The Taunton Press Inc 6 South Main Street PO. Box 556 ,
e-mail: tp@tantoncom
INTEROR DSGN Mary McKeon
A YOUT: Rosale Vaccaro
LLUSTRATORRon Carboni
COVR HOTOGRAP Scott Pillips
NT ROR HOTOGRAPY Lon Atkinson
RARY OF CONGRSS CATAOGNG-N-UBATON ATA
Waner, Pt 1943-
The route book / P Waer.
. m
Routes (ools) 2 Woodwor. I itle
T203.5 W3735 200
684'08--d2
Printe n te United States of America
987
20010279
E-Book ISBN: 978-1-60085-578-8
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To my wife, Judy Ann, without whom this work
would still be a pile of dust handwritten folders.
Acknow ledgments
I peny of elp on tis boo Plese let me tn Jrgen A mtmnn
for is engineering expetise; Ntn Deoit for is compter si s;
il Stivers for is excellent woowor in prepring te meis fo te
iny potos; Aln Goosel n Crlos Venito for tei roter bitexperise; Pt Spielmn Sroer y, o Lngson n eff Soltz
of Porer-Cble; Jon recy of Wetzler Cmp; Cris Cson of Bosc;
Bry Rnsrom; rn Kne; Gry Rogowsi; Jon Goff; Dve Kele;
Ricr Wee; n Erc Jonson.
ABOUT YOUR SAFETY
Woring wit woo is inerenty ngeos. sing n or power toos
improperly or ignoring sfety prctices cn le to permnen inry or
even et Don try to peform opeions yo lern bot ere (or
elsewere) ness yoe cern tey re sfe fo yo If someing bo
n operion oesn feel rig on o it oo fo noer wy We
wn yo to enjoy e cf so plese eep sfety foremost in yo min
wenever yoe in te sop.
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Contents
ntroduction
Chapter 1 - Introducton to Routng
Appicatons
Types of Routng
Chapter 2 - Cutter Pathway Control
Bearing-Guded Cutters
Colar Guides
Edge Gudes
The Subbase
ool Shank
he Crce Cutter
Other Gude Options
Chapter 3 Fxed-Base Routers
Router Basics
Lea ding Fixed-Base Routers
Department Store Routers
Best Fixed-Base Appicatons
Chapter 4 - Plunge Routers
Basic Anatomy
Power as an Asset
Addng Stablty
Helpful FeaturesBest Uses for Plunge Routers
PorterCabe 7529
DeWat 625
Chapter 5 - Laminate Trim Routers
Guide Systems
Other Features and Applications
Bosch 608
2
6
7
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Chapter 6
-
Router Tables
Router Table Basics
The Fence
Protection from the Cutter
Depth of Cut Strateges
Cimb Cuttng
The Miter Gauge
Router Table Safety
Chapter 7
Router Bits
Evauating Performance
Cutter fe
Materas
Shank Diameter
Cutter Types
Sharpenng
Chapter 8
-
Router Accessories
Gudes and Bases
Router Table Acessories
Chp Collecton
Chapter 9 - Simple Shopmade Jigs
Right-Ange Tempates
Sot Makers
Shopmade Moriser
Tenon Maker
End-Lap Tempate
Adjustabe Tenon Maker
Crce Maker
Router Horse
Pn-Routng Jg
45-Degree Beve
84
84
91
93
95
98
99
100
106
107
11
12
14
14
121
122
122
127
130
131
31
132
133
134
136
136
138
138
40
140
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Chapter 10
-
Router Safety 1
Hand-Router Safey
Rouer Table Safey
Clmb Cuting
Stock Preparaion
Cuter Surprises and Risks
Heath Concerns
Chapter 11
Common Router Limitations 1
Risks and Probems
Weight and Ergonomics
Chapter 12 - Starting Up the Router 1
Preparaion and Seup
Router Table Seup
Chapter 13 Template Routing 1
ools and Maeras
Template Uses and Types
Making Basc Templaes
Resources 1
Index 1
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Introduction
Wt I lie most bot roting is e bility to mnge is
now wi e rigt cttes j igs nd ixtes cn
remove te ig mont o wood in te igt pce e biity to do
tis does not ppen overnig oweve. rcice espec o te mte
i tention o cte dynmics nd good ixres ll ply pt
Roes e e big time pobem solves o te powe too ingdom
ey ve more pplictions tn ny singe cting ool ey pply
temselves wel in jo iney, decortion nd in imited wy, millwor
Moe n 1,000 cters nd conless j igs re yo disposl olmos ny oing ob.
Nevereess, oing does ve is imittions Spend some time
wit tis boo nd yo will discove te prcicl limits nd lso te
stengts o roting. Js eding te boo won't me yo ino n
expet roter se, b o o pctice will. Expec to inis is text
nd w wy wit te ndmentls o te crt ow to coose ct
e nd roter wen o pply tem, wen to conside n lenive,
nd ow o se te oo sely
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oters hve wored themseves into the premiere spot mongwoodworng power tool nly drills otsell them mong portpower tools. Its even frly ommon for woodworers to own
smll fmily of roters n different sizes nd shpes Bt the sheer size ofroter fed n me the job of hoosing the right too seem dntng the vst nmber of essories on the mret oers fest of hoes thprovides nother hllenge o nvgte ths se of hoes nd fnd sond strtegy to inorporte ths tool in or shops, we might thn bowhy we se these toos to begn wth nd wht mes them so spel
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The auo's mortising jig uses a pair of edge guides and a pair of jig stops so it can be
adjusted to rout vrualy any mortise.
Rouing is basically the hgh-speed removal of stock from a workpece;
hnk of as the measured wasing of maeral. Al sorts of maerals can
be routed, but solid wood may be the most common And whe the oo
has many uses oher than woodworking, most router bts are designed pr
marly for use wth wood and plywood However, medum-densiy fber
board (MDF), pastic, solid-surace maeral ven rock or mea<an be
roued given enough power, the right setup, and approprate tooling Buhe majorty of us work wth wood most often
Many woodworkng processes, ncluding routing, are subtractive I
can' think of an example where routing adds anyhing o a workpece n
many forms of art, such as ceramics and godsmihng, the materal is
reformed and added to he whole, hus conservng materias No so wth
wood: We chop, saw, sand, drl, pane, ont, and rou mos of our resource
away And routers are the preeminent stock removers They can remove
stock on he edge, on he ends of a workpiece, or anywhere n the mdde
And they can remove stock in nearly any profile, from a thin slice aong
the edge for jointing, to complex shapes for rased panes, cope-and-stick
joinery, or decorative deails Depending on the power and size, hey canremove the iny burr of plastc lamnate while trimmng a counertop or
hog out a mortse n hard maple So as we invesgate router choices in
subsequent chapers, a major consideraion wil always be he scope of the
work and the power requrements
Rouing is rarely done o rough stock Routers normaly are used after
the onter, planer, and table saw operations That s one of their distinc-
Introducon to Rou
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6 Itoducto to Rotg
tons ey cano souln'tcopete wit ools tat pepae sto
Tey ae ntene o pecson wok is will e taken into accoun
we iscuss te vaious coices
But outes unlike any an oos nee gs, ixtues, ences an
oles to apply teselves Ege an cola guies custo suases
vaious kns of eplates ae vey useful But even oe potant a
te igs fixues an pafos ta povie a way o o pecise oineTe oute is seiously anicappe wtout its accessoies. You can
wi eaing-gue pofle cuttes wout uc ao, u viually a
Tis smbl is not ca by any sttc but for a iftm w oodworkr ty wil l cmost routing callngs. From lft DWalt 621 ung routr PC-690 md-ang fix
routr 31 OPC trim rotr PC-7518 fxd bas routr
Flutn g wtr on fat stock or mountd on a at is on of t routs im ortant
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Fnis carpentes typically use routers to morise fo inge s on c stom door instalations
Trim roters may get tei eaviest use in c ountertop farication . Here pla stic lami nate iseing flus-trimmed after eing glued down on te particeoard sustrate
Itroducon o Rout
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PES OF ROUTING
oer ct (witot earngs) will reqre soe g, fxre or exernal
ge Anoer conseraton ten, s te roter's aity to work we
wit a varey of gs an fxres
Becase of eir grea an vas otental, roters are aor woow
ng role solvers No oer oo fins its way nto so any facets o
wooworking Roters aly teselves wel in te oinery an ecor
of yor work, excel n aking igs, fxtres an telates, and
veneterey can sally e yo ot of a a Tey are it's re e
ent on a assive array of otenial igs fixtres olers an cters
tey also e solve neary every wooworkng roe No oter too
ofers so any ctng an saing ossiilies. An no oer oo r
ves qte te sae callenge wen i coes to soring trog al t
coices o get te rg toolng o ac yor ariclar nees
Applcations
So far we've talke aot te roters se for a variety of wooworking
s relationsi to oter ools, its array of accessories an te way it ca
reac any art of te workiece L es ake a nte an talk aot te
ortant criteron of e all e roter's secifc alications Te
as tree aor areas of alication: ecoraon onery, an lwork
Type Decrpto Dty Cycle Power Demad (hp) Roter
Lghtm Fush tm Sho < Tm oute
amnae/venee.
Shaow, sma
cutte outing
Decoative tim, ightduty edge Shalow edge cuts 060 minutes Y2 Medum
up to in x in fixed-base
Volume, ogees, beves, oute
ball beang decoato
and empate cuts
Punge Insde mutisage wok, Can be long 2 wi be unge
age excavations; accepabe fo oute
castng must be most wok
suppored fo punge
Moises, cices
and aps.
Table A saionary wok. No me imt + Fxed-base
o punge o
(moe com
Heavyduy hand oute Edge and tempate A day3 Bg fxed
fu-hickness cus. base
Templae atem wok lne , No me imt 1-3 A oues
faconal o u and abes
thckness cuts.
8 Itrodcto to Rotg
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DECORATION
Categorically te greatest nmber o roter bits are or trim an ecora
ton Catalog nventores say excee 50 ercent n ecorator ctters
s is strange in a way becase ecoration as so ittle to o wit ract
caity; yor esk jewery box or be wi srvive j st as well wtot eco
ration Neverteless inising an ecoration are two o te most imor
tant crteria in wc woowork is jge It wo inee be a mistake tooverlook tem
JOINERY
e ower o te roter is n it s joint-making caability Neary al o
Western joinery is ossible wit a roter wit te aition o ts ctters
j igs an yo It as ts limitations ike bre joints an ee sknny ove
tas bt it can aress an enormos nmber o bot orinary an secia
joints Bt te roter snt erect an tere are many occasions e to
xtring ctter esign an so on tat a jont s comromise Yo may not
excee or even meet te caacties o a an joiner bt o exect to make
mortses an tenons; tonges an grooves; as; gle jonts; trog bin an slng ovetas; slines; lock miters; coe an stick; box joints; an
varios combinations
Tis scrw-drivn ror fnc moys a dia indicaor o aciv accracy in ou
sands of an i nc rang
Applcat
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0 Itrodctio to Roting
Ti s atform jig uss an ovrsizd bas and a ball baring rabbting bit to form a sq
tnon on nd of a workc
Routing nds itslf wll to a wid rang of joinry calngs
MILLWORK
Roer work ha oesn' all no he ecoraon or onery genres c
mlwork hs s no he mwork assocae wh shaers an moeRaher, s work ke rmmng anes o engh onng menson
an sqarng sock I also se he roer o make gs an reqeny
make shor rns o gs an xres or hose o yo who raher woo
work he laorms an her wnows are say emlae roe
sqare ences asabe slos an rabbee sos are also roe
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Wid glu-ups pos srious dimnsioningprolms A jigsaw routr, and tmplatcan usd to squar off t nds
T nc on t work o ldr can adjustd paalll to its work dg. Wit t curoundd y an MD F straigt fnc you ca joit and macin to widt in on opr
I nxpnsiv rout ts can pr oduc a vaty of traditional pro fils
Appcato
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2 Itroductio to Rotng
Types of Routing
I wo e a misake o hink ha all of hs applcaion can e eno
wih s one roer can' e one here are some cngs ha if
o fll eph will reak he cer someimes he roer s s oo sm
an nerpowere for he o Cerain cs p he work or he opera
risk wih he wrong roer here are prolems of scae ha may req
he roer ale Sma os may e eer sie for a rim roer anmlisage work shol e one wih a pnge roer However, roin
versaile an here are sincons yo shol know ao
LIGHT TRIM
Freqenly, rae work calls for very igh an shaow cs in woo m
or pasc hese cs are of shor raon, an reqire lle power o
p complexiy Yo may no nee a fll-size roer for hese cs Exa
incle he morsing of hnges, chamfering, an small ronovers B
mosly 'm alking ao he cing an rimmng of plasic laminae
(Formica) woo veneers fierglass an hn amnm his work salways ligh y, shaow one wih ony !4in ool shanks, an only
rim roers
T PC-310 trimmr and offst su bbas ar a good matc to trim (bvl) ts dgs
work can b sn troug t astic bas wil t routr is kt flat on t work.
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Sli din g dovetails ae geat fo locking legs and ails Sockets ae made on te oute taleand te tenons wit te and oute
Bead and utte tim (cove) cuts eqi e ao t a sap ctte, and a med um weigt ixed ase
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4 Intoducton to Routn
HEAVY-DUTY HAND ROUTNG
Ip
h h
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PLUNGE ROUTNG
Roters esigne to alow canges in et witot stting o te
macine ave come to be cale nge rotes. Te base incoroates a
mecanism wit a series of stos so tat te rote can be owee ince
mentay e esign allows yo for examle to qicky ot a ee mor
tise in a nmber of smaler stes tat only remove 4 in or so of material at
a time t also allows yo to start a ct anywere in te mile of a workiecean it is esecialy sefl wen oting on anels
Altog it's ossibe to lnge" a fixebase rote into te wok it's
an inerenty nsafe oeation becase te base isnt sorte ring te
oeration lnging is simy not safe wit a fixebase roter. Te nge
Mortiss and tnons rquir fixturs for quality and rpatabliy A good fit lik tis mposs a lo t o dmands on t j igs
Half-laps ar salow and larg n ara prct fo t pung outr Ts ar mad i atplat jig udr t work
Type o Rotn
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1 6 Inroducio o Roui
oter is expressly esigne to fnction in yor hans wth the a of g
ty ts springloa moto hea tret stops pstop hanle gips motor
an switch are all sitate fo yo to slie the too to its estination w
the ctter retracte an motor on Now with yo at the contros yo
safely change the epth ner power an waste woo n stages
The pnge roter oes ts est wok plnging" Plnging is best
ie ot an sometmes only possble when the rote is completely s
Tongus and goovs of all sors can mad on t rotr tal wit straigt its.
Stod on mortiss ar safly don on t outr tal
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rone y sstrate. Pnging wt ony a o te casting on te wor
can tp te roter over or, n some cases arrest te pnge acton atogeter.
e saest arena or pnging ten s on nse cts e mortises at s
not to say tat pnge rotng cannot e aong te eges an ens o te
worpiece It j st means tat te ase casting as to e on soi gron to
spport its pnging nction an reative top eaviness Cttngs tat are
eep an wie or oterwise mpossie wt a singe-ept setting soe one wt a pnge roter Pnge cts too angeros or a ixe-ase
roter aso nce insie in excavations were te ctter mst e
ner power an extene to egn te pass
TABLE ROUTING
ae roting essentay trns te too nto a stationary macine wit a
ence tat wraps aron te ctter an spports te worpece Unie
portae rotng operatons, te worpiece moves past te ctter instea
o te reverse More tan 80 percent o a rotng can e one on te
roter tae. ere are restrictons to ts se sc as very arge wor an
ong stics on en) t te majority o roting is on inva worpecesan qite manageae on te tae
Roter tae wor more oten tan not, emans a ot o power
ere s no singe roter taiore excsivey or te roter tae. ig
motors, resistant to canges in momentm an oa, are reqre ere
ong-grain, cross-grain, enctting an some insie cts are posse on
te tae Joinery an tempate wor are aso common Ony se very
ong ctters over 1 /4 n. ese ctters reqre at east a 3 p motor an
wor est wit variae spee contro.)
Complmntay tmlat oiny is about t on ly way to join wood alo ng cu vy l is. Onsaml is a la lft, on is glu jointd m idd and t ot is tongu and goov to.
Type of Rout
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1 8 Inroducton to Routig
I use these templates to make the platfom fo the tenon-make S nce the instctions
already caved" into the template, you ca't make a mistake.
TEMPLTE ROUTING
Tempate roting aows yo to rot mtipes of neary any sape by
a patten tat's attae to te wokpee an ries against a ge pin
ote refeene srfae. Tempates an be se fo jo inery, making opmotsing saping, an mang parts fo jigs. Most repetitve rotng
an be expeite by a tempate.
y fa te most popa type of tter in my oter oe s te pa
ten bt wit a beang on top. Tese ome n many iameters an eng
for se in a variety of stations. Te art of tempate oting emans a
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THERE RE OS O CCESSORES avaiabe o exed he capabie oyor roer. There are, or exampl e aermarke bbae made rom
cear plaic a lower e above) ha wil alow greaer viibiy a
yo re makg a pa wih he roer Ao avaabe are bbae wih
a oe deg pper e) ha provide greaer coro becae more
o he bae i o he workpece a yo work.
Aoher caegory o acceore i he edge gde, whch ac mch
lke he ece o a able aw ad rde aog he edge o workpece
pper rgh) . The wo a op are hop-made edge g de he b ack
gde i he mddle a aermarke edge gide made by Mcro Fece
ee eorce o p.
There are alo a varey o collar gde lower righ) o i mo popar
roer. The colar gide i o he bbae ad rrod he bi provdg a way or he c o ollow a empae.
nerstanng of a orms of rotng gie systems, campng pocees
j ig makng, an basic wooworkng Tempate otng can be one on te
tabe or on te benc wit pnge or xe base t is te essence of rotng
st as no singe knie w work n te kitcen no snge roter wi
sice or a rotng appicatons yng to cover a bases wit one roter
wi ave yo overpowere n one sitation an at isk n anoter
peraps emptyane te roter is te p in te roter tabe st as
te jigsaw raia saw, tabe saw, an bansaw aess yor sawng neesso o te trim, pnge, meim an eavy fixebase roter cove yor
roting nees
Type o Rot
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2
Cutter P athwayControl
HOW we yo onro e paway o e roer i eermineqaiy o yor ress. Tere is more o roing an er ro wio i yo ave noing. Cer qaiy, maeri
preparaion ee rae, sep an aenion o eai a pay a par in qaiy o yor ings wio onro o e er paway ynever ge o praie e iner poins o roing.
roer an move in a sraig ine or on a rais as roe r
ing in ree axes a e same ime Sooping air seas or making gono an easy ask wi a roer, an very sopisiae engineering an
ring is reqire o o so. Han onro o e roer, weer in a
or sraig pa, in one pane a a ime, an e esaise wi er
ings, oars, pivos, ege gies empaes, an varios ominaions
s menione roers are vey exie oos an an, nike a a
an saw, operae as easiy in e mie o a workpiee as on an ege.
roer i an ener rom any srae eier ae any ege eier en,
aong e rais o a rve Te an e in, ener rom e ege a
sop insie a-in), or pass rig rog i Tis m reeom o
reqire preise gie sysems, is may no o e as aning as i
appears roer gie an e as simpe as a oar ampe ono e workp
Tere are many ways o onro e roer Tese vary rom e i-in
ros an asi ege gies o miromeer-onroe ire gies an ev
omperize posiioning evies a are osie e sope o is ook
or isssion prposes, i's proay es o sar a e ener o ings
e varios ways e i ise an gie e work a an
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Bearing on Top
Topbeainggided ces, or paten bs,
are always sed wih a empae -
Templae Workpiece
Bearing on Bottom
End-bearing ces ypically oll
aog he wokpece
Wokpece
Collar Guide System
A ypical col lagide sysem uses a empae
ad a smalle b so ha he cig pah is
offse fom he empae
emplae Wokpiece
Sank
Cue
Beang
Cuter Pathway Cot
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A consumr-grad gspd sl utiity t lik t og is guidd of t stl ilot on its
nd. Tis inxnsiv ool is for sor-rn s only
Som of t nd-arin g cuttrs can sd wit tmlats tat ar acd undr work
sots of roe its se a earings on te en Many ae ecorative
poe ctters t a few are se o join winow sas, make raets, sot o
s trim ey are easy to se an won't n te stock Most often tey
ae se for ong on eges an en-grain, or w a tempate.
t oesn't take mc sk to o wi a eainggie cte: Yo se
te ep of c ock te moto egt an p te roer inoar o get
te earing to engage e wok. ese ctes are essentiay se on te
Bearn-Guded Cue
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work so at no time is a roter ase stting on 50 percent of its footprint
40 percent s more typca wit ess tan 25 percent at te ens of te ct.
ny ctter mst reac maxmm spee efore t toces te stock so r
ing part of te ct te ase casting s sifte even more off te work For a
1 n iameter ctter in a roter wt a 6nameter casting tere s
ony 37 percent of te footprint on te work on startp an tat isn 't a
ot of staity. earnggie ctter simpifies te roting process eminates te
nee for more compicate gie systems incng te roter tae, an
provies te cance to work on assemies tat migt oterwse not e
rotae sc as instae anrais or contertops
On te ownse earings foow ege efects cattere or rog
ege wi yie a cattere profie. earings, wen pace on te en
effectivey engten te too it an te more stant te earing is from
h si d prssur from a baring can b so h ig that i mars th
work If hs is a problm , somims two barigs can b usd
earng-Guded Ce
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TE RS NUER N EC CHR ery i he bore he hoe) o he bear
g he ecod mber he dameer. he widh hicke) o he
bearig varie b hey are coa whi a ize her mber
are o pariclarly impora Bearg bore ca be dimhed wih
lmi wih mal precio preedo rg Thi i a precie machie
hop pracce ad m be doe wih care rror baace or a rig
ha p o ca be hazardo.
Beaig are gr od o very igh oerace. Th e hardware ad c
er geomery or edocter bearg ch ha hey hod alway
occao hey may be dic o ide oo he hak, however,
ad may reqre a pre i a hak i oo mal eavg ome pay
o he bearig o he hat he aio i hazardo ad he bearig
hold o be ed A bearg hod have ome reace o i i
o he hak ad hod be ixed wh a hak colar
SANDAD EAING AND SHANK SIZESDmss pv a s b st,
f by th uts amt.
d-Moed Bearig
n. xn
n x n
n x n
hakMoed Bearg
X n x n.
X n x n
X n x n
n x l n
n x n
J n. x n.
J in x n
n x 1n .
A routr with pattrn bis and a tmpa can han d c rvd join ry wth tight tuns
Bean-Gded Cue
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28 Ctte Pathway Contol
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T bai nggu idd straigh bit wll prod c a copy of th tmpl at profil
exape) Too uch cutter extension s aways hazardous In response to
this dea PR (see sources) has designed a set o cutters or any prac
tical thckness o teplate (/ to /4 in ) and workpiece thickness to li n
The syste uses ive cutters two o which have a / in oset ut into
the so the inal pass with the lush trers w e soother with a
constant / n overhang
The negatives o the endearng its also apply to the topearing
its ut a ltte ess so (They still have relatvely short ves and transitteplate edge deects and wear on the router) On the other hand the
earings are right up against the colet so there is less stress also earings
or shanks are igger hold ore lue and last longer
Two other positive points wth these cutters incude their access to the
work and their ality to otto cut ore than their diaeter A teplate
can e paced anywhere on the work which eans that edge end inside
ind through and halind cuts are possile wth these cutters Also
ecause the otto o these toos are ground to otto cut they can exca
vate an area greater than their diaeter
Collar Guides
Teplate coar guides ike pattern its are essentially used ony wth
teplates hey ehave siilarly to pattern its as they surround the
router t j ust like a earing There are our sar types o collar systes
Coa Gd e
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30 Cutte Pathway Control
Coll ar guds ar usd with mplats for oinry li k cutting this half ap
Th co lar gu id and cutt r sstially act lik a pattrn it wit a arig o topshow a lft
Porter-ae he olde and ot popular ha a two-piece ring and naey hat faen o the uae. och ha a ayonet faening y
( like the lene of oe caera n whch you ner the colar tha lo
into place) that aten to an acceory that crewed to the uae
Mwaukee ha a collar hat crewed drecty o the plaic uae A
there are other hat faen to the ae catng. (Alot all router a
facturer ake acceorie for the Porer-ale yte a we a ther
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Coas coe n a vaey of daees and lenghs soees fo vey
specfc obs
he engh o he coa shold wnd p js shy o he hckness o
yo hnnes epae I se �_n o hcke epaes, so I've hacksawn
y collas o n
Th PortrCabl collar gud systm hr on its 42193 offst routr bas provids a simp way to us a varity of bus hing sizs on th sam routr. T y ar intrchangabl andfit n t ing assmbly.
Thr of th most common coll ar-gu id systms: (lft to ight) Bosc h PotrCabl andMilwauk.
ola Gide
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Dbe Dty frm C la rs
Route-bt gu ie colars are so
ceap I usually buy te pars
Wit te sae iaeter colla r i two
ieret routers you ca o bot
roug a s work wit te sae
setup. Wit two ifeet iaeter cut
ters you ca let te irst router o te
irty work a let te seco router
wit a slgty bgger cutter a set
sligtly eeper cea up a fiis te
job T is way tey ast loger so you
ca get ore leage out o te.
32 e Pahway ool
A colar-guid systm cuts a path thats offst from th busingso yo nd to takinto account wn dsign ing tmplats
On dsadvantag to collar systm is tat t colla r s aways
an cttr i sronds s mans tat t mplat ct s mag
on osd adi and smallr wt concav crvs Tis dscrpancy is
cad by sbtractng t radis o collar rom radis o t
Mak yor tmplat smal or larg to accont or tis drnc
ollar s s nv as prcis and prdicabl as bainggidd c
A collar mst b witin 0.001 in o cntr o so o it o b pactica
concntic o t ctt Ts rarly appns and is not ncommon
a ct to b o om cntr by n or mo T osc slcnt
collar sysm s said to b adjstab to witin 000 n o cn To
miz ro casd by t ccnticty, don' roa rotr as y
gd it against t tmpla Kp t andls, or xamp in s
orna ion to t work as yo mov t otr in t c
T colar as a spcia saty advantag in a yo can always
xtnd jst rigt amont o ct or job Any xcssv c
byond sbbas sold b minmzd Fo ll icknss cts pro
t bit / in byond t maia tcknss
On t down sid, maximm xnsion o any ctr is comp
msd by s o coas; amost all o t collt nts on al rotsit som pat o collar collar is not sd, cttr may b
xtndd rr ttr xnsion and lng, mplat sbbas an
workpic ticknss a aways n conct wit barings and colars
rl t pactcal and sa lmit o llticknss cs wit baingg
ro cts is 2 n bt 1 in wn collars a sd ck stock
b otd bt pobably sold b workd on a sapr ts larg
� in will not ntr bo o most coas
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Also collar gds ik dg gids and patrn its wi allow th
ct to transr tmpa dcts to th work
Edge Guides
hs accssoris s a par o ods that it nto h ror's as casing
providing a way o astn a smal nc that gids h or paral oth workpc dg h advanags incld contnos adjstailiy and
th larg conac srac which tnds o vn ot mnor imprcions in
h dg and provid a smooth ct
Edg gids do imi h travl o th or o a lin parall o th
dg o th work whth cvd or straigh hy conss o thr compo
nns h pair o rods a ody and a nc Th nc can stragh or
radisd o mach crvd work. Each gid s dsignd xprssy o its
ro hogh an atrmark vrsion th Micro Fnc is availal o i
all poplar ors Typical cs a aong h dg across h nds or
across h width o stock Edg gids don' hav h wok accss o a colla gd and mplat and hy a snsiv o wokpic siz For xam
p narow stock lss than h radis o h as casing dos not prsn
nogh srac o th stailiy o th otr
Edg gids a latvly nxpnsiv don't mar th work and ar
continosy adjsa cas th ody/nc can posiiond any
wh aong th rods hs lxlity is prcisly what maks hm s
spcialy or th shop-mad morisr Oddy I nd thy work poorly on
most ohr jgs hy ar saly sd drcty on h work
A edgeg de sysem ses a pa o ods and a n
adjsabe fene a sides again s e wopee.
Wokpiee Cte
Edge Guide
Base asi g
Edge g ide oa wh wo Edge gde
Edge Gid
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his ommad dg g id is mad from hardwood, aumnu m barand sl rod.
his afrmark dg gu id from Mic ro Fnc uss a m icromsyl adjsmn fo prcsion
34 Cuter Patway Cotrol
dg guids can b asily adjsd o vary wdh of a cu A n bi, for xampl,mak a in.-wid rabb
Sinc dg gids corrspond to t fnc on t rotr ta, t
can sd at tims in t asnc o on, t nr as a sstittWit simpl, smalld iamtr cttrs yo can mak raisd pans for
instanc. Tis is mssy t t cttrs ar small and ts saf to s in
tis way
Edg gids ar cmsy; dont xpct to work on of ts prfctl
yor irst try Not tat t nd of a ctting pass can a prom c
only a o t fnc rmains in contact as yo finis t ct nlss
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pacic png a sma poion in conac w wopic,
o will pvo and spoil c a simlanos ncions
o yo o conol old-in, oddown, and slid-aong On an insid c,
any dviaion o nc om dg o wo wil l in c . On
an dg c yo j s c wo a pnaly nc says om
Th atho r's mortising jig mploys d g gu ids and stops to confin th cttr pathway toa squar or rctagular h ol
Kping th whol stp flat is mpoant whn making a raisd panl
Edge Gide
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Ofset Sbbase for Added Stabiity
All routers ae ustable we al
or less o te base castig is o
te work A oset rectagula r su b
base ca overcoe istability a
we use wit a straigtege, pro
vie a secure a accu rate gu ie
ecais Wit oe se o te sub
base loger ta te oter its uc
easier to apply pressu re over te work
piece a keep te router ro tppi g.
A squar suas provids a vry
accurat gu id s urfac. If you workth sam dg of th as againstth tmp lat and ocat th tmplatin th sam plac all similar cuts will th sam.
36 e Pahway onol
A round suas is not a prcis guid for outing Any rotation of suas ca causwidning of th dado caus cuttrs ar rarly pfctly cntrd
wopic An os sbbas, sc as t PotCabl 2193 can co
a aning fnctions an sotn yo laning cv
The Subbase
sbbas itsf can b s as a ot gi wi a cv tmpa
staigg It is t last acca b qickst o st p Yo clamp
stick own on t wo, o t ot against it an ot its fas b
nv picabl o pcis Ctts a nv wlcn to t
of a on sbbas, so any otation of t o ing t ct wi
xpss in a lsstanpfc ct (Plng o bas castings com
many sapsconsqntly t g can b s as a gi to n
cnt)
poblm of giing icty of ot bas isn't limit t
cn anomaly" owv Roting ictly on t wok against a
clampown staigtg will cas t o to viat as cip flo
boncs an collcs btwn ot an t gi Moov t s
taot an cip accmation n t ot wi inf wit its an slt in vaiaions of ctting p Caly, oting wit
casting o sbbas as a gi sol b a ast sonot a fis appo
An avantag o sing t ot bas as a gi is at yo can
any ct an to is maximm pt a no baings to ngag
collas to fsat t ac of ct iscov tis by acc
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wi trying to mak a ong tnon ct wit a sort cttr and collar wit a
tmpat. T sqardg sbbas garantd a straigt ct at a constant
dpt and t m xtnd t sort cttr to its maximm dpt or t
lngt o tnon ndd
Tool ShankLik t ixd-pilot sat on t nd o t tool t sank o t too can
aso b sd as a gid bt ony or sort drations wit smadiamtr
bits Yo sold nvr s t sank as a gid i t tool's ctting diam
tr is gratr tan t sank is is stricty a smal straigt tool proposi
tion, and a tmplat o som sort is ssntia .
Yo can s a in straigt bit or xampl rom t insid o a sris
o drawr opnings covrd wit pastic laminat. Yo' pnc trog
t plastic aminat and tn alow t sank o t bit to rid against t
solid wood tat ssntially orms t pattrn wic amonts to two opra
tions at onc ( t ctot and t s trim) Onc in a bl moon, mays t sank o t too wn making compmntary tmplats rom a
mastr to minimiz t ost I av also sd t sanks o sort in
sol id carbid straigt bits to gt into tigt cors o tmpat mortiss In
any vnt t sanks gt ot and t tmpat ( nss o plastic aminat)
Just as th nd of th tool can b usd as a gui d so can its shank h ctig damtr ofth too must b ual to or lss than h shank diam r his practic shol d b confin dto small ( lss han in . d iamt straight bits and l m itd o vry short d ty
oo Sa
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38 Ctte Pathway Coto
Compar th radii of h cornrs of hs moriss Obviously h small cutr cus a
sqar corn.
gts won qicky, so ts is mo o a ciosity tan a viabl and impo
tant mtod o ot patway contol
The Circle Cuer
A ot astnd to a stick wit an adjstabl am o wit jst a ol
in it o a pivot, can ct t cicmnc o a cc Ts is an nt
ng mtod o patway contol T ot as now to go bt in a
cic, and t cttings a xcnt Yo wi nd a small plng o
to do tis say It is mssy, as tis is a lldiamt ctt patway, b
t a sva png ots wit vacm attacmnts tat will co
t cps
t is intstng tat t a so w owtc lowskill pocsss
oting tat a so pcis and asy T a lips maks tat wok
w also bt asd om cicls sgmnts o ccs, and ipss, don
know o any ot ss o a ot ttd to a pont o points. It sm
t sold b mo Wtot mc ado, I can mak a cc w
000 1 in o its intndd diamt wit a $ 1 00 plng ot a $ 0 bt
dola's wot o mdim dnsity ibboad, and a pvot stick, al in
w mints.
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Th author's crcl cutt confns th cuttr pathway to on fixd adius.
This sotmaking jig lmits th slot lngth with a stop Th slot width is on cuttr dia mr
caus th collar cant squiggl i its slot
The Circle Cue
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Templates Go First
When making disks or rngs, hav
ing a template at hand removes
vrtualy all the risk. The procedure s
to make the tempate (%in . or 1-in .
medum-density fiberboard) trace its
circumference on he work, bandsaw
the dsk leaving 1 n outsde he l ine,
clamp the te mplate to the work and
rout o pattern wth a patern bit. Thereis no need o poke a hoe in the work
or the pivot.
40 er Paway onol
Other Guide Options
Usually on guid sysm p opaion s a tha is ncssay. Fo xam
pl a colla guid s usually not quid whn a aingguidd cutt
pay ut i can us suas stops and dg guds o conol th c
pathway whn makng motss and also us a suas stop and colla
guid with my slot mak to din th lngth o th sots it maks h
poin is tha th a mutipl options o al you nds
Fhand unguidd outng s awok You can lan to cav and
wast hand u it will ak tm Smal light outs wih los o
cut visity (P , DWal 6) will giv you th st chanc
signmakng is you hing wok wih ig ts a shallow dpths Sha
cuts a ssntial Highspd s can gound o a shap dg
than caid; t may h t choic i you hav th gindng skil
to kp shap
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Fixed,Base
Routers
In Unid Stats ixdbas ot as bn dominant
ot dsign o o al a cnty tool is simpl wit w
moing pats and in my iw is sa tan a plng ot o mos
opations moto campd imy (ixd) in its bas casting as a
simpl dpt adjsmn bt i mst b stoppd and st btwn cts
T plng o ocoms tis disadanag and is t tool o coic
o dp motiss tat mst b ct in sal passs (s capt )
A fixd-as routr lft is st applid in sng-dpth dg cttings Th p lug routr
rgh, is dsign d for succssiv dpth chang s ndr powr and is bst fo multi stag
insd xcavations lik mot ss.
his 1 960svintag
Black & Dckr modl
442 is sti l l nnig
chapte
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Fixed-Sase Router
_
42 Fixed-Base Rouers
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44 Fixed-Base Routers
CASTINGS HANDLES, AND SWITCHES
Base castings vary and ae quite distinguisable All have windows o
good cuter visibiliy, oug mos base plates are black and ide te
surace. DeWalt and Pore-Cable will supply accessory transparent su
replacemens. A router at can readily sand upside down or bi cha
is a nice convenience. Porte-Cable, DeWalt, and Milwaukee ave
accounted o this Te Bosc model has a adius on te moor cap ocomfor, but at some expense for upside down stabiliy
Te knob or andle assemblies o most fixed-base ouers are pla
low on te macine and provide sability Plastic , wood, and metal a
ypical mateials, and mos people will have ei own opinions on w
ae most comortable. I use an oset subbase on all o my fixed-base
outers, and control te tool wi one and on e base casting and
oer on the oset base. Tis coniguration allows maximum contol
cially aound te cornes and along e edges o te work. Howeve,
should be aware that the position of te two casting knobs supplied w
roue is well toug out. So give em a good try before consideing
changesWie ses are eite two- or hee-conductor depending on ow
tool is insulaed. Double-insulated tools will ave two-prong plugs wi
he gound. All commecial oues use rubbe jacketed wire sets but
ae dieent lengts I am 6 . tall and always use an exension cord
I would like the plug to emain on e ground and or me tha means
O-t wie se.
The DeWat 61 0 shown here can be supplied with a cea plastic, round replacement
base for col lar gu ide use . he flat head provdes a sable base fo trn ing it upsde do
bit changes.
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Th mapl knobs on th Bosch subbas gt yo as clos to th work as any outr
h Portr-Cabl mod 690 bas casting is th prfct siz for my had I'v got th samcontrol on his rotr as th quaback has on th football
Switcs ar slid, oggl, ock or tigg, and tr locatons vary
wold not slc a rotr basd on t switc; t's a good ida to clariy t
o posiion so yo know t ool is o wn yo plg it n t away
Also, prpar yorsl or a qck stop and kp yor ands in a convn-
Rouer Basic
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46 Fixed-Base Roues
For addd safty th autho r hi gh lig hts th off dirction on h switch
int ocation o itting t o btton asily Yo nv now wn
camp may slip o somting ls go awy
POWER
Fixdbas ots in t commcia class ang om abot 1 to 3
Wigt and appopiat applications scal p wit t pow xpct
o 8 ponds dinc witin tis pow ang Mo pow also mmo mtal and consqnty t capacity to soa p at A ot
avy s can at p and i t at xcds t cooing ans capac
tn t ot gts ot to t toc Howv t long it tas top t ss lily it wil ba down om ovload So i yo ot
consistnty ot dc t load o gt a bigg ot
Potabl as vy pow ang covdom k p to 3
DWalt's only nty is 1 5 p osc as mods in p and 2 p aMiwa in 1 li p and 2 p Ryobi Maita and Sas/atsman al
av ixdbas ntants o vaios stngts, bt Maita is t ony
commcialgad too wit two ntis at 1 p and 13k p Pota
as an xclsiv in t sstaind allday pow class (518, and t
no ot ixdbas ots o its siz (3 p )
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-HANLE ROUTERS
T Dandld rotr is t last poplar fxdbas dsign and t most
costly t dos noy a imitd nic mart, owr. ts adocats caim
safty and control bcas a pistol-styl switc is grppd to start t
rotr To stop yo j st rlas. Wit t switc n and yo can st
down qicky bt n my w tat safty margn is mor tan ost by a
loss of control A Dandd rotr is always ld t sam way and asss stability as yo fnis a pass at t nd of t workpic. Moror, t
oblgatory D-andl n lin wt t tra of t rotr intrfrs wit
cts mad wit dg gids and colar gids.
h D-handld sy of routr provids on-andd control which is oftn convnint for
rptitv work
T PorrCal 691 D-hand casting
Roue Basic
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Poer-Cable 690
Weght
Speed
Amps
Sof sar
Horsepowe
eght adjuster/mechansm
Colets
Basepate dameter
8 bs
Singe 3000 rpm
10
no
1
Contnuous, motor ws
Y4 n. Y2 n
. ,
n
& metrcs opton
5% n
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squat casting shown with pgradd lock lvr and accssory offst bas povids somch cotro that t ca lik an xtnsion of your hands
Leading Fixed-Base Routers
There s no snge perfec roer Mos have some exceen feares,
mae compromses n oher mporan areas Some are o esgns ha s ll
or el l ohers offer ne soons o some s cy prolems he DeWa
610, for eampe, s a uay oo has een n proucon vral ly
unchange for over 30 years (frs as a Blac & Decer ool an Elu oo)
On he oher han, he Bosch 161ES s a relavely ne oo h some
nnovave feares. Each of he roers has s on personaly an s onse of srenghs an eanesses
TH E DEWALT 61 0
As menone aove, he DeWal 6 10 esgn s a leas 30 years ol an
essenally unchange A rac an pnon gear rases an loers he moor
n he housng I can e ajse, le he 690, o zero a any pon n s
Weght
SpeedAmp
Sof stat
osepoe
eg aduse/mecansm
Coets
aseplate damee
DeWalt 61 0
3 bs
Sge pm
no
1 .
Rack & pno
% n & n
6 n (sho h an accessoy
oset base)
DeWat 610
eading Fxed-Base Roer
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50 Fixed-Base Roues
The three moor pack projections add anoher 1 n of travel to thi s DeWalt 6 1 0, whi ch
also show with ro nd collet n t and co la
ravel and is depth ring is indicaed in /4ths A wing nu is sandard f
ightenng he casting around the moo, bu a shor lever s beter (a
ool, KHB- 1 , for exampe) . The casting is not sawn through as on Po
Cabe; raher a /4in. srap (band) of the casting is cinched on the mo
on he rack sde of he base he gip is not as sure compared wth thePoter-Cabe, but he moto never slips
Two postive changes in he DeWalt 6 0 that warant prase ae i
collet nut and moto barel exensions. The collet nut has been milled
fi inside s accessory collar gudes The closer he collet can ge o ts
template, the less deflecion there s wth he cuttera nice touch h
610 (and its ancesors) have never had much up and down moor rav
and used o be quite popular n he outer able neverheess. When h
tool cared the Eu and Black & Decke abes, s moor pack was
redesigned o accep a longer ack fo is deph pinion gear. his cleve
change added anothe 7 in of ravel fo a ota of about 1 3/4 n Howev
more tave is at he expense of securty. If the /4-n deph is exceede
the base casting's grip on the moo pack sn secue.
The 610 hard-sat, 1 -hp rouer is moe sensiive o cutter mbal
han oher outers its s ze. 's fine with small , squaty pofile cutters ik
ogees roundoves and beves, but t vibaes more han like with lon
( � in ) cuters of equivalen dameer his gets more pronounced w
beaing-guded route bts he moor rests well upsde down fo cue
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hanges an requres two erent sze wrenhes to unlo ts ollet
hrough the sueeng years ts astngs have eteorate soe an sef
tappng subbase srews have eplae through-hoe ahne tappng
Whle uner the Eu label the 610's olet was at ts best: eght-slotte
an self-eleasng. Uner the DeWat abe the olet was splfe to a
sngle sl t noneleasng esgn. ts shot length (4 n ) probaby on
tbutes to ts vbraton senstvty Nevertheess t oes grp the utterwel an utters o not st n the ol let
he 6 10 aepts few aessores but DeWalt oes have lea roun
an oset subbases for ths tool n ther atalog Wth ts short stabe
geoetry ts abty to proet the olet nto a ollar gue an wth ts
tanspaent aessory subbase the too s patualy well sute fo ove
tal an bo-ont teplate wor. It s just as stable along the ege of sto
wth eoator utters he early Bla & Deer toos wth essentally the
sae esgn wee esgne to go ght ba to wor after a 6-ft. op to the
loor. he swthes ast foeve but the wre sets see to have about a two
year l fe span f use egularly.
TH E BOSCH 1 617 EVS
Bosh s the frst to poue an a-new outer sne the Porte-Cabe 690
osse ove fro Rowell. t s however a stanar-loong router an
requres lose nspeton an a few pate uts to be appreate
he base astng s equppe wth a two-stage epth ajuste. t s by
no eans a oeter but sall ontnuous epth hanges an be ae
by tunng the srew auster whle the otor o s sengage. he
oto has thee sall retangular nothes on -n enters le nto t
or on opposte ses he epth auste engages a noth for ts rough pos
ton an the verner s use for the fne ajust. he total otor travel sabout 1 n. ts not a goo ea to eee that If the otor snt
engage wth ts epth ajuste asseby the lo syste wont wo prop
erly. One nterestng note he oto an be nserte n two aetraly
oppose postons wthn the astng so that you an easly aust the
swth poston for ease of operaton
Wg
Spd
AmpsSo sta
ospow
g adst/mchansm
Colts
Baspat dam
Bosch 1 617EVS
bs
Vaab 8-25, pm
1 2Ys
2
T n ncmnts
wh sconday connos mco
n in & % in.
6 n.
eadig Fixed-Base Roe
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52 Fixed-Base Routers
A sprng lock egages a notch in the casting for the ough �-n changes on the Bosch 1
Bosch designed ths too with vaable speed double insuation an
soft stat. The castngs ae magnesum, and with its 2hp motor it's as
as the DeWalt 61 0 Hgh power and ight weight don't usuay go toge
You might expect the tool to run away from you ke its 1604 sngle sp
predecessor On the contrary the 16 7EVS s a delight to out with.
The colet seat s med ight into the end of the armatue; there
no coupngs. Ths, aong with its precision bearngs algnment ama
design, and balance make ths the smoothestrunning motor of all the
outers I know of
Bosch has solved the moto lock problem that pagues some other
routers. The base casting is splt though its height on one side and ha
vey usefrendly overcenter lever ock much lke a togge camp It
adjustable for wea and stretch and is designed for a close ft between
motor and the base castng
The base casting s dilled for its own subbase, and has the same t
hole pattern used for the Porter-Cable 690 specialty accessory subbase
route tabe The design of the interior of the base casting and its subb
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allows the gue coar to get wthn 000 n or better o center The
16 1 7EVS s useful or al feepth cuttng wth a 2 hp router. t has
unque avantages n cose quarters an ts orgvng soft start wll prevent
an unwante c nto an uncut area Moreover ts feebac electroncs
start the tool graualy (soft start) an prove a new easure o saety
not oun n harstart tools. he 16 1 7EVS can aso absorb netc acc
ents such as an unepecte g nto the uncut atera f ' nto eperenta wor Ill choose the 1 6 1 7EVS for ths reason because routng can
be cey In ornary wor the otor behaves le a sngespee tool but
there s an nstantaneous overoa ths s the router I want to be usng.
It also has an atonal 4hp ratng over the sngespee 6 1 7 for ths
purpose
MILWAUKEE 5680
he M wauee s a 2 hp sngespee harstart coercal grae router
that has reane essentally unchange for ts lfete o over 20 years.
The otor heght s ajuste wth a pastc rng engage n a spral
groun aroun the outse of the otor he otor s hung" n the castng by ths rng so the echans oesn't wor when the router s upse
own t's not a great choce or the router table. heres aso no way to
zero the vertcal poston n the router. A epth changes are thereore
reatve to the last reang o the epth rng. he otor travel s about
1 n after that the castng begns to ose ts grp on the otor
Mlwauee s crete wth the rst utsplt selfreeasng coet ts
1 n overall length an eghtse nut s a cobnaton not to be oun
n any other router. The otor has a very lat an arge hea or easy bt
changes upse own
he Mwauee 5680 s one of the nosest an toughest of routersesgne to flop aroun n the bac o a pcup truc an has long been
the stanar for carpenters an outse traesen he 5680 s we bal
ance an ergonocally acceptable but the nta cbac on startup
has got to be the ost powerful o any 2hp tool. Its squat heavy otor
helps eep the tool flat on ege cuts
Milwaukee 5680
Weight
Speed
AmpsSo start
Horsepowe
eig adjuse/mechanism
Coets
Baseplae diamee
85 Ibs
Snge 26 pm
1 2no
2
Ringng moo twist ng
Y in . Y n & in
6 in (sown wh an accessory
ose base)
Prevent Accidental Goug
Apowerul router especialy
wtout a soft-start eatue
lu rc we you irst lip t e swit
elp prevet cotact wt te wo
piece keep te router a ull oute
iaeter away fro te wo rk at
Leadg Fixedase Roue
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54 Fixed-Base Roers
h Mi lwauk 5680 has th ony ig h-sidd col n t and is on o h fist with an
slottd slf-rlasig collt
The M wauee caing are beter han o bu ill need oe
debring n y view thei pli-bae cating deign hold the oor
bu ther wng nt aebly for ightening i too all Ive repaced
with a et cew and n The niqe crewon colar gide yte a
otor travel and high power of thi roter ae i paticay ueful
doveai/bo oint tepate wo all edge cting and pattern ct
TH E PORTER-CABLE 7518
he PorterCable 5 1 8 i he arget fied-bae roer Boch and Blac
Decer ed o copete in thi nche but the 518 i now aone in th
cla t not ofen thi happen upect he reaon for th pcing
he econoe of cale; neverthele thi i ju a lot of outer at a price
PoerCable 7518
Weig
Speed:
Amps
So sta
osepowe
Hegh adjuste/mecaism
Coles
Basepate diamee
145 Ibs.
Vaiabe 5 speed
10,000-2 000 pm
15
Yes
3.25
Contiuos moto ws
X n , Y in . % n.
& mercs opo
7 i (sow w accessory
ofse base)
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With its lon g motor barrl th Portr-Cab 751 8 has mo up and dow travl tan anyroutr fxd or pl ng.
that can't be beat This heavy-duty achne s the ost poweul ied-base
us. router at 10 volts and 3!4 hp Eveything about this route is big t
weighs n at ore than 1� ties 5 lbs) its closest rva. t has at least asuch up-and-down oto travel as any oute It has the lagest base cast
ing ootprint o any outer. And it has an overa height o ore than a
oot. One would epect ths achine to be hard to han dle and t can be
with bg cutters but it is deceptvely tactable in noral use
The otor its in twin spials within the base castng and one otor
revolution transates nto 1 in o cutter height change he tool is doube
nsulated sot start and ncreentally vaiable in steps o 3,000 p
Leading Fixed-Base Roue
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58 Fixed-Base Roes
Basic notchs a anothr strong point of th fixd-as rout r
his stp and rpat dcorativ cov can managd w with a fxd-as routr agu d and an offst suas Mak su to p ull th coll ar firmly against th tmp latdviation will spol th whol pattrn.
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Fixd-as tools ar th st choic for tmplat-dg cuts. Thy hav a low cntr o gravity and ar lss likly to tip than a plng routr.
pnge roter cs wth a cter fly eended ay case a roter to tp as
yo psh the tool aong, especay wh a shortbase fooprnt n the drec
on o travel. ( Pnge roters don't generally have rond sbbases ) Al l
edbase roers have rond sbbases that beter spport he ool nder
these condons
The fedbase roter s a necessary roter or the lee woodworer
or hobbyst. Nether a pnge nor fedbase roter wll cover all ypes of
rotng saelyso plan on ownng one of each
Bes Fixed-Base Applicaio
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6
The plunge router which has been around for about 50 years
rom a ixed-base tool primarily with the ntegration of the m
with the rest o the tool and the ncorporation of a pair of tu
that provde the mechansm for controlling the up-and-down motion
whole assembly is designed to unction as a sngle unit and doesnt co
apart for bt changes or anything else
Al l plunge routers all comprised of a base casting and the two po
shed tubes or the motor to pogo" (move up and down) on A stop tis a common feature and used to regulate the depth changes. An up-s
is often used to set the motor head at the same starting point Also st
dard on most plunge routers are motor locks handles swtches edge-
accessores depth gauges and split self-releasing collets. Some other u
features sometimes found are: a sot start so the machine doesn't jump
when yo ip the switch; variable speed; two-step saety switches; vac
funnels for chp collecton; spndle locks; protective bellows for the p
tubes; two-stage mcroadjusters or precse depth control; and electrc
braking
Plunge routers are desgned to be used in your hands with the aid
gravity; they arent really meant for the router table where many of th
are found today (The issue of ust what makes a good table router wil
dscussed in chapter 6) In my view the plunge router can be utlized
ever use of the ixed-base seems rsky or is clumsy o be sure a plung
router can be modifed jigged or ixtured for nearly any cut that a fx
base machine can do but ths doesnt always make sense Simple s be
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his squard-off as casting is a typcal plung routr configuation. Fixdas castings
ar rond h polishd ts and plu ng arings in th DWalt 621 provid th tool with
a smooth pung action
Th pstop on this PortrCa 6931 can sd with a fin-adjust kno for continu os
adjstmnt It also can st so you kno w th cuttr is clar of th work whn th had is p
The pnge roter's essental advantage is its abity to star p with
the cter retraced and stab into the worpiece in a controled ashion.
Thereater t can remove the remaning sock in eqal passes changing
depth, and ceanng p its mess ( in many cases) all while its motor is
rnning. Wha cod be sweeter?
Pluge Roe
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62 Plnge Roes
Spee selecor
Pge lock
p-sop l nge poss
Coet -
Buon epesse
will lock armare.
Turret stop
Base casn g
MOTOR HEAD
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Th RT-1 00 pl ug ou fom in i s h nws of a las g h 3-hp mach ns I hassof sa, vaiabl spd and a 3in p lun g sok
Th DWa 621 igh, has is moo lock in h lf-han knob Spin i o lock o unock hPo-Cabl moo lock, lf, is on" in is dfaul posiio A wis of h lv unlocks i
PLUNGE TUBES
All oto heads are astened to oced on, and pogo on a pai o plnge
tbes. They ae hardened, sally pol shed and soeties covered with
protective bellows If a wench sips o the collet nt, it will dng a tbe
and spol the sooth tavel o the oto head (Soe achines now se
one o the tbes or chip coection when attached to a vac.) The
idiosyncasies o the tbes ae not reason enogh to accept or reect a
Basic Anaom
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Some pl unge routers wil l jam if you
plunge down on only one handle
which you can l ive wth. But if com-
pession on both handles does not
resut n a smooth up and down g ide
of the head to t s fu l extremes, that
router should be eft aside
roue bu ther nerplay wh he oto head and colun beangs
You should caefully chec for a sooth acton when consderng a
puchase
he spngs hat pogo he roue on the posts shod be such hat
pc he oto head p to ts sop n a easured and nearly boyant f
on An ovespng otor headhat s one wth too uch sprng
pevent a sooth plunge acton
BASE CASTINGS
The base casngs of plunge routers are all deen szes and shapes. T
eason for such dvesty s control The desgnes of hese devces ass
hat a stagh secon on a base castng cod be sed aganst a gude
ore conto and accracy. n pactce he subbase/castng s the leas
accuae and ost roublesoe ethod of gdng a roue. In fac th
truncated castngs aong wth the eevaed oor head are the reason
plunge routes are so unweldy. A round base castng s the bes cop
se he Poter-Cable 7 53 9 has the bggest; the DeWat 621 has one
the worst whch w addess later. Large cear plasc stably" subases are avaable for soe plunge roters.
The castngs eceve the pnge tubes; povde a eans for collar
gude subbase and edge-gde atachent; and suppor the urre so
They are soetes also used as funnels fo the vacu systes. The
vac syses do wor bt he hose can get n the way. Durng pro
ton he hose s soees sppoted fro above the woer.
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T DW 621 as long een te oute o coce n
midweigt plunge outers Tis 2-p variale-speed
sofsta 9l macine as an egonomic design
and an excelent plunge action ts plunge stroke at
2% in s a it soter tan some outes ut sustan
tial noneteess
Te DeWalt as a two-stage dept adjuste on a
ackandpinion gea Te fine adjuster s a screw
penc" witn te coase aduste Adjustments to a
few tousandts o an inc ae posse oweve a
ock to pevent slppng wile outng woud e an
mprovement
Also standard wit te 621 is ntegated cp
colecton capailty Te ase castng vacuum funnel
and ts exaust tue (douing as a plunge tue
were engineered as a package not an afeougt
Te system woks very well on nside cuts te main
arena fo te punge route aulng a ose as you
DeWalt 621
9 lbs
rout is not great un ut its ette tan getting M
n you eye
Te 621 as a spindle ock so only one wenc
needed to cange its ut tis as ts dawack
Te outer must e on its sde or te cutte can
wil not st upsde down t is easie to accdental
as one o te punge posts wt a sipped spin
wenc tan if you ave two wences gasped
and opposng one anote
Te doulensulated outer as an 8ft wire s
tat's sor for a 6 person Also its sor su
axis s n te directon o travel so tat te tool ca
easiy tp i te cutter s deeply engaged in te w
An afemarket lagedamete suase is avala
te 621 tat wl elp keep t at on te work
ne common featue tats ackng n tis plun
outer is a stop to limt te upwad tavel
Weght
Speed
Amps
Vrbe rpm
Soft stt
osepowe
Colles
Bseplte dimete
Pge stroe
Power as an Asset
Yes
4 in & in
/i x 6in ctte
hoe oset2
I think plunge routers do their bes work on inside cts dong ulistage
work ike orisngjobs hey were desgned or A pnge router can
approach an inside cu nder power, no tip and wase away sock in
stages o an in or so in seconds. Three or for quick passes and yore
n to 4 in deep A ct hat deep would break a ot of rouer bits in a
fied-base ool. A -in -deep ct wth a -n- or 4-n -diaeter sraightbit and a -ap tool is a cakewalk wth a pnge router. Wih ore power
you can do t faster and take deeper cts b not ch ore; the cters
cant take i. Consequently, or a lot of plnging uch ore han 2 hp is
wased.
Power as a Asse
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CHIP COLLECTION CAPABILITY
negraed vacm collecion sysems are a good idea. he DeWal 62 1
and 625 and he PorerCabe 7529 (and oher PorerCabe roers) are
vacm ready Afermare vacm accessories are becoming common
Chip and ds coecon are no ony imporan for or heah b he
qaliy of wor can improve oo. A rec chip wears on he cer and
fols he fooway n gh qarers especally wih emplae morisingCoars and bearings ransmi edge and empae defecs ino he wor. f a
bearng rolls over a chp can case a bmp on he wor. he vacm
hose s roblesome b beer han a chaered profile Some wor espe
caly wih plascs wl reqire ehas rgh a he cer
REMOVABLE HANDLES
or hand conro grps are essenia or roer able se hey are nnec
essary he DeWa 625 and red 2000 for eample have removabe
handles for easer nsaaion he Hiachi plnge roers all have handles
ha pivo.
220 VOLTS
he only pnge roer wh vols is he Bosch 165 and is soon o
be phased o he 2hp Bosch 617 (fedbase) has a vo opon.
Roers wih 10 vols are capabe of heavy wor b hey are no prodc
on oos Someimes hey are sed in prodcion wor b he eqiva
en operaon s sally done on he shaper if hors or shfs of he same
operaon are called for Shor very heavydy cngs are ely o brn
o a sandard roer he vo oo will rn cooler onger whch is is
essenial benef.
Even if shaper power and drabily were availabe in a roer he
presenday n shan ools coldn sand he sress. he power o aea deeper c a a higher feed rae s nce b he lming facor is he c
ers which are liey o brea
SPINDLE LOCK
Spindle locs are fond on mos plnge roers n my vew he wo
wrench sysems are easer and less iely o case accidenal harm o he
roer and o he sqeezer. sspec her presence on plnge roers is
more for mareng prposes han pracicaiy How else can yo eplan
heir absence on fedbase oos?
COLLETS
Al roers have coles A cer seizing in he cole sed o be an ordi
nary eperience B oday essenialy a roers se mlispl self
releasng designs. hey al e go of heir cers handy on demand and
hold he cer igh No mch can be said abo coes ecep eep
hem clean ( inside and o) and hrow hem away every 300 hors o
500 hors or so or mmediaely if a cer slps in one.
Pvnting Thft
Some sops use a 220volt
as a meas to prevet te
teory tat most potetial tiev
wont ave te igt electrcal o
use te tool
Hepl Feae
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68 Pge Rotes
his offst su bpla can b usd wit Pot-Cabl colla gu ids.
Ths co lts a sim la Mak tm so you won't accidn tally put on i n h wong
Sinc h collts a captud on thi nut, thy pul out of t amatu and nv sti
th out
Best Uses for Punge Routers
Cearly, a plunge router can e used wheever the fixed-ase route can
the fixed-ase route poses soe riss to the operato n applicatons w
the punge router does ts est wor We have aleady estalshed that
plunge oute is handicapped doing edge wor, so what can t do est?
MORTISING
Mortsing with a fixed ase is arely pactical o safe A plunge sta wi
fixed ase and cutter extended ay cause the route to self-feed or e
the cutte. A plunge outer is the est too for otses or speed and
accuacy a g shoud e used wth an edge guide on oth sdes of the
and jig (see chapte 9) Motise depths to aout 2 n are the practc
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70 Plunge Routers
You can ou fom boh sides of he wo wen making a disk o hole. Obviously use
same pivo hole. If you eave a in membane, you can jus sna p i ou of he bla
Full-hickness slos ae mulisage cus. The wok is clamped below he window whe
colla guide s siing. A sample is show on he j ig Thee is p eny of plafom suppo
he oue
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CUER-BREAKING TROUBLES
Bes Uses fo Pluge Roue
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72 Pnge Roers
Th us of this :i-radius roundovr bit imits th am out of bas casting on th wdu rng startup to lss tha 0 prcnt, so I scrwd an ual thicknss stick to th caor sup port
oute in this uti ity" function wihout hesitation its instail ity notw
sanding. Moeove any cutting eo fom he staight i wil e com
pleey eased y he dovetail it Fo the es dovetail cutings ty to
plow with the next smale doveail it ahe than a staigh it
ROUTER TABLE USE
Plunge outes ae poaly the most popula choice fo ote ales,
especialy fo heavy use his is mainy ecause hee ae moe choicein the 3 -hp ange than with fixed-ase oues hey'e also eaively
inexpensiveas 3-hp oues go
But he choice does pesent sevea polems Since the plunge o
moto head is insepaale fom he es of the oute you can't change
i easiy if the oo is olted ight to the aletop. Consequently, mos
fos compomise y ataching the plunge oute to a ig piece of plas
meta tha's inse ino the aletop. The whoe assemly is emoved fo
changes
n my view this compomises the outing pocess as well as he ta
top integiy and flatness. Inevitay the top wil cup up slighty and will he pastic inset Expect inteuptions as the wo umps into h
tansitions whee he pastic meets the op Moeove, expect the pas
defect as you pess the wo down and against the cutte Cose wo
e fusated when a tale has the inset consuction 's not so muc
plunge oute eing in the ale it wil wo, u it is he inset and i
insaaion hat ae polematic pefe a fixed-ase oute oled di
to he undeside of the oue tale op
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Porter-Cable 7529
Weight
Speed
Amps
Sof sar
Horsepower
Collets
Basepate diameter
Puge soke
Porter-Cable 7529
1 1 bs
Varabe 10,000-23000 rpm
1 2
Yes
y in , i. , % n ,
& metrics opio
6 .
i
he Pote-Cable 7 52 9 plnge ote is new in the us aet and
designed to copete with the best of the
o openes the Pote-Cable has a hefty pnge stoe ( 2/ n. total)
and a age, stable base castng wth a ond sbbase. he Pote-Cable hasan p-stop that does doble dty as a ll ange icoadste in both
diections of tave he 7529 also has a spinde lock, bt the copanys
standad pai of wenches can aso be sed.
his doble-insated 2-hp, vaable-speed soft-stat too also has an
electonc bae an ipotant safety feate t has a eatively qet and
well-balanced oto, with a 10-ft powe cod.
he aoed egonoic gips ae cose to the contols. One conto,
the depth stop can be adjsted with the left hand while hoding the gip
a the while aintaining contol of the ote, a Pote-Cable ecsive.
Th PortrCab 931 lng rout
T h o on h Por-ab
an b work whil or lf ha
i l l on gr a mart af m
Poe-able
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DWalt 625
74 Plnge Roers
Pote-Cable has also desgned the base astng as a vauum funn
wth a onneton fo a -n vauum hose Colletos ae also avalab
o edge tmmngs whh ae hade to pk up.
The vaable-speed seleto s saely out o the way, but s dul
otate The tool has two swthes wth themal oveload poteton, b
have touble wth the tgge swth oodnatng the two steps to lo
on The plunge glde s aeptable, but the head wll am downwadpessue s only appled to one knob The tool s heavy at 1 1 lbs and
wde than t s thk, makng t unstablebut less so than most
Anothe plus s that Pote-Cable has desgned ths tool fo oute
table o hand use wth a mehansm that povdes fo ontnuous adju
ment ethe upsde down o ght sde up
Pote-Cable also has two othe plunge outes The 693 1 plunge
oute s essentally the 69 fed-base oute wth a plunge base The
and 7539 ae plunge vesons o the Speedmat 3 -hp fed-base ou
DeWalt 625
The ndusty standad n the heavyweght lass s DW-6 25 omely t
Elu 3338. Lke all outes, t s not peet but deseves ts poston as
best bg plunge oute. ts ontols ae well stuated and funton sma
The plunge glde, as on the DW-62 1 s as good as t gets The mam
plunge depth s 2 n Its eatues ae othewse unemakable eept
ts onspuous upstop. t lmts the up-tavel and untons as the fn
adustment knob.
The 625 s a double-nsulated, 3-hp, vaable-speed, soft-stat, 3
tool t has a spndle lok o one-wenh utte hanges a two-stage
depth adjuste, and a tgge swth wth a lok. It's a good toolt sues fom the usual plunge oute nstablty poblems beaus
base s so small, but an oset subbase wll keep the tool at on the wo
Also, ts base astng s tunated and the utte openng s so wde th
an snag on the ones of the wok. Anothe mno poblem s that t
aton of the up-stop quk elease button s stubbon
Wegh
Speed
Amps
Sof stat
Horsepower
Colles
Basepae diamete
Plunge stoke
DeWalt 625
133 Ibs.
Variable 8,000-24000 rpm
15
Yes
3
Y4 in. , Y in . & % in.
5 n. x 6': in
2716 in.
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La minate Trim
Routers
Lainae ri roers are essenialy sa roes designed or lgh
dy hores. They have 4-n. oes range ro � hp o 1 hp and
generay weigh 3 lbs o lbs hey spn as (25,000 rp o
30,000 p) b se sho r ers Wih a sal diaeer o ah
he shan sze hese ers don' genealy have baane pobes a his
high speed.
The eld has gown o he pon where here ae qie a ew hoies,
inlding Poer-Cabe DeWa Bosh, Hiahi, Maia Ryobi andFred Pore-Cable has hee deren odels, so hee are a leas nne
hoies. he DeWal, Bosh and Pore-Cabe riers an be spple
ened wih lng o ose-base asings hese wil l alow spealy
operaons sh as sribing a onerop o a wall wh he oner in
plae. The Hahi sandard base wi i 0 o 5 degees.
Guide Systems
In a way he variey o anae ng syses is a bi sprsing They
range ro sipe ba-beaing gides o aeae iroeer-ype syses sh as he Mio Fene gde wh preison roee adjsen.
he bal-bearng-gded ri e ay be he spes ehod o
ng ainae lsh o s sbsae. The sandard sh-ri b has
he bearng a he boo o he er b he op-oned bearng s
5
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76 Laminae Trim Rouers
This Bo sch Mod el 1 609A offset trim router
has he cutter off to one sde so it can tr im
closer to an i nside corner and scribe the
wall profile onto a countetop or back
splash
The ti tingbase Htachi Mode TR6 t
router can be used when the edges o
sub strate are at an ang le . I can aso
used with an edge gu ide and straigh
bevel wih a straight cutter
Top-bear ing pattern bits used wth tr im routers are excellent for temp late rou ting jobs
as small hinge motises.
inceasngly popula. The Achilles heel of the ball-bearng trm route
the bearing Small bearings at high speed just don't ast very ong. Yo
get as ittle as an hour o so of cumulatve use befoe the bearing runs
of lubrication and fas to spin propey
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all-bearinggUided bits can be
expected to rim about 1 ,200 ft
off couterops at a feed rae of 20 ft
per miute. That's about 120 average
legth coutertops.
78 Lamnate Trim Roues
Most trim routers have these accessory roller gu ides availab e. S ince the bearn gs d
spin at the rate of the route, they last a long time
Solid carbide bits can trim and bevel si multaneously, and ae surpris ngly inexpensiv
However they leave skid marks o th e edges of the work
SOLID TRIM CUERS
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EDGE GUIDES
In place o (o n addon o) ball beangs soe anufacues ae s
pe plasc edge gudes ha fasen o he subbase he edge gude has he
advanage of connuous adjusably and he sde pessue s ansfeed o
he casng o subbase nsead of he cue o aaue. hps can ap
heselves beween he edge-gude surface and he wo and scach
Edge gudes can aso be ade o nes n cuved suraces Wh an edge gudeyou have oe cue choces bu cabde s essena wh pasc lanae
HE PRER-LE 30 HS G
hed its ostio as the idstry
stadard i tim oters t has
bee odctio fo ove
25 years eviosy der the
ockwel ame his qet
(27000 rm, 4am, 3 .75-b.sqat oter s hadsized ad
the east toheavy of trim
mes. Wth its sral god
motor ied by the deth rig
ctte height chages are easy
ad tavel greate tha 1 i
is ossible. The rod moto
lock kob s ot great bt
accetabe.
itig ad osetbase cast
igs ae o oger avaiabe fo
the 310 A two-wrech colet ock (o sidle lock s ather coveiet. I'd recommed a arge trasaret ofset o rod sbbase fo
ths ote.
As edgeoy toos all tim oters are stabe, ad the 310 s o
exceto. ts sde switch s exosed ad verabe to a accideta
start tte vsbily is from oe sde oly becase ts moto is cetered
i its widowed castg ad is ot cateveed like the Bosch ad othes.
Poer-Cable 310
Weigt
pee
Amps
ft strt
Hrsepwer
Height ste/mecnism
Cllets
Bsepte imete
7 bs
inge spee: 7 rpm
4
N
Abt
Rg hung twist rng t
1in+ rnge
in
4n sk
Gude Sysem
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Other Features and Applications
Trim roues are indeed ouers es we foge. They accep oue bi
guides, spin a abou 2 5 000 rpm o 30 ,000 pm and can rou he sam
maeria as big rouers. As such a im ouer can be used or genera
and nonerous meawor. Howeve I woud never epec indusria
ouer service fom a rim roue.
A trim router can be used for hardware mortisig emplate cutters like this one have
mou nted bearing s to follow te pattern
he transparent sub base accessory will accept the two-piece Poter-Cable col lar gu d
assembly.
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This roudove it is perfect for knocking off the sharp corners rom the planer or jointer
You can template-out shallow excavations usng top-bearng-guded
bts Also, ts handy that both the PoteCabe and DeWat trim routers
wil accept PorteCable colla guides or tempate wo Smal poile
cutters ae also good or oundoves (up to a adius o X in.) , bevels, and
Vgrooves. But d eep the depths o cut very shallownot more than
the euivaent o /6 n square
I now a carver who wastes shallow reie rom hs blans beore
using his chsels. Wth an edge guide and straght bit you can mae wide,
shallow, decorative abbets here isn't much depth adustment with trimroutesmaybe 1 n at most Remembe, these tools ae designed or trim
mng, not o timbe-rame oney.
STABILITY AND TRANSPARENCY
You woudn't thn one-handed tools would have stabity problems but
they do. he suat designs ae moe stable but the tal Tom Collins"
tumbler desgn is more precarious A 3 -in.- or 4n.d iameter subbase tim
route with a -in. cutte has less than 2 sq. n o contact on the wor
piece as it rounds the coner. t wi ll tip A lager subbase is recommended
Also Ryob and Mata have clear see-through subbases all the rest
have blac bases, and the cutter vsibi lty s poor
Oher Feaures and Applicaio
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Mke ife Esier
Use wo wrenches o change he
bis on rim rouers so you don '
have o srugge o hol d on wh ie ry
ing o urn he wrench.
82 Laminae Trim Roues
The author's offset subbase provides increased control for edge work, especially arou
turns ad on ends.
SPINDLE LOCKS
Th spndl loc is sots pasd as a good fatu fo out-it chan
I would ah us two wnchs A spndl loc on a i out is unwi
th otos a so sall that you can't hold th whn using a singl wn
Howv cus an't changd that oftn n th t out
DEPTH OF CUT CHANGES
Th cut dpth whn ng plastic lana s no citica Plus o
nus n. is asy toal and quid to distiut th wa ov
lngth of th fut Sinc h sn't uch dand fo a pcis dpth
cut fancy dpth changs a not found on os ti outs h on
xcpion is th Pot-Cal 3 0 which you can adjus vy accuat
Th oo s hung on a dpth ing hat vnly suppots t. A un of th
calatd ing aiss o lows th it in a pcis and asud way.
Cantlvd oto/castng dsigns wih scw lfts tnd o ja unss
suppot h oto with you f hand as you chang dpth st ings
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Wit
Sp
Aps
So sta
orspowr
t ajust/hans
Collts
asplat iar
Bosch 1 608
Bosc 1608
35 Ibs
30000 p
5.6
o
Abou 7/
Srw-n vs s, in an
n
%-in x - in anl
he Bosh 608 tri router a 5 6 aps and 3 5 lbs , is ight and
powerfuand wih is shielded swih you an aidentally fire i s
upanddown ehanis is better han os wih Ip in of srew-driven
depth adjustent. The ole is spli three ways and holds its uters wel
is tighened with one wrenh, while the arature is hed wih anotherwrenh near he top of he tool ts retanguar subbase asting is stabe,
bu no ore so han a round one. The oo ould beneft fro a larger or
oset subbase he oor is interhangeabe wih oset, iling, and under
sribe bases.
BOSCH608
Bosch 0
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8
Router Tables
Aouter table can hande ost routing procedues, but not all
the safely and efficiently he router table has a big advant
whenever its boad conto sufaces (fence and top) are requ
The table's ost efficient use eploys the wide surfaces to support the
worpiece for edge routing. he ost difficult operation on a table is
ing on the ends of ong, narow stics ie stiles and ails. But even di
cult jobs can often be safely accopished by using jigs and fitures
designed to securely hold the wopiece and eep you hands safely awfo the cutte. But it's aso ipotant to reeber that a handheld
outer can be the best solution, especially for age or awward worp
And, as with a route operations, neve forget that the spinning
ter is unfogiving and provides no second chances.
A route tabe can range fro the siple to the idiculously cop
ost ae over-engineered Fo soe peope, a poduction-ade pastic
ainate tabe wi do For othes, a handade, jobspecific contraptio
bette. To be sure, a good table with basic features does tae tie to
well if you build you own.
Router Table Basics
The outer table has lots of appications, but it does have its liitation
You can rout short or odd shapes otherwise unsafe to rout with the ha
router, but you can't rout big, wide, long stics or anything so big it
tip the table over Edges and faces of narow worpieces are easily rou
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The authors router able has an MDF top that's suppoed by a seres of ribs underneathHe us es a fixed-base router so he can permanently attach the casting and emove the outermotor for bi changes
bt a table isn appopriate for woing on the ends ornatey in those
cases where the rote table is not sitabe a hand-held roer wi do the
ob. Neverheess 70 pecent o 80 percen of al obs can be safey and
accrately roted on the tableTable roting is ofen more efficien than hand roting Most of the
wo needn be camped o wored wih a fixte; a fence with a vacm
sysem will eep he able clean Adjsments ae easy and setp is qic.
he same stic or pane can often be roted on is edges faces o ends
with no changes in setp An enclosed roter able is also relativey qiet
Since he wor can be fed j st as easily on its edge o face a cte
may have moe appication on he roter table than in the hand roter.
Roue Table Bas
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Usng a fence with a cutte allows you touse more of the cutting surface. he balbearing desgn esticts cutting to a smal
portion of the edge By rasing ths cutterand positioni ng the fence can use a section o the cutter that has not yet seenany wood.
86 Roe Tables
made this fence for chamfering the edges of round subbases he work rolls on twobearings and th e depth o cut is determined by raising o r lowering the cutter.
A 30-degree beve cutter for exaple, can produce a 60degree beve
the work s fed on edge. The fence and cutter height can aso be adju
so any part of the flute can be used to better dstrbute the wear he s
p ioted cutter in the hand router wil wear out its flutes near the bear
eaving shap carbide near the shank.
A router table can be a patform for routing with piloted bits and
lars or you can use the fence. Most cuttngs on the table use the fenceand as such no ball bearings are needed on the cutters. he sae cutt
without a bearing is often saller and safer but not necessarily cheape
When cutter bearings are absent and the fence receves all of the hori
tal force fro the work, the router and bit are under ess stress and las
longer. Moreover when bearngs are not used edge defects are not
teegraphed back into the profe and in general router fence cuttngs
crisper, wth ess chatter.
A typical router table has a stand top and fence. The stand's essentia
functon is to bring the heght of the work up to a cofortable level
should aso provde a eans for supportng, fattening and attachng t
top. Materia (usuay MDF) and rgidity w inhibit vbration and co
noise. A stand ade fro in plywood and in by n egs will su
port a router But a stand with 2 in by 2 in egs -n by 2 1in ra
and 5�in .thick MD will be stronger and support the coponents n
subassebles
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A outer stand should e le the stands or jonters planers and and
saws: no drawes or storage, aye an access door, and a place or eect
cal equpent. t shoud e stong enough to e puled around wthout
cong apart a not opposed to casters ether peranent or detachale
have a we wnde n ne as well as an -n . straghtedge and a -n.
shoulder olt to loc a set o spacers on the top to t the wor to vaous
heghts n reaton to the t
A 5amp rocker switch bued in a mortise pevents accidental startps but s easy to
shut of
he wire wnder can hold about 8 ft of wre here is a 6in disk beneah the 0-n o ne
yo see . he straightedge at left comes n handy for setups
Rouer Table Basic
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Y
OU can use t he adstabe table of
a drill press to detemine the
most comfortable router table height
Try clampi ng a straghtedge (to simu
late a roter table fence) on the d ll
press table and run pie ces of varous
szes over the setup Try the proce-
du res at heights from 36 in. to 42 i n
and bi ld to th e height that woks best
Safety note: Do not out on the d rill
press, just go th ough the motions
88 Router Tables
The router table box rests on four 1 -in . ball casters that are screwed no theaded bra
inserts Two Lexan brakes keep the 8D-lb bo x fom rolli ng away.
use a 2-ft.-wide by 2-ft-deep by 3 9-in .-high stand can just ma
a hefty 6-f. board whch is aso my physical lim so wouldnt need
bgger sand he bgger these things get the heavier hey getand th
more likey hey are to warp.
Rouer work is not lke chiseling or oher common woodworkng
aciviy You should not epect mos shop furnture to be at the optm
heght for rouing m 6 f tall and al my rouing surfaces are high
about 38 in. o 44 n
Obvously he sand s used as the support for he top As such yo
shoud put some framng nto he upper rals o suppor and connec i
able has si upper rails that strugged to ge ino the same pane Thprovide the means to keep the op fa so he top iself can be as thin
pracical.
he maerial, desgn and thickness of the op depend somewhat o
the router able design and whether a fed-base or plunge router s us
But before address tha would lke to presen my case for a fied-ba
router n the table. Usng a fied base simplfies the op and mproves
rouing accuracy
FIXED-BASE OR PLUNGE
Alhough both types of oos are used n rouer tables prefer o use a
fed-based rather than a punge rouer. One reason for tha is that t'spractical o bolt a plunge router o the underside of he tabe. ts moto
permanently fasened to he casting so cuter changes upsde down ar
complicaed Most people screw the plunge rouer to large metal or pl
subbases which in urn are nesed nto rabbeed wndows wthin he
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Wth ths arrangeent cutter an epth changes can be ae snce the
router can now be easy etracte. Nevertheless that one aneuver
brngs about one coprose after another. or eaple the tops the
seves get overy coplcate wth teeolngs or lanatons of fber
boar pywoo or partceboar The wnow has to be a precse atch
or the large subbase an the absence of a thr of the top (for the wn
ow) wll spol ts ntegrty an proote cuppng an twstng n whats left
Moreover the eges where the nsert plate an tabletop eet becoe
ust colectors an nee constant cleanng to prevent the work fro hang
ng up. Precson work wl be ore fcut because the pastc nsert can
ben wth ownwar pressure causng sa changes n epth o cut
Every te you pul l the router an nsert out of the tabe you nee to
leve an nspect the rabbet seat an nsert for a goo ft A ebase
castng bote recty onto an MD top has none of these probles. You
spy reove the router otor fro the castng to change the bt
Spc ty agan s always the best opton. Ths oes lt your router
choces however. or serous router table work such as rasng panels youay nee a 3-hp achnean there are any ore avaable as plunge
routers than as ebase routers However the PorterCable oel 7 5 1 8
oes fll that bl. or lghteruty router tables there are a host of a
chnes n the varous power categores.
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TBLETOP MTERIL
Given the fxed-base opion, then, the material o choce s MDFth
(k n.) MDF f you table s stessed wh enfocng rails Cabinet-gr
MDF (such as Mede brand) is fnish-sanded to a unifom hicness
untreated surface will wea and scratch easly Howeve wo o three
of Watco will mpar a Masonite-le oughness to t and do no harm
wll no be as tough as plastc lamnate but i wll esist wea and last
long time What could be easer?
I would not expect to use cute-hole nsets or the same reasons
wouldn't use a baseplate nset A 2-f by 2-f by 5k-n MDF slab s a
$2 so its bete to mae a spae than degrade eithe one with an nse
Mae one wth a hole fo you biggest cute and one wh a cuter ho
general use exchangng hem as necessary
MDF can be boled down on a table frame wthou dimensional c
quence; no allowance is necessary o changes n humdty o tempera
I would mnmze overhang though as unsuppored suface can cup
hi p h n hndd f h f ing wih w Fn ng h Gph min wihin 0.002 in
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A dial ind icator on a routr tabl fnc may b ovrkill , but or prcis joinry it can sav
prcious tim.
The Fence
he fence s the ost citcal eleen of a oute tabe dealy shoud
be staight and squae o the abletop A stic on a pvot wil do bu fo
speedie adjusens a spl fence wth a scew-dven adustent s be
e Also note that ang a pecse oue fence s uch ease if you
aleady have a fence So you ay wan to find a good staigh boad to use
fo a sate fence Moeove even he os copehensve and sophsti
caed of fences ay no be copatibe with all cues. Fo eaple it ay
no ae sense to ove-coplcate he design of you fence fo the occasional use of a 3 -n-daete panel bi Insead you can ae a second
uch spe fence wh a 3 -n cutout fo hat opeaton.
The oue fence has wo essenal functons: One s to gude you
sc by the cute and he ohe s to eguate the hozonal depth of cu
The gudance functon as pled, is no tha dffcut o desgn no the
The Fenc
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92 Route Table
A rot tabl fnc can b as simpl as a pivot stick and a copl o clamps
Th auhor's rout tabl nc is drivn with a machin scw T 1 -in alum inu m binto ways ct into th bottom of th fnc so that it tracks straight and dosnt twist
fence; a wel-ointed stick will do hat. he deph-o-ct fnction is a
easy to manage, b it is more o a challenge and is oten ovelooked.
Roer bis, horsepower and the natre of wood ae sally in sc
conic tha the desired l depth of c is not possible in a singe pa
(the easies way to manage this poblem is wih an adstabe ence) . know of three methods o moving a fence: the tap and clamp, the piv
and the scew drive. he first and simpest ence is camped o the a
and tapped with a hammer fo adjstment s nsophisicated nep
able, and rstraingb is the most common mehod. he second
tem ses a sick wth a pivot so only one clamp is needed (Stops and
screws can be sed to advanage hee. ) he thid mehod and the ea
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coon incorporates a eadscrew to drive the ence. My own is asse
led on a carrier throgh which a couple o clap levers secre the whole
thing. he leves are coped to teenuts eneath the top
Protection from the Cuer
A roter it is an nfogiving ctting too One of the safety eatures o aote tae is that ost o the tie the ctte is uried in the stoc or
ehind the ence so you are protected ro it. I your ence is spit its
good practice to iniize the ctter opening to redce the cutter epo
sre. When roting ll thicness alow only 6 in or so o cutter aove
the stoc again to hide as uch too as possile. Pastic cutter gards are
vaale in soe cicustances and yo shoud se one if yo need ore
protection. or e if thin a pastic cutte guard is necessary then
now ' at ris and wor ot an aternate roting strategy to iniize
it. f the wor is too narrow short or peculia or pts y hands too cose
to the it ll uild a holder or a specia tility enceA roter ence has a ner o uses esides the usual fnctions such as
giding the stoc hiding the ctter and controlling the inandot depth of
cut. Its also handy for pacing a variety o stops and oers a plator for
dst-collection equipent. My ence has a vacuu port right ehind the
ctter and does an ecellent o of picing up the chips Pastic vacuu
accessories or router ences are coon (see Resources on p 1 80 )
Usi ng a saightedge an d sh ims the author adjusts te outeed haf of the fence for a
O.020 i -deep cut he cutter line s up wth the outfeed ence to make a full thick ness pass
for a jointed edge
Protection from the Cutte
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94 Rote able
Wheher your ence s spit or no you can use i or o nting ope
tions and making other ull-thickness cuts With a carbide stragh bit
can oin plasic wood M pywood, and some nonerrous metals
However, MF and plastic will ruin HSS onter knives he oueed
ence should move in and out abou /4 in., and you adus it parale
the need ence and n line wh the highes pont o the cutter i wi
uncion lke a onter. I t wil l take a thin slice rom the u thickness the workpiece. You can do the same thng with a one-pece ence by
ataching some hin (0 0 10-in o 0002 - in.) meta shims on the enc
beyond the cutter A straghedge placed on the outeed side should u
touch he high poin on the cuter
Open mortses and other sopped" cus are easy to do on the rou
tabe Oten hese cuts are ony 2 n or 3 in in length so the outeed
ence can be posiioned slghy rearward and ou o the way I made a
with a slo to slide and lock on the oueed encea nice convenienc
designed o stay above the table so it won't accumuae a pile o chips
here are more hings you can add o a ence Several small comp
nies are even makng a busness out o it Jo inech, Wood Haven anIncra or eampe make ences and accessories or dovetails and bo
onts . Nonetheess, your ence mus always be straight and square to t
tabe o be accurate My ence aces are uninished, so I can sand scra
and true them up I keep hem a to plus or minus 000 in.
The 1 -n p lastc tube is a DeWat 61 router accessory (3859-00) that comes in hfor chip col lection on a router table. A brass (crome-plaed) 1 -in drain tube s alsogood coice
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A deep, pen mise ike this ne i f attempted in ne pass will break the cutter r sta themtr Rutng n %-in. ifts slves te prblem; remve ne fr each depth change. The
sul der lt keeps the l ifts frm slidi ng
I se an 1 8- in Starrett gru nd straightedge t verify the straghtness f the fence haves. AO001 5-in feele gauge cannt get unde the straightedge.
Depth of Cut Strategies
Maeria o be cu on he rouer able mus be la, uniform n hickness,
sraigh and square. ha s no a peculary; all woodworking machnes
require . If your work is cupped, bowed, or oherwise disored your cu
ng resuls will vary. Gven suiabe maerial a good rouer able will cu
o plus or mnus 0.002 in o cu hs cose you need a good fence and a
a abeop f any of he hree (sock op, or fence) legs of hs riad is
less han accepable your resuls will vary.
Dept of Cut Stategie
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e adjusted y he rouer or he fence should e adused y one or the
other (not oh) for a gven cuter Changng oth wl easy doue your
chances for a screw-up ortunately he choce of whch o manage for a
gven cuter s easy o mae.
HORIZONTAL DEPTH OF CUT
Large-dameer ts are usually shor often ntoeran of vertca depthchanges and are used on he edge of stock; o sage-cu wh hem you
move the fence o do ths set the vertca depth" to ts fnal poston n
ally and move the fence n equal ncremens. The dameer of the argest
avalae router t s around 3 n.and 'k n of that s usually for a
earng. hat eaves l 'k n. for the profile so hree or four -n fence
changes wll complete the cu Usng spacer lfts and fence changes at he
same tme should e avoded. If you fnd yourself dong oth you shoud
consder movng up to a shape
The sample on the eft has a pretty good sde wal but the outside edge of the corner istorn The sample on the ght as been climb cut (fed eft to ight) but only about Y2 i n
Depth o Cut Strategie
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98 Rouer Tables
I se this sled holder i he work is too narrow or too deep to work safely I hold the the toggles.
Climb Cuting
Th convntional an saf wor-f irction on h rotr tab is f
right to lft as yo fac th cttr In this way th f is agains th
roaion an as sch h wor is safy pll into h nc covrinth bit Li planing agains th grain th rotr bi can cas taro
h wor is f against th cttr rotation. Sharp cttrs an spira fl
sign can a this ss of a probl bt xpct so arot sp
on iicl woos ing h wor fro lf to right h clib ct
arly rc taro bt at sbsantia ris. h clib ct is so n
bcas o th tnncy for th rotr or wor to pl (or clib) as yo
to f vnly h wor is constanly bing pl fro th hans an
away ro h nc. This ct is chily s for ificlt woos in wh
th grain changs irction is ss fficint han othr cts an as
or orc is rqir o conro th wor This is risy bsinss. ortnatly hr ar conrasrs
h ain s for h clib ct is as a vry light scor" a as a
initial pass h ight in. ph of ct hlps prvn th svr cli
acion. No ha yo shol a a habit o pacing th wor in a h
that ps yor hans wl away ro h cttr for clib cts Using
tchniq witho sch coonsns proction is xtry ang
h ony ti to s a clib ct withot a holr is wih worpics
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ae so lage ha you hands ean wel away o he cue. In any case,
don ae off oe han a !z in o a sngle pass.
An MD wo holde is pey heavy and esisan o powe ansfes
fo he cue in a clb cu Even if an acciden should occu, you
hands ae on he jig and canno be pulled ino he oue b.
inally sae cib cung can always be done wih a powe eede.
Bu you shoud noe ha a oue able should no be consdeed a poducion oohe vey eason o a powe eede he seup s aso echnque
sensive and you oue abe has o be a qualiy one The feede wil
pess down had on he op and agans he ence. If ehe shoud delec
you cungs wi l vay.
The Miter Gauge
he ie gauge can be useful on he oue abe, bu is no y favoie
choice I jus can hold he wo on one and eep i o slipping.
Moeove os iegauge cus ae acoss he gain and subec o eaouas he cue es he wo A bacup wase piece is alos always
equedconfoundng handing even oe. A ie slo in he face of
he able can weaen i o cause ohe ino pobles f a ie gauge is
needed a bee souion s o use wo epoay peces o in. MD o
ap he blade of he gauge ahe han cung ino he op Wh hs
saegy he fence can eain n play fo added wo suppo. A bee
soluion ye is o build a sed fiue wih sops and ogge caps o hod
he wo (see he phoo on p 1 00) . Welldesigned fiues ae ipeaive
o good wo educing accidens and injuies.
wo piec es of %-in MD clamped to the table provide a temporay pathway or the mitergauge blade. h is method doesnt co mpromise the router table by ctti g into it or agroove
Te Mite Gag
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00 Rouer ables
It takes a major calamiy to kick this jg o t of my hands Work held in a fxure away
machines well
Router Tabe Safety
It is cear that hghspeed spinnng ctters have two possible reslts: o
to ct the stoc the othe s to ct yo There are other theats on th
oter table, bt none as foridable Safety s an atttde that when fo
lowed wll ipove yo effciency and ctting reslts Once in a wh
there are genine sprises bt ost eegency roo visits are de to
essness. A shoddy setp, diclt wood, infeor achney, and a fgh
pilot entaity are soe of the factos This boo can help yo wth th
nepected, bt not yor disposition And frany, if yo are clsy, adent prone, and patent, yo shold not be a woodwore The ato
obe indstry has done a yeoans job of potectng yo fro yose
and others: air bags, seat estants safety glass, and so on. oweve, th
woodwong ndsty is a wo-safety dsgrace Start to beeve that, a
yo wil be a conscentios woodwoe
CUER SAFE
Edge otng s the ost coon tabe oting practice Yo can ot
whoe edge or part of t. Ether way, there snt ch ctter eposre
ecept at the end of the ct. Roting narow stcs ( Z n or less) cascay becase yor hands are paced near the ctter for best reslts
Whenever possible, pess down and aganst the fence beyond the ctte
Shod yo have a slip, yo hands will dash away fro the ctter Wh
paying attention to that anever, prepare fo the ctters sdden app
ance at the end of the wo
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When edge-rouing the full hcknessoining for nstanceprojec
ony I/6 in of cutter beyond the work Any more is unnecessay and rsky.
For bes results, mach the ute lengh o the hickness of the wok
Push stcks are always acceptabe, but hold-ns, hod-downs, and
feaherboads can pesent thei own dangers In my vew, they get n the
way, upse the uniform tavel of he work, and present some risk them
seves To me, they signa tha trouble is near; the work is too narrow, tooshot, too long, or oo awkwad
I'm the fis to act when t comes to safety. f you see the need fo a
hod-down or featherboard, hen start lookng for a ig , fxture, holder, or
an alernative method. It coud easily be hat what you're tying o do s
no a able-ouer opeation at al Some dangeous ouer table cuts are
uncomplicaed when done wih a fixture and a hand router And ust
because you've seen an operaion n a book or a magazine, don't assume
it's safe If you resuls are inconsistent, you don't lke doing it, or you are
otherwise uncomforable, you ae pobably at risk and should consder
another method.
Always push own and against the fence beyond the cutter when op eating a router table.
Router Table Safety
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2 Rote Tables
TRAPPING THE CUER AND THE WORK
Because outes geneate so uch toque, t's cucal o eep he cutte
fo getng tapped. he wo can be tapped beween the cute an
fence o unde the cute. he bi can aso be tapped n he wo o
in the side of the stoc. hee of he fou situations should be avoide
altogehe The fouth s essential to outng and quie coon, but d
at a is you should now abouappng he wo between he fence and the cute s abou as b
dving on he wong side of he oad The quesion isn whethe an
dent wil occu, bu when Neve set he fence so tha the wopiece
sandwiched beween i and the cute Any sght devaton in stoc t
ness wi j a the wopece and ( vey lely) pul you finges into h
You can aso ap the wo unde the cute his is fa ess co
but the hazads ae neay he sae. hee is less s of he wo sef
feedng, bu i wil liey un he cute and the wo Be awae: if th
happens, i is the esut of unsafe pactce.
An inside cut ie a slot o dado again taps the wo between th
e and the fence. A bad feed o an ill-pepaed (pooly jointed edge)
wopece w un the cut, ay bea he cutte, o ic bac the wo
Ths s coon pactce on tabe-saw dovetail and box-join jigs andeason fo caution when usng a fixtue fo such a cut. he cute si
has no pace o go in the event of an accden except nto an aea of
wo you didnt wan to ou
The same size dovetail s possib e on different thicknesses of stock if both cuts are re
enced from te same side o the work But tis strategy shod be avoided; it is very
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A tongue pr oduced thi s wayboth cuts referenced from the same face of the stockis
high-risk woodworking f your hickness plane is welltuned, there s never a need fo r this
If tere s a safe" method of widening sots it is on the ou ter table Bu beware of the sur
prise climb cu Wih the work tapped between the fence and the cuter a bad feed may
brea k the cutter and jettison te work. he safe feed di rection to widen t he so i s always
against the cutte rotaton (eft to right in this case)
An accdenal clb cu can aso occur whle wdenng he pahway
on nsde cus you gnore he cuer oaon Wdenng he so as
shown n he phoo above wh a rgh o le hand eed s a clb cu and
wll n all lelhood p he wo ou of you hands A eed ro lef o
rgh s no a clb cu bu any devaon n worpece ravel can spol he
cu neveheless
Rter able Safety
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104 Rouer Tables
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Soe cterssch as those for sotting and oring gle oints
are bried in he wor or nora operaion. ha is to say, i yo lit he
wor while roting it, yo wi spoil the ct. Again, yo can brea a cter
this way and the wor can ic bac Yo need to ae sre yo never
ift the wor while sing hese cters. Moreover, i the wor is bowed,
twisted or cpped, is trip down the roter able wil be tippy and it cold
a and y bac at yo nteritenty pressing and relaing he force down on a bowed worpiece wil increase its chances for a icbac A
hold-down ay nepecedy tip the ends p on sall wor he best
defense agains sch a caaiy is good stoc preparation wih at sraces
and sqare edges.
BLIND-END TABLE CUTS
As enioned, there are penty o nsafe bt relatively coon wood
woring practices he roter has is shareaybe ore so than the
jointer and able saw. Blindended cts are those cts hat begin and end
inside the stoc and do not eit or enter throgh the edge t is possibe
to do this on the roter tabe, bt clearly the cter is trapped in the worhe heroics go ie this: the daredevil irst claps stops down on the
roer table top, trns on he roer, bts he wor against he sop, tits it
p, and drops i down on he trning cter Net, the operaor slides he
wor to he oher stop and its i off he table. f sccessfl, said craftsan
eeps his aternoon bngee p appoinent.
he above procedre wi brn the wood at boh ends o the pathway
and the s ighest waver will rin he c on both sides. B the proper
alternaive is obvios. t is he epress prpose o a plnge roter o
facilitae blindend cs hey shold be done with the wor in a ig or
fire and roted wih he porable plnger and edge gide, never onthe roter able
Route Table Safey
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Router Bits
It s nterestng to note that the purhase of 10 o 5 oute bts a
easy eeed the doar value of he ost epensve rouer These
hghly engneered arbde oute bts an stand fou o s egrnd
even hough ost hobbyst woodworkes raey shapen he
But despte hs duable aeral, a new utter an and w ea ou
break ou or hp out a peetly good staght-graned pee o wood T
ute shapness or geoety doesn ae nearly as uh as a sold u
standng of whh bt o useand how o use the bt one you'e there
A few premium cutters can often exceed te price of the rote they're used in These or abou t $7enou gh t o purchase nearly any -hp router
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The cer is a crical facor he sep and he ype of oer are he
oher wo pars of he big pcre. All hee facos play ogeher n he
cing process he wrong roer, an l-conceived sep, or a poorly cho
sen oe bi can n he work. Workng wh hese vaiables does ake
eperence, b a coser ook a cers can ceranly hep he opeaor
ake soe nfoed choices
Evaluating Performance
Manfacrers have a lo o say abo roer bs Soe of he ore co
on bzzwods are sper cro-gan, faige-poof seel, spn balanced,
ankickback, precison grond, op hook anges, and efon coaed
B he boo ne s perfoance, whch can be prediced fro spe
nspecon or even knowledge of ong. A single anfacrers ces
can vay in qaliy, and dsrbors don always carry a anface's
enre nvenoy, so selecon can be peplexng.
As in oher prodcs, a anfacrers repaon and ongeviy n hebsness are reasonabe consderaons. Vey cheap bis shold be sspec,
since yo will "ge wha yo pay fo A good le of hb s o selec one
or wo ces and evalae her perfoance he folowing wi show
yo how
FINISH
he fnish ha a new cer eaves on wood shod be nearly flawess.
Rogh grnding will elegaph self ono he work When sed properly
yo shold expec ile or no earo, no brnng, and an ohewise
sooh and glassy fnish Use he oe able o evalae hs; i s he
leas sensve o echniqe.
Any grindng dfct on a carbid bi wll show up plainly on th work.
Evaluating Peormace
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108 Router Bits
To check fo vibration in a large bit, stat it at the slowest of speeds and ncrease the
a notch at a tme. This PR trimmer s the longest of all commonly avalable router b
Vibraion s your wos enemy Clamps loosen, scews unwind, ences
squiggle, cuers slde up he coe, and he work can resonae agains
cuer In he wors case, he cue breaks or comes ou o he coe
Mno vbraion of he roue b, once uncommon, seems more a
more fequen. Bu any vbraion, in my vew, is unaccepable o es
cue vibraon, use a variabe-speed roue and sa he oo a is s
speed. Hold he rouer n he ai and advance he speed seleco a se
ime f you ee vibraon, sop he rouer befoe gong o he nex sp
(Wih a hard-sa oo you don' have hs luxury)
Cues whose diameers and lue lenghs are less han % in. shospin o 25000 rpm wihou vbaion Bigge cuers are fa more likey
vibrae even hough hey are supposed o be in baance beyond 30000
Be suspicious of all new big cuers and all newly reground cuers A b
colle w make mos medum-szed cues vibae, balanced o no
Beaings, good or bad, may make a bi vbae, oo, so o ule ou he c
as he soe vibrao remove all bearings and screws from he bi
Jus how cose does he manufacurer grind o he saed specificaion
as radius and diameer? Mos makes hod he shank diamee o anexeme olerance o pus or mnus 0.00025 n, bu he es of he oo
may vay For decoraive bs, ovolos, beads, and oundovers, or exam
i doesn' maer much if a radus is of by a few degees, bu joinery c
shoud be moe precise he fi rom ongue-and-groove oos, gue-jo
cues, cope-and-sck bis, and doveas s vey sensiive o ginding
eros.
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Adjustment for Bit Wobb
Make some trial cuts n he
ed material and adust you
to accoun for the cutter's actua
fie. If your spacing between dov
actualy measures say, 0.76 in.
cause of cutter deflectionand
want exactly :4 in-adjus the sp
on the t empate to reflect the pa
error (n effect, 001 in. closer)
Evaluating Performance
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1 1 0 Roter Bs
The overall easureents o the outer bi ae soewhat dficu
establish pecsely without eaborate equipent op dead center can
dicult o ind; he cuter needs to be paced in a specal holder o j
specal easurng gauges ae equired. A ore pracica stategy is to
ure the wo cu by the too. your seup is good and your ling is
cse it will be easy to easure your cuting resuls Fo exaple a da
Making a tes cut and measuri ng the results with a set of calipers i s a sure-fire way t
check the accu racy of a router bit.
Straight cutters come in three primary styles: spiral bts, frst and second from left o
shear; and standad staight cutter. he s pia and o n-shea r bits ct more clealy tha
straig h bt
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Cose i spection reveals the cutter wear
in e on the work. The s ight step wi l rus
trate or prevent a close-fittin g joint
1 1 2 Roter Bis
Shaper cutters, whic h have holes for the arbor, cut the same profles as router bits
as te straight cutter at rghtbut will outlast them by a factor or 10 or more.
wth one cter and fnshct the eanng 20 percent to 30 percen
wth a new tool a fll deph n one pass Unfor, lght cts ay excter fe three to fve tes
Yor cte s ready for a regrnd when t stars bnng stock, nee
ore handfeed pressre and shows wear lnes on he work Jonery c
(gle jo n rabbet, stragh, or dovea) sed for exended peods at
deph w show wear lnes at anoher depth. f yo n 50 ft. of a n
4n abbe on MDF and then ake a 6n sqae abbe, the /4n.
lne wll lkely show p For a decoatve pofle ct, he wear lne a
ater; bt for a doveta and socket, the pars ay no f properly Bcters wl sll ct, bt hey ae effectvely dead sodes.
Roter bs vary n atera SS sed o be the cheapest and os co
only avalable B os roter bts for he sall shop ae now ethe
cabde weded ono stee or sod carbde Poycrystallne daond s
anoher opton, b s sed n prodcton work only
HIGH-SPEED STEEL
HSS s good atera, and capable of vey sharp edges that can be shaened by he end serbt doesn't hod p nder proonged se W
SS expect ony 1 0 percen to 20 percen of the nnng e of car
Its vae today s fo the vey shorrn, csto profles o pehaps for
expeent. f yo're wondeng abot how the acta profe of a $35
bde ogee gh look, an $8 bt wl gve yo the answe And t gh
even seve fo the shor rn n a gven poject.
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Another advantage to HSS is that woodwoes silled in too gind
ng can make ther own custom poiles HSS outer-bit banks are avail
abe or this purpose especiay e HSS bits o mortisng, since they are
oten ground to plunge better than a carbde-aced stee bit, and a mortise
un o a piece o urnitue is usuay a short run
CARBIDECarbide on steel ( the most common mateia and design) w outlast HSS
5 times to 0 times. ts actual le wl vary, but t s cearly the best com
pomse o router-bit lutes both economically and pactcaly he mate
ral can be egound (but never as well as the actory setup) shap enough
to un nearly as ong n my view, hand damond honing is agey symbol
ic, and proessionas should grind carbide or results and saety
Cabide s the god standad in too-bit materia today, athough t
does vay in hadness durablity, and density Some cabide bits are
selected or their duabity n speciic mateials; one gade does not t
a occasons
POLYCRYSTALLIN E DIA MON D
Polycrystalne diamond (PCD) is vey had mateial, unnng 50 times to
100 times onger than carbide. his is sticty producton mateia, mosty
custom-made and designed to un o hours or days in materals ie MD
iberglass and aeospace composites. But cutters ae vey expensive, start
ng at about $200
his Wis consi n Knife Works cutter has an over-center gind i n the e nd o the flute for better
p unging.
Material
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1 1 4 Router Bits
Shank Diameter
Shank diamete n the Unted State ae /4 in 5/16 n 3h in. and in
metic ize ae common in Euope Lage hank povide moe uface
fo the collet to uound and ao geate tiffne. Conequenty -
hank ae the mot popua. Fo a gven too geomety thee often le
machning equied fo a -n tool than the in equivalent
Conequenty they ae about the ame pce. The advantage to male
hank tool i thei mal adii fo coe inide cut, o whee it j ut m
no ene to ue the lage hank. Tim oute ue ony /n hank.
Cutter Types
Thee ae many way to caify oute bit They nclude poted (wth
beaing) o unpoted bottom and de cuttng decoative pofile and
jo iney bit a wel a vaiou combnation. Hee a ampng with p
featue you hould know about.
BEARING BITS
The beang ued to guide a cutte can be paced on eithe end of the
oute bt o between a et of cutte dependng on the intended ue.
cae they lmt the cutting depth. Cutte with beang on the end o
too typicaly o ll aong the wok and ae often attached to decoative
file bit. Beve ogee oundove cove and bead ae the typca cu
They can be ued in the hand oute o on the oute tabe Eentiay
they cut vaiou pofile. Thee cutte ae plentfu cheap competitiv
and pobaby the mot popula of a oute bt They emove a ot of
woodand ome ( aedpane bit) ae enomou Often they ae of kickback deign
Solid carbid bits last long than th sam-sizd bit wit brazd-on carbid tips, l ft
Unfotunatly fw cuttrs ar soid carbid
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he Amana Nova Ctter System has replaceable carbide ctters that lock into the arbor
assembly Their carbide not havng to be braed, has been selected fo its keen edge.
Bearings come in a variety of sizes and can ft above below, or between ctters
he an -cbac tool has a lot ore stee n than a convenona
b an runs soother because of s greaer ass an even balance. Thecuter esgn s such that t can ony chop at he rate of 1 n. o 3/64 n per
revouton. The guets of these bs are shallow an soc oesn get
caught n the hey on't c bac the wor ust a that he cu
quaty at 20,000 rp s nstngushable fro hat of a sanar cutter at
tha speean tha both wll ceranly cut you.
Cuer Types
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1 1 6 Route Bits
The sa ndwich of temp late-work-templ ate shows two beari g and ctter optons for
the same r eslt The topbearng pattern bit is easier o set p ad there are mo re
cutter optios
BEARING IN THE MIDDLE
A few bis have beaings sandwched beween wo cues op and bo
The beang ainans he space beween he cuers and povides a
o li he sideways deph of cu I is sange ha he os popular
hese he ral and sile ses use a bearing a all This s a roue abe
only and os doo wor is sraigh-line and should be woed off he
fence Noneheless hese ses are supped wih bearings ongue-and
groove cues and a few oher isceaneous bis are suppied wh cu
o bearings sandwched beween each oher
BEARING ON THE TOP
Sraigh bs wih a beang ouned on he op ae os ofen used w
eplaes. They roll aong he edge of a eplae for an eac ransfe
he desgn o he wopece he praccal and safe ii for full-hic
eplae cus is abou l n Longe cues are coon bu should b
avoided You can howeve use nceena seps o each deeper f a
2-in -hic pece of wor fo eaple is roued wih a - n rie
can use he achned surface of he soc o copee he cu Essen
al op-beaing ools ae used wih he eplae on op of he wor. U
a epae below he wor equies a rier wh a bearing on he e
DECORATIVE PROFILE CUERS
Mos cuers ha decoae do so aong he edges and ends of he wor
They are iporan and occupy one-hrd o one-haf or oe of os
e caaog invenories. These cuers usualy have bal bearngs o l
he deph of cu o abou one adius. Moeover he bearing-guided o
wee designed piarily for he hand-hed rouer Ogees beves beads
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coves and so on are generally suppied wh R3 bearings (0. = n
1.= 3/6 in.). f he wor is anageable and he cuer won coe apar
hese profiles should be roued on he abe whou bearings hese cu
ers produce a lo of wase ha can be easiy coleced, and he wor is
ore ecien when guided o he abe fence here is also less operaor
rs han wh he hand rouer.
or exaple a 6in.daeer rouer (he ypical base casng daeer) aways has less han 5 percen of s fooprin on he wor while edge
rouing f a ndiaeer ogee bi is n he rouer hen on sarup here
is only 38 percen of he rouer on he wora hazard indeed When he
bearing ( say an R-3 ) does fnaly engage he edge of he wor, ha nuber
ncreases o 6 percen. Bu as he rouer urns he corner o rou he ends,
less han 25 percen of he base s fuly suppored his oenary insa
bliy is a bg reason ha burnng and icbac are so liey a he ends of
a worpece hs doesn' happen on he rouer able
BEARING ON THE BOOM
Flushri bis are designed o ri a worpiece o he sze of he eplaeor underying subsrae. These cuers are ypically used wih he hand
rouer, bu can jus as easily be used on he rouer able. Wh a rouer
able ore e and sill are required o ae he epae and safely fas
en he eplae o he wor. is reaively easy o jus cap he e
pae o he wor on he bench and use he hand rouer.
A patern bit, et, has to have its entire flute extended for the bearing to engage the tempate he end-bearing flush-trm bt can be extended the m ini mum a mount to engage itstemplate.
Cue Type
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1 1 8 Rote Bits
Flush-tri bis are safer han top-bearing-guided oos beause thenot boto ut" and you an always eend us enough bit to do thutng Bu with he shan-bearing tools he whoe ue has to be
etended for he bearing to engage the eplate Moreover these oo
(top-bearing utters) are boto utters and as suh present another
tng surfae where none s needed he end bearing on the flush r
overs up he sharp edge a the end of the oo for additonal safetyush triers are very popular bu due o the poor seleion of st
dard bearngs ost are only in diaeter wih narrow webs of 7hz in
less. What that eans s inreased defleion. No atter how sharp or
who suppies he these tools w dee signfiantly when their flu
are an nh or onger. There just sn suffien eal lef in he ore
he ool to eep it fro bending. The few 4-n uing diaeter (-in
shan) flush triers are very strong however
In spite of its -in diameter this trimmer is pretty narrow in te web, less than V4 in aend of the tool
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Bits fo interocking oinery must meet i gh grin ding standards to do their ob Your setup
must also be exact to minmize erors
Though the faces of ths glue joint don't line up the proiles do nest in one another
JOINERY BITSRoers are good a joinery Coon joins incde half lap, onge and
groove orise and enon, cope and sic, scar, inger ge and doveail.
Many cers are precision-grond precisely or he ob; ohers are no
Soe doveail bis are job-specifc; so are he ge join and cope-and-sc
cers. Halap, onge-and-groove, and orise-and-enon bis are non
specic b reqre precson noneheess For he os par, good onery
s qie dependen on good lling and good j igs and resand less on
Testing Joinery Bits
Jonts made with dovetal and
straght bits are usaly quite
gvng, but it is good practice to
lght swipe on the edge of some
or b irch deeper than you ntend
on the oint. If any wear l nes or
telegraphy are evident on the s
expect to have prob lems with th
These defects are never cancele
oppOSite sides of the joint and a
tined to frustate cose joi nery.
Cue Types
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Examps of scary potntially angros bits, from f Th 1 0-oz lock m itr's iamt is5\ tim s larg than its sa nk. h rabbt bit is fiv tims g ratr h big ovtail bit haslss han a 76 in. of stl in t wb h HSS spia bit is so flxibl it "zngs whn it cutsAn th cabi Oflt is 1 2 tims l ong r than ts iamt.
Sharpening
A utting toos get dull As they ose their utting edge, thei powe
deand to ut inreases, the tools ae woed harder and duing inreases
at a faste and faste rate A router bit's life is shot, so have developedstategies to inrease it One way to inrease utte ife is to sequene its
use A utte that buns in end grain, for eape, ay be aeptabe on
long gain a utter that won't ut edge gain will burn the end gain, but
you an probably rout MDF with it f it wont ut MDF it ay ut pasti
but not for ong. A utter that won't ut plasti ay abade MDF but
won't eally slie it. o be sue fo the best of uts on any aterial, use a
new utter
Carbide grinding equires sophistiated diaond tooling the stuff is
hard You an diaond hone it a ittle and you an sharpen highspeed
steel But to get the aiu tie between sharpenings, epet to have
you tools professionally ground t is very osteetive Four to sireginds are possibe if the utter has inured no serious fratures It is
ipotant to note that if 80 perent of the utte l ife ( if eground fou
ties) is fo the grinding servie, not the anufaturer, finding a good
ginder ay be oe iportant than finding a good anufaturer.
Sharpenig
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22
s mentioned, routers can t do much wthout a gude of some
A cutter wthout a bearng on it w require a router tabe o
accessory to contro its pathway. Even cutters wth bearngs
requre a j g or tempate to guide the too around t so happens there
quite a few accessores for routerssome that are manufactured and s
that you can easy make yoursef Heres a sampng
Guides and Bases
The coar gude is avaiabe from the manufacturer for most routers,
whether fxed-base, punge, or trim These devices fasten to the subba
the base casting, surround the cutter, and with the cutter act ike a pa
bit but wth an offset between bit and guide They are used wth tem
especiay with doveta and jonery j igs The router is pued aganst t
tempate to estabish contact wth the coar. The coar sides aong t
tempate and cuts a swath parae or concentric to the pattern. A 1 i
diameter too bt is about the argest cutter that can be used with a co
nay kits ncude a coar, seeve, and �in.-diameter cutter The seeve
oset the cutter pathway to compensate for diameter dierences of the
and coar f the cutter was ike a aser and coud cut wth no waste, th
and the recess it fits nto coud be created wthout the seeve on the co
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Guides and Bases
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With an aftermarket offset subbase and a shop-made edge guide, its nearly mpossibspoil this decorative cut
EDGE GUIDES
Edg guids fasn o h rour-bas casng wh a par of ods Na
rous ar dsignd o accp h hough no al anufacurrs a
h for hi rous. h guds povd a ans o cu paral o
dg of h wor. hy ar coninuousy adusabl and gnray usd
wih p olss curs. Add-on or rpacn fncs can b ad con
rc o insid or ousid radii so h who pacag ( dg gud rou
bi ) can ravl aong curvd dgs
ROUTER SUBBASES
Round os squar and ohr shaps of subbass ar avaabl for r
parncy cono and spcaly applcaion Sars DWal Porr-Cab
Woodhavn Vron Aican and ohrs cop in his afa
nich (s Rsourcs on p 1 8)
CIRCLE CUING AND ELLIPSE MAKERS
Plasc pivo subbass a in os caaogs and h all sl and au
Micro nc jig can cu pcsion cicls (shown a righ) Th ig is a
dsgnd o wo wih an llips bas shown a fa rgh whch povan asy way o adus h inor and ajor axs
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DER ORIGNA EQUIMEN ROUER COLLS oen would et hei cuters slp
o gue" themselves to he cute Two wrenches, equenty dieen
were and stll are a necessty for
cute exchanges. ewe colets
are asened to he collet nus
raey sip and aways ee hemseves om he bit. tl thee ae
hose who thnk tha is no enough.
Two aemake companies have
been ryng o ceae a market for
wench ess coles he Jacobs
Powe ole s ooless and he
lminato chuck uses only a
T-handled hexkey hey are some
wha outer-specfc but gven su
cen dsbuton hey shoud be
avalable for al outers soon They
are bgger han the ogina coletsand hold their cuttes well bu they
can vibae moe
he Jacobs Power Collet replaceswrenches wth a snap -in system that
reeases and tghtens with a click
Mico Fences adjustable cicle cuting jig fits most routers and can
be tuned to wthin a few thousandths of an inchUsed wit an aftermarket j ig, the Micro Fenc e can be u sed t
rot precise el ipses he mountin g plate and a set of pivot
blocks provde a way to qu ickly set the min or and maor ax
the el ipse
Gides and Bases
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L Vallys Routr Bit Jack is attacd to h dpth stop of a plung rout. T tool allows
dpth cangs with a lvr (Photo courtsy Vally)
Router Table Accessories
Routers are essenialy desgned for hand use and as such do no necessary
adjus up and down very we against gravity when underneath a rouer
tabe. Eractng he springs fro punge routers and reroftng the
router with an afterare fine-deph aduser are coon straegies ha
can hep
A coupe of dieren devices fro ee Vaey and Jesse oolCopanies accopish the sae hing he Jesse Rout-R-Lif is a subsi
ute rouer able inser hat carries he rouer in a crankdrven echa
nis The ee Valey Router Bi ac uses a ratchet echans fasenedto a hreaded rod of an upsde-down plunger.
Router able Aeorie
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he Jonech fence adjusts contnu ouslyand can be used on other stationary tools(Photo couesy Joinec.)
128 Roter Accessories
he router table fence rom In cra Jig can be used as a standard fence and, wth an atment, for cutting dovetals (Photo courtesy ncra Jig)
ROUTER TABLE FENCES
Incra an JonTech are the ey player n afterare rouer tabe fen
The ncra g fence yte ove a notch a a e on a aw-tooh ra
wth a nob for fne ajuten between op. The onTech ue a
for connuou ajuent hroughout t range. (See p. 9 for ore o
fence)
PIN ROUTING
Pn routng an neretng eplate eho of routng whereby an o
hea pn n lne wh he cuter, engage the ege of the eplate fa
o the wor. he cuter then r he wor even wth or parael o t
teplae ne wor ao poble wth the yte.
DOVETAIBOX-JOINT MAKERS
here are at leat fve oveta jg for han rouer hree of the fve a
capable of box fnger an oher cae-corner jon The On g a
Porter-Cable oo wth any tepae for box, through haf-bn a
ng oveta
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he Po rter-Cable O mn i g is an i ndustrial dovetai jig that has
many accessories for various k inds of dovetails, as well as other
joinery. (Photo courtesy PorterCabe.)
he eigh Jig uses adjustable fingers for cutting variabespaced
dovetails and it has become the industry standard for this opera
tio n Leigh offers a wide variety of accessories for other jon ery
applications as wel . (Photo courtesy egh i g)
he Kelle Dovetail System uses matched templates to cut
through dovetals on fixed centers he idea s to do only th
dovetails but do them well and with a minim um of setup (
courtesy Keller Co)
Half-bl i nd dovetai l j igsPoer-Cable 41 1 2 is shownare
mon ly used for drawer constuction he setup s rathe fus
though and can require several test cuts (Photo courtesy
Porter-Cable)
he Kelle ig is a se of epaes ha clap o he wo, one fo
ails an he ohe fo soces o pins he openings in he auinuepaes ae fie so he oveails ae c on fie cenes
Leigh ] ig is he os vesaie of he join aes, capable of vaiable
space oveais, bo jo ins, an ecoaive ineocing joins shape lie
flowes he wo is clape o he benchsuppoe j ig
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SimpleShopmade Jigs
Shopade outer jg and ure ue he route to i lit. Thee
jg and ture can be vey iple or ereely cople. Soe o
the itue Ive een are o ophicated tha you'd need o be a
achin to build he.
Router g and ure eentialy erve o hold and nde the wor
a we a provide a guide o a controlled cut. A te the j ig or iure
hold the wor o the cutng can be done on he router able At othe
tie, hey hod he wor o a handheld outer can be ued ealy andaely. Eithe way, g and ure can be thought o a aety device or
pece anageable and contoed ouing.
Right-Angle Templates
Righ-angle eplate are iilar o bench hoo ued a holder and cut
tng guide wih hand tool. Ued with clap they hold the wo and
etabih a pathway o the oue to cu perpendcular to he edge o the
wor. Ue he wth cola guide or paten bit.
ae ine ro -n M The eplate hould be at ea a longa the wor wide and 6 in. to 8 n. wide. Two or thee deent length
are better han one ize or al. Screw and gue a 2in ceat to the bot
o o the eplae. To get the o ou o one o thee quare boh
wong edge o the ron edge o the cea.
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132 Simple Shopmade Jigs
Rightangle bech o oks registe r off the frot edge of the work ey can be used w
col lar guid e, as show n. Backup scap is clam ped to te ear of the temp lae to preven
earot and breakou
he adjustabe stop on my fence is useful for cts like open moses.
Slot Makers
Ajsable sops wih sloe ways are qe common n wooworkng
wiho a j ig hey're no easy o make. solve hs prolem y ceang
wnow slo emplae I clamp he work ner he emplae an se a c
ge an plnge roer o make he slo The wih of he slo is sa
one cer iameer an s lengh is reglae wh he sop.
Mae he plaform rom -in MDF an ig enogh o camp o h
workao 1 1 in. y 1 7 n Make he narrow openng js we eno
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Sotte mortises require a jg ere the workpiece fits nerneath an the pattern bit rns
in the slot
or yor collar o slp n n s a common collar dameter Make e slo
longer tan te longest slot yo plan to se6 n n my case
Yo'll need some ences nderneat to regster te work, and on
wc o mont a clamp Slot te MOF ences or a par o screws and
wasers so ey are easy o adjs
Shopmade Mortiser
A good morse s essental o qal y jonery ere are many ways to
make tem, eac wt ts advantages and mtatons Gven well-mlled
materal, a good plnge roer, wo edge gdes, and my sop-lt mor
tser (see te op poto on p 3), I can ndex and excavate a mortse p
to 23h n deep n s a mnte or so
A lock o sragt-graned ardwood s te ondaton o te j g
Make t aot 4 n y / n y 2 n and screw on some /- n y
/- n sock o te same speces or more roter srace Add a clea to
te otom o eac sdeone or jackscrews o spport e work, and teoer as a old-down
A se o tree oggle clamps screwed o one o e cleas wll secre
and ndex e work To e sre, a par o adjsale stops on te op o te
jg wll smply te morsng process Poston and slo tem or te
lengts o mortses yo expect to make A g, a waser and macne
screw wll old em n place
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34 Simple Shopmade Jigs
his mortisin g g uses a pair of slidin g rods so it can easily adst to make manymoise widths.
This simple tenoning jig uses a abbeting bit with a ba bearing and an oversized ro
base to cut square tenons he plung e mechan ism al ows yo to cut a deeper teno t
the width o the rabbetng bit
Tenon Maker
Squa shouldd, can-acd sagh nons a a snap wh my sho
mad non ( aov ) h wndowd pafom, comnd wh a plu
ou on a wd wood as, a h ky componns o oung pcs
nons h wo s ndxd campd and squad up fom low an
h ong-shan a maks h non chs fom aov Should
wdhs vay as h dam of h and ang dff
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Fr the y the j g se /4 n MDF r maple Screws aes an
ange rackets are se fr the assemy Ct a wnw n the tp r wrk
an ctter access Als ct ne n the vertcal memer s the ctter can
access the entre sectn f the wrk
Y can clamp the g t the ench when rtng shrt stck r
camp the wrk n a vse wth the j g campe t the wrk r g an
ng stcksAn ajstae fence that pvts wll permt angle tenns A small
tgge camp n the ence w acltate setp, t at least ne ther
Ccamp wll e neee t hl the wrk saely
Wi this teon make a a alleaing g uieraetig bit you can easily form tenons o teen o te workiece. The winow cutout al lowsaccess o te en wi e the workece is secure
to the ase of the jg y a cla m
T enon Maker
Wiow cutout,
3/4 X 6/4
Route atfor
316 x 8/ X 1 3
3 4
�
Tonge an groovean screws onlatfom to
Camng oar,�1316 X 5/4 X 3
Clearancenotch i sq
MaChie screw
vo in
I
/
Ha ko a ows
qu ck astent_o fece's angle
Austale iexi g fence516 x 3/ X 7, ivots oa machnescrew ivot in.
/
cang oa
Inex-fencelocking ot
Slot is aiuseeative to vo i
Coner racesscrewe o toenforce latfor
Tenon Make
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136 Simpe Shopmade Jigs
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and roang leve fo connos adsmen The ork s camped o he
fre, hch s clamped o he ench/beam
Make hs one o o ood, almnm, and MDF fo he adsale
emplae Make a ghange assemby as long as he des sock yo plan
o ork pls 8 n o so or a fence a camp pedesal, and a hodfas Yo
ms e abe o he j g o a rgd scre
he emplae shold be 5 n. o der fo peny of roer sppor ravels on a se of n paralel ars morsed no he plaform and he
Screwadjustable platfom gud ed by a ls provides precise positon ing . Toggle campsquickly secue e work
screw
Platorm edgegudes router.
Panhead scew
eeps patformfrom liftingduing travel
J g odingarm
secure ig i na vse
Toggle clamps
Tenn Jig
" 'i.
Moving bocis screwed toplatfom.
I
o
- Paalel rails of steel oraluminum guide platfom.
Pivot screw
Lock scew
_ Fence
lamp pedestalis screwed toL sectio.
Ts adjusable teno n make has a sliding plaform syou can ea sily adjust the thickness of te teon ogclamps o ld the wokpiece vertica and a collar gui drides along the pl atorm edge
Adjutable Tenon Make
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0.055
emplae iel. i dive by a crew ha / . i diamee by1 8 head per ich
Two clamp o he pedea ecue he work A fece (pivoig a
degee) quare he work o he emplae he hodfa i 4 . wide
crewed ad rabbeed o he ig
Thi ubbae (above) ha a l dg pivo ick o make cicle o dk
i wih a puge rouer ad a oid carbde aigh b fo be eul.
The hape of he oo i o crical, bu hould be a mal a praca. The bgger ge, he moe lkely i o bag o camp a i
evolve You coud ao ue a paddle wh hoe i , bu a ig wih a
aduabe arm a lo hadie
Make he g fom -i. mape wh a log lo i fo a adua
lde you wa, make everal ide of diere egh fo covei
u a ew hoe he ide fo a pivo p. A flahead machie crew
ee he boom of he lde ad exed hough he lo ad o
u o op o ecue he arm
Mo had-roued work i eiher doe o a aemby or a looe ick
Aembie ae uua y abe eough o rou clamped o he bech w
ou much ado Sick, o he oher had, could ue a f hi ho b
how a lef wa made wih lo of ovehag o ge he work up high
eough o ou comfoably. Nomal 3i o 36 . high aemby
beche ae oo low o ou o
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I
27 i n . -
Mae ths 1nthc jg abo 6 in hgh and 36 in ong. A 6-in o
8-in width will sot a 10n to 1 2nwide woiece The oo is
joined n fo laces The oehang on the hoizonal sface is somewha
abay: allow abo 4 in o 8 in. The eical end iece s oehng by
10 in o allow bete so fo woieces held on endThee is no need o comlcae ths; jst hod the jg togethe wih
shaow dadoes and a ltte hadwae The bottom stic is sed o hold the
g down and s inned by a clam. Afte assembly, add a fence to he e
ical anel and agan some handy toggle cams o hold the wo on end
he gh-ange jig can be sed o adantage hee fo maing tenons
o dadoes
Permanet C-Clamps
A
Route Hose
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Compared to other technologies woodworkng and machinery
processes change slowly The hazards and risks associated wth
power and hand tools are essentially the same as they were
decades ago. Its a dangerous busness and accidents are common-a
fact that's refected by insurance rates or woodworkers
Workng with wood requires sharp cuttng toos often used very cose
to the operators body. It shoud come as no surprse that butchers use
bandsaws on anmal carcasses, and orthopedic surgeons use hammerschses, circular saws dris knives and sanders on humans.
The rues of ote safety are sim ilar om ma nual to ma ual , b ut it's sti a good dea to
read them.
1
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142 Route Safety
Haring protcton and a ust mask ar snsib prcations
Wooworkig machiery is i the ark ages compare to the at
bie as far as safety goes he atomobie istry has oe a thorog
protectig rivers whie the cars they are rivig a rom the o
they may crash ito Seat restrats ar bags hazar ights ABS brak
oor pae gars teescopg steerig coms safety gass a pa
ashboars a protect the rver However efesive rvg skis ar
as importat as ever wooworkig as we i ts st as importat to
a active roe i yor ow safety to ear how to prevet acciets a
practice that sk costaty
make it a poit to rea a roter safety res i texts artices a
roter owers maas hese maas are very poor; bt yo sho
them evertheess becase this book I am gog to omit forma t
o rotg a eectrica storm wearig OSHAapprove saety ga
a the regatios o jewery og hair og seeves a og exte
cors am aso ot goig to repeat the materia o overreach chr
proxmity operator fatge the fece o acoho or rgs orcig
too goo hosekeepg or savg strctos or ftre se wi t
yo abot the thigs that have scare me eary jre me a tak
by srprise These expereces have e me to eveop some precatiothat yo wot f the operator's maa
I sho poit ot that a of my acciets a earaccets we
etrey my fat 've ever ha a acciet e to eqipmet air
wrecke a acre o woo bt 've ever raw boo from a broke t
or a machie fare A as we a kow there are geera heath iss
besies the rect physica agers of rotg.
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Hand-Router Safety
Fied-bae and nge oter were fit deigned for right e n the
hand of the woodworkernot to be inverted nder a rote tabe f they
are ed wthn ther degn lmit they are retty afe They are ntmidat
ng and cary bt they are afe
CUTTING RESISTANCE
The amont of ctte engaged in the wok determne it gr in the
tock Ctte tracton increae roghly by the qae n othe word the
area wet ot in a -in by -in ct i nine time greater than a -in by
-in abbet not thee time A ch the ctting dynamic are omewhat
he cuttng procedure for the -i n. by in rabbet eft s the same for the %i by %-n
rabbet r ight bu t the volume swept out in the latter is in e times geater tha th e smalercut Expect substantial chages in handlng as you scale up.
Neglect the motor lock i n the route r table and expect the depth of cut to change like it didwhile routi ng this slot.
Hand-Route Safey
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144 Rote Safety
npredctale Dn epect e same cntrl wen dlng te ct
yre n dt make dep canges n sma ncrements e dffere
are especay ntceae n end gran were e fers are a rg ang
te ctng drecn Epec mre eertn n endgran r crss-gra
cts lke dades
SPONTANEOUS DEPTH CHANGES
On ccasn, a mtr may spntanesy sf n te casng r a c
may lsen n te clet A plnge mtr may as mve n ts pss
nt gtened dwn eng Te cnseqences can range frm a mn
msap rned wrk
t s yr respns lty t make sre e mr n a fedase t
des n mve nder pwer ey rarely d, t eeve wng-n l
levers sld e repaced w lnger levers fr mre gtenng prc
Plnge levers sld as e pstned s tey dn rn f tws
trave efre ckng p te mtr Al pnge ck levers ave an ad
ment fr s
INSTABILITY
Rters can nepectedly tp wen nder pwer ey can e awkwa
se and dffct ld secrely as y wrk Fedase tls are sm
tmes sed n narrw edges, r w less tan alf er aseplates n
wrk In eter case, a le can case e cter t dg nt te w
even reakng r endng te ctter and reslng n kckack Often
rer tale s a eter cce fr narrw sck ecase t allws mc
ter cnrl Y can als se se rer ases, as swn elw ta
fr mre cnrl y makng t easer t press dwn drecty ver te w
pece. n s case even an verszed sase can make a g dfferen
The locking lever of this PorteCable 690 router has been replaced with a long er ver
The extra length provides more torque for easier locking
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Addig an ovrsid sbbas to a plng otr, shown at owr lft, can add a lot ofstabi lity to th too .
cttr is loos ly trappd bwn two sticks o qa l thickn ss st to t maxim mintndd dpth for th ct st wih a 5- lb or 1 0lb psh t o s if th tool is n stab
A plnge oter nde sl ar condtons can aso p e andles are
wdey spaced and oten g p on te poss. a ong ctter s engaged n
a deep c yo and-eed orces ay tp te too over
VARIABLE SPEED AND SOFT START
Vaable speed s a elatvely new eae n roes and a good one
especaly o sowng down agedaeter ctes. Also all varabe speed
tools ave sot (ap) star a nce saety eate evereess sowspeed
otng can be rsky. A slower speeds ctng ecency s redced and
Dry Rn o Te Setp
Eve though you wo't be c
stock ts a good idea to g
eel o a pl ug e cut beore you
the moto Smulate the cut wit
motor o ad the cutter at its m
mum depth Move the router a
get the eel o it ad to make s
opeatio wil go easily ad sm
For diicult cuts, it's aways a g
idea to do a test cut i scrap st
Hand-Route Safey
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takes more hanfee force to move the work or roter As a rest, th
risk for pening the roter increases an aeqate campng s essen
Before rotng at sow spee, psh an p on the work ences stops
ege gies to check ther secrity: yo be sing more force than s
f yo o start a ctter spnnng an engage t in the work beore
reaches maxmm ctting spee, yo may break or ben it A softstar
too has tte rotationa kinetc kickback on startp so the keihoothe ctter samming nto something beore t is at maximm rpm s es
a probem Conser a softstart variabespee too to be the eqvaen
a shock absorber in yor car ths making accients sch as bt grabbn
en grain ess terrifyng Withot ths eatre, the knetcs (reaction
forces) rng ctter jams an bobbe are spontaneos an mch more
frightenng.
S RE DE H FERRKE SEED CONROS ae as good as he
vaable-seed eedback microrocessors i ew roes. my vew
that s o tre ad some oomakers wi ot guaratee ther oos w
aemake devces i use.
Vaiableseed cools o outes ae ot aticulay accessble
ad o good reaso eed-corol devces ae sed o sow dow
lage-dameter ools; a hgh seeds hey reset moe sk. I he
seed cotro s vey accessbe, t could accelerae wth a accidet
bum thus causig a accidet
I ay case i you use oe o hese roec om a accidetal d
chage. aly advertsemes showed the cotato o he oea
o's beta vey sae actce.
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Wit this template on a sight i ncl ine you can ou a grip into the side of this box
KEEPNG THE ROUTER HORZONTAL
Tere w be occasions wen roting wit te roter sidewas (sndle
oriontal) ma look like a temtng solton to or woodworkng rob
lem I wod resist tat temtation ot on w o get cis in or
face and air, bt te dnamics of te oeration are so ecliar tat it s
nvariabl dangeros Rotng on an angle, owever, is safe as long as te
ange is not stee enog to make te roter easil t
Router Table Safety
As a roter table woodworker, o sod kee a few tngs ermost
n or mnd Most basc of a s keeing te roter secre n ts casting
wie monted sde down in te tabe Fare to tgten te cams
can also ave obvos drastic conseqences And cearl, or roter tabe
mst be secred we o work Aso ke is wirng a swtc nto or
roter table so tat o can qickl trn t off
Wt tese basc recatons, te roter table s rett safe most of te
tme, bt tere are some rsks n general, o sold se a sit fence forsafets sake o can more easil tre fence alves and sde te alves
left and rgt to crowd te ctter, ts exosing te mnimm steel
Vacm colecton and a sod means of secring te fence are essental
Witot a secre fence, a sl cod make te roter grab te work, or
o cold lose or baance.
In corporating a switch in the outsrouter table base provides safety by alowing for q uick s hut-off in than emergency he switch is mortican't be accidently struck
Rote Tabe aety
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148 Router Saety
This pair of nlong levers at 6 n from either end of the fence securely lock then p ace he levers lock nto nuts under the table
Dont do this Sl idi ng the work down the fence onto this spinn ing cutte s done at coerable rsk f the fence moves you can lose your grip on the work; or i the work is byou can break the cutte
SMALL WORK
Work ha i oo mall for he han roer can e ale roe a
ale an ence are no reaon enogh o ge yor han cloe o he
er Avoi nneceary rel iance on ho-in an holown wheneve
ile hey ocre he cer an hiner conrol of he workpiece.
work eem hazaro enogh o e holown i hol e he ig
ha anoher kin of ig or ire i reqire o nee a fire ig
enogh o keep yor han away from he cer an ry enogh
erve a a plaorm for op an clamp The j ig may no e eay or q
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to mke t yor eslts wll e ettern mch cheper thn n emer
gency room visit .
DOUBLE-BLND ENDED TABLE CUTS
Dropping the wok on spnnng ctter is ngeros t s common t
rsky prctce. Selecting the en ponts o the ct s gesswok chngng
epth o motises {n other cts} is iclt, n hnlng the work sprecros. Any elxtion or momenty loss o control s crtins"
Expect chttere ws n ns t the ens o the piece s yo revese
rection Yo'll kil the ctte premtrely n this is n nse prctice
The hn pnge roter ws invente to ccommote these lin cts
so yo shol se i t
THE HDDEN CUER
t' s common when workng on oter tle to hve the ctter e
mch o the tme rng ct only to hve t ppe nexpectely t the
en t's impotnt to sty let yo mst ply n ctive prt in yor own
sety. The sen ppernce o the ctter is jst s thretening s ctter tht s wys in yor ce
ROUTING CUR ORK
Fo roting on cve the sl strtegy s to se erngge ctters
with strting pin o to the sie so yo cn ese the workpiece nto the
spinnng ctter Withot one the work is kely to kick wy rom the ct
te. Even with pn it s possile tht the ctter wi ctch the strting co
ner n whisk the wok ot o yor contol Wheneve possle lit
tle scricl mteril to the en o the wok or n esier stt n ny
cse yo shol ee the mterl gnst the ctter rotton
Two-Sep Cting
For thck stock o r an nderprouter it sometimes heps t
a trim ct in two passes Use a
bt that has a larger beaing tha
ctter for a initial pass, the f
that up with a fina pass sing
tr im bt .
cutter wih a be aring bigger thctter diameter will lig hten the cload for the first pass secondwit a pattern bit flush wth the
will leave a smooth srface.
Makin g the groove is so effoless o ne may forget thee i s a cuttersoon to emerge as the work passes over it
A staring pi al lows you to start the wok in a controled wsafety essential with curved work
Rote Table Saety
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150 Route Safey
BIG CUERS
Feed Direction
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Climb Cuing
T saf androing fd drcion sold f o rig (agains
cr roaion) on osid of work On an insid xcavaion
fd dircion sold clockwis aso agans cr roaion is is
a good r fdng agans cr roaion sal cass som
aro T ffc is smilar o copping agans grain w a cisl
w moving cisl in dircion of cop I s vr ffcin
cr can gra and ar o som sock If ror is fd rig o
lf on mos rcalciran of marials will ar o onl ral
incniv o clm c
Tr s som rsk in fdng w cr roaon ror can
sffd T cr ransfrs is roaonal forc ino a forward pl and
nds o pll awa from work as sffds. Tis dosn appn wi
sandard c cas opraor is psng agains a forc B
wn or psing ror in sam drcion as is sffding
ndnc s mc ardr o conrol Howvr lg cs w smal is
ransfr vr il forc ack no ror. Clim cing wi m israv saf T iggr cr grar powr ransfr T
prolm also gs mor srios on ndgran wr crs av
mos racion.
On ror al cm c can ransfr a lo of nrg no a
raivl lig workpc s vr as o os work wn fding f
o rg And onc workpc sars o sffd or fingrs can
plld no cr a dsasr indd f o av work n a oldr
a as som addional mass likood of a sffd s rdcd and
o can kp or ands saf awa from cr A workpc no
hese toggles not ony press the work down on fiberboard but ae comfortable enough to
se as handles.
Climb Cuting
Reversing the ou te's feed d rection
eslts i the risky c lim cut-son
ecause the roer bit tends to pu
cli mts way aog te workiece
Climb Cuig
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152 Rouer Safey
THE ACCIDENTAL CLIMB CUT
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maeria o relieve sress ad e wor ages sape e i ba sel
eedig, or or igs a be expeed
Cutter Surprises and Risks
Roer bis or desroy mos igs er paway eve eyre dll
ey a eve ge o ad br yo ey a aso brea espeiay ieyre smal i diameer Mos o e ig ad ore o a er a wor
is a e ed o e b Te lever (disae) rom e ed o e oo o is
weaes poi a be log eog o brea e ool modes worig
odios doveail bis are oorios or is o mimze breaage we
o oer er wi do, se soid arbide or ae e sages wi a
plge roer Also oe a a soppy sep ireases e lieood o
breaig e oo. Keepg a er oied o is paway elps sa e
odds i yor avor
No oermeasre wi preve all aides Cers brea or
aely ers a brea i sde s lose er ie eergy lyagais e wall o e ad ey are say rapped ere by e
over o e sbbase ey are rarely dageros A er breag aog
e edge o so is a rea, b rare ve eard orror sories b i
yore more liely o ge by lgig a a balsi oo b ve p
i osads o ors bed roers wi all sors o ersew, sed
experimea, balaed, regrod ad so oad ave ever broe
a er wie edge roig ve aso ipped a o o arbide we ig
ails os ad embedded ardware b ve ever bee by er
srapel.
his table leg, ou t of squae wil rot diffeently on the router table dependi ng o n wichface is against the fence. If it s too far out of squa re, it co ld b reak the cutter.
Ce Srpses ad Rss
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Let your collet fll up with a resin ous messfrom a softwood routing s ession an d the
next cutter in the collet may not be secure.Colles should be immacuate if teyrenot you'l l see a loss of hold ing power
154 Rote Safety
This slot cutter is engaged i n the work Lif up the work while routing and anything chappenusually what happens is not good
THE TRAPPED CUTER
A rappe cter s any bi tha will esoy the wok if yo lift he ro
hese ince sot cters, keyhole bts an oeail bs Any of he
wil rin the wok if yo ip or lft he roter f the cter s in the ro
able an yo lif the wok yo also rin the c Yo may also nw
tingly isoge or pll he ctter fom the collet an change s ctin
epth, casng boh angeros an nexpecte resls Thee s no myo can o abot ths bt pay atenion
OUTOF-BALANCE CUERS
Bent, sefshapene regron, big ong, singe-te an een ornctters can be ot of balance Diry o worn coes can sen a we
balance oo ino a esonant frenzy, oo Wth any of the aboe, test
he tool n a arable-spee oter for baion fis o the moto
wih both hans with yor thmb on he o swich Acceeae a ste
a tme an sht he tool own he nsant any ibaton is fel Opea
the bi only a spees beow resonance (make ibration) o no at
rankly wol ern an ot-ofbaance bi for a refn or eplacem
Unfortnately, I hae seen new ctes fom most sppies hat haesome ibation
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Health Concerns
Routing is a dirty, dangerous, noisy business Eye protection is essential,
and goggles that won't let a chip in anywhere are cheap Ear protection
should not be overlooked Routers are noisy, and with a vacuum they are
douby noisy Noise suppressors safe to NRR: 25 dB minimum should be
worn at all times when routing, as sound-energy insults are cumulative
and can lead to noise- induced hearing loss
Every reasonable eort shoud be made to colect the dust and chips
from a router to prevent nasal and lung damage The router tabe is very
easy to set up with dust collection equipment, and you should use this
whenever possible Repeated exposure to wood dust is a recognized heath
hazard, so you need to minimize exposure. ( For more on this, see Woodshop
Dust Control by Sandor Nagyszaanczy, The Taunton Press)
POSTURE
Most shop furniture is too ow for routing, not only for inspection of the
work but for your posture For me the best height is around 36 in. to38 in high for table routing, and about 40 in for hand routing. Select
the best height using the adjustabe height of the drill -press tabe as an
experimental surface Theres no sense in stooping and tiring before youre
ready to uit
Hearing protectors, safety goggl es and dust masks el p prevent long-term heath damage
from frequent router use.
R
outing can produce very sh
cornered w orkpieces-sha
enogh o cu your hand. Altho
routing with goves can have its
hazards, I do use rbbe gloves
me o time for protecon. Be ca
tious hough If a cutter caches
gove it can pll your hand with
winding up he glove n a second
Health Concerns
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Du l cutters, or even new cutters, if lef to coninue beyond the ir cuttng t imes ( tme t akes
to rot the cut) wll brn the wood.
Risks and Problems
've menoned he nheen nsaby of roers and ha hey ofen have
oo vsby becase of back or oaqe sbbases Roers aso rodce a
o of wase fo he ar, and can even n yo hearng f yo fa o se
roecon The cers ae obvosy vey nforgvng and hey can
qcky weck a wokece f yo ose cono They aso w case sevee
njy f any ar of yo body ges n he way
s aso ossbe o beak a oo b evey now and hen and have a
ece of mea whng hogh he ar (ahogh hs s ae snce bokenbs generay ose he enegy rady agans he wokece sface)
Pehas he mos common coman agans roes s he endency o
rodce earo n he workece Panes chses, and saws have he
own obems b hey don ear ke roer bs do
Roes can nexecedy ose he deh of c As oned o , he
moor may s n he casng, o he ce can sqm n he coe (ese
cay wh dy o worn coes o f he oo shank has been scrached o
dnged) And, of cose, worn roe bs can aso bn wood
PRODUCTION WORK
Neay a of he obems menoned above show more feqeny whhghe and hghe odcon aes he sandad 1 10vo oer can be
oveworked when made o do heavy cs sch as ased anes n nea
connos-dy condons Yo shodn' exec hs odcon efom
ance fom a -vo oe Sho-rn med odcon can be done
wh wo roes havng smar ses Le one oo do mos of he dry
wok even f he cer s won o ched and e he oher oer wh a
Risks and Problems
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nly h right cornr w l ar on this crosscut so a spoi l boarcamp on th g wil pvnt tarout. Th cuttr spins in toth work g on th ft an cant tar
T up-spiral bit lavs a fuzzy surfac
Th floor o tis abbt shows th slig ht swirls of th cuttr tp h wall is typcally muc hclanr than t bottom cut.
Roer echnology hn een perfeced o cheve gre rel forh oom poron of he c Roer e degned prmrly de
ce. Coneqenly he oor of mny profe my no e wee
he wl c from he me ool. Thee n mch yo cn do o h
lgh core c n. o o) cn elmne lo of ero long he
oor/edge coner nform feed e commenre wh he cng re
nd chp eecon w prodce he e c
h cut on th ft was pr-scorY-in pass. Th cut on th right w
Risks a Pobems
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ry usi ng a pattern bit with a top
mou nted beari ngthey're fre
que ntly arge in d iameter and stiffer
instead of a flush-trim bit. The pres
sure on the top beaing causes less
deflection Collar g uides also have the
same effect
160 Common Router Limitations
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close enogh o joney with any of the DeWalts xedbase eado is
accate to 4 n , bt nealy iossbe o ead and its acandnion
gea eacts too qicy to adjst o sa changes
Mxng eic and Englsh nts on the sae indicato only confonds
the oble osch and De Walt boh have nealy indeciheable ndcaos
Weight and rgonomics
Rotes do the shalow-deth wo of chisels saws oding anes, and
othe hand tools hogh they do he wo vey wel, they can also be
awwad o handle They ae geneally egonocay designed o basic
bench wo, b they can be difcl to hande de o thei weght and
the act hat he ctte is not a diect extension of the tool, as on a chsel
o hae head. thei adatabity aes the sefl in ess-than
dea cicsances Moeove, becase he ctting oo is ess han e
cent of the achne by wegh closeness and contol ae coosed. A
wallo o a allet on a chse on he ine is a ety staightfowad execise t conoling the cte athway o a ote wth two oosng
nobs and 0 lbs o coe, steel and aln beween the taes soe
acice Fotnaely as with bcycling exetise wil coebt sets,
igging, and sch will ae tie acice is the essence of otng and
woodwoing
Weght ad goomcs
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Starting Upthe Router
Ror nq and sp ar qi indvdal Many if no m
woodworrs arn by ria and rror rar an rom a orm
ors B w mllions of ror ownrs o r nd
rainng is ovrwlmng. Aog ror niq old asily ill
anor boo Ill ma a fw sggsons o p o nov
To do a propr roing job yo nd o prpar marial s
wor and s p ror T aa rong nq is sraig
forward b wil dsrib wa wors for m My niq s basd say iny rsp for qipmn and so and o ors
qaliy rs
Preparation and Setup
Roing sodn' b don on rog nprpard so. Jigs frs a
ror gid sysms ar all snsiiv o sap of yor wor and ma
ral prparaion. Pronond mll mars rom joinrs and planrs for
xamp w as a baringgdd r o bon and lgrap
irrglar sra ino Edgs a arn sqar wll rgisr dinly n yor jigs. Jons won' f yor wor is poory md.
Qaly woodworng rqirs ara maria prparaon yo
nd is sil o g onsisn rsls wi a ror or any or ool
ms sragn flan nssplan and sqar p on dg of yo
marial bfor yo rn o a ror A ab saw inss planr and
joinr do s ob qiy and araly wn s p propry
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Overzealous joi nting may yied too few and often b mpy cts i the
stock. A ball-bearing cutter wil l b ouce o n these m l marks andtransfer imperfections to the work.
There is no reasonable substitte for preparing stock prope
the jointer
To BE SURE N CCENL
startup whie changing a
cute o motor seting
can be a catastope
Because I sometmes
cange cuters 10 to
20 times a day in 5 to
10 outers, unpluggng is
a lot o lost time o me
so don't do it. On the
other hand, aways
ceck the switc position
and pay speca attenton
to ts ocaton so I dont
accdentaly tp it. his s
active and necessary
saety vgilance. But fo
• • •
Sears and some other power cords have red LE Dsin their transpaent sockets indicating they're hot.
This socket also has a clamp in it that holds theplug to 30 Ibs of pul l
novice users, o tose wo only use te tool occasonaly I 'd recom
mend unpluggng Also emembe tat plugs and sockets are not
switches and tey pesent tei own electica hazads. Moeove the
ears powe cords use ave pug ocks tat equire you to press the
ock to reease te plug Foget tat and you uin the socket.
A powe-ndicatng amp on the moto ead woud be a geat featue;
but n te interim actve saety practice is you responsbi lity. D on' t
expect te government, ndustry, o anybody ese to be answerabe to
you safety. f tat means unpug ging the toolten d o it .
Smooth S urfaces
or smoother edge cuts with
router, use a edge gude wh
ever possible istead of a ball-b
guided cutter. The edge gude w
bdge small imperections ad
vent them om telegraphg thr
to the cut
Preparaion ad Setp
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166 Starng Up the Rote
Th n rsi o this sloting ji g sown hr, has a st of stops to crow th wor osis an a st of togg cl amps o p i th.
Ths mortising jig fastns to a bam T twocamp nobs go rght thog th bnca st o Tnts on th bac si of th g
SECURNG THE WORK
Clamps o a ll sors wl l mpose nense orce on e work, bu usually
us a small spo For example, and screws exer 200 lbs o 00 lbs,
I-beam Jorgensen bar clamps more an 2,000 lbs and some orged
Cclamps squeee up o 0,000 lbs Een so, oen akes een moe
e local concenraed orces o keep e wok rom mong Frequen
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you ll eed o fece it i as we ll as clamp it i place. You'll eed at least
two clamps to out a wopece ats ot feced i
's rarely a good idea o deped o a sgle clamp for a outig opera
tio Two is safe. Templates ad fxtures ot oly old te wo bu tey
also eed o be clamped dow Do't deped o a usecured jig tat c a
slde aoud te worbec as you rout Put a couple of clamps o it, or
fd a way to secure t o te bec or oter wo supporDoublesided ape ad route mats are commo wor olders but
teye ust ot secure eoug I do't use eite. Bads ad ot glue are
safer but stadard idustry practce icludes clamps cams, eces ad
cowdig te wor wit stops. A sigle clamp as plety of local foce but
wll ot preve te wor fom roaig; a worpiece wt two clamps is
very ressat o roaio
ROUTER SETUP
Befoe you set up fo you fis cutg operato brg your ouer to te
bec uplugged wit its collet weces. For a basc fxedbase router
emove te motor fom te base assembly ad uscrew te locg ut oe collet. Iset at least 3/4 of tool sa te colle Do't ser te
bit so far at e flute fillet ( sow below) s te col let ad do't
clamp dow o e area wee e flute starts o fade out ito e cute.
If te sa botoms out te colle lift i up a lttle (about 1/16 i) f
you use collet reduces, e gp is bes we e slos te sleeves ae
led up wt te slos te colle I your tool euies two wreces,
squeeze em i oe ad to abou 5 lbs fo i wreces Adjus te
cute dep ad loc te moor
Cuers wi small cuig diameers ofen requre some gindig io e sak, unlikelargediameer cuers of % in or more on -in sanks Do' cam e colle on efadeou
Saving Knuck les
Removing a outer bit with twwrenches can be hazadous
your knuckles If you're not care
the sudden release o the collet
catch your knuckles in a scissor
bte as the w renches suddenly c
together. You can prevent this b
using the benchtop as a second
Position one wrench so that ts
place against the benchtop and
down with your open palm on th
other wrench.
Pepaato ad Setup
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168 Sating Up the Route
To ensure a good tool it gri in te colet squeeze a air of wences i a "andsakg i to 1 5 Is or so.
A safe cut egi ns wit a wid e sick wit two clams on it. e stic k as seen at east tjoi nte r and l ane r; te V4-i raet it (cuting a Vin . y V4n . raet) is extended V4 in
Bgnnrs sh st p f a practic ct with a straght it fr a
/4 in y /in rat n a wkpc clamp t th nchtp nspc
stp an with th t still nplgg pass th tr ang its ntnpathway f y n't snag th wir r rn int a clamp wth th rt
y ay t plg it in Rst th tr n th wrk, t kp th cat ast n cttr ais away fm th g Fr ns cts with a p
rt, kp th it p in th as casting Thn start th mtr an
it int th wrk Dn't am t aganst a aing r stp
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he feedig mi hld be eady eve gracef Sdde lrche
ca cae ear ad break cer
Th fir lgh pa a preview c fr me. he fr few ecd
f rg, lear hw harp he cer wheher I have egh pwer
wheher 've e he cer deep, wheher my camp are hldg, ad
he geeral dyamc f he perai
Beger hd pracce a hallw deph crap piece 1 0 20 ime befre mvig he wrk. he impra pi keep i
md are aly wd, perir millg, gd wrk lckp, igh cer
ad mr ad gh eady c
A a r le, edge c are he fir hig de by he vice wih ew
rer ad cer ad hey are meme dffic d we Sice e
ha half he caig alg he edge ad le ha a arer f he f
pr pree a he ed i early impible keep he rer la.
here are afermarke vered rer pae maage hi iabiliy
Ide c ch a mrie ad dade are a mch f a prblem here
becae he bae lid grd al ard he c Y wll hwever,
eed a jg, edge gide, r emplae fr iide c There' away a radeff
Feed d ecton o the oute is
fom eft to gt-conecock
wise aond te wokpiece eed
di ection fo e ote table, ow
eve is te evese ecase te
oute is iveted.
Feed Direction
Wopece
-
.
Safe feed direction
Peparatio and Setup
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A straight bt is quite satisfactory for making rabbets on the routertable. Close the fence down so there is 'B in . or so of ai aroundthe cutter. Project the cutter above the top by Y4 i ad move thefence Y n b ack from the 12 oc lock position of the cutter's circle
Always keep the work down and against the fence Walk alongsort stcks and use suppor rolles for long ones These fenceare straight parallel to each other, square to the table, ad flatany o those variables and your cutigs may be in consistent
170 Startig Up the Router
Router Table Setup
he setup for the router table requres a few more steps than for a han
held router Again, you'll want to unplug the router. Remember that
accidental start may eect the motor pack from a fixedbase casting if
forget to tghten it before startng the router The cutter nsertion s tsame You wil need to adjust the height from underneath the tabe
sometimes an awkward move, depending on your router For a 4in b
-in. rabbet you need to poston a fence and bt so that a straight
extends exactly /4 n away from the edge and 4 in. above the tabe.
Before routing press and pull on the router fence to check ts sec
A fence that moves unexpectedy can ruin the work or the cutter Ta
routing is very similar to rppng on the tabe sawbut without nearl
much kckback risk Its easy and safe Nevertheess, take no chances.
only when the process adds up safely in your mind
Once you're ready to go, plug in the router, and feed the work ev
from rght to eftthe opposite of the handhed direction because throuter is nverted Push the work down on the table against the fence
side t steady at a rate of about 10 to 20 feet/mnute Wax the table a
fence for more sip if necessary
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Template Routing
T
13
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172 Template Routing
Precision ues calper, compass and hardeed-stee squares ae necessary for close
In addtio to ayout you'll need these to solate error, should that ever occur
Founately, making he templae is reatively easy. he echnque
used ae usually ordnay woodworking poceduesnohng fancy In
much the same way, the actual use of the empate s fairy saghtforw
or example, he aveage woodworke can mase he haf-bind dove
drawe-makng templae jig n a few hours
Templaes for makng eraed onery (box joins, doveails, etc )
some of he easies o make Rouers are the idea ools o make these
"comb ype emplaes The ouer simpy cus one cuter wdth in h
emplae maeial and is sepped and epeaed usng a bock or bar tondex subsequent cts; anybody can do hat. Getng the numbes to a
up so tha the acua cuers, bearings, and coas do her job is anoth
maersomethng we don' have space fo here, eihe At any ae,
sisency is cica, and accurae measuremen is necessary
empates sove many of ou mos compicaed woodworkng pob
lems. hey ake much of the rsk ou of pecarous woodwokng The
accuracy alows preview of any operaion on scrap sock befoe sking
he expensive chery, maple, or wanu on he acua projec. You can
un hrough an enire joinery sequence, for nsance, from sar o fni
whout rsking any of the projec sock
Tools and Materials
You choce of maeral depends on s use and to a ceain exen on
skills in shaping i Mea, plasic, fibeboards, and wood ae the ypc
materias Dimensonal sabiiy, ansparency, expense, wea, hcknes
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availaity, a woraity al play a rol t coc A sortru tm
pat migt st ma of irc pywoo or ust a scrap pc of ar
woo A prcisio ogrru tmplat migt rquir plastic. Crta plas
tics (Lucit a a) ract to gsp a arigs siig o tm
y mtg Plastc lamiat will tolrat at, ut ts oious ust may
a prolm. Tr ar may factors to cosir
Tr's otig facy aout t tools for maig tmpats Youl a staar assortmt of wooworg powr toos: sars, saws,
joitr, r prss, a routrs aout covr it Goo ayout tools ar as
importat, toug You soul av a st of maciists ruls, grou
straigtgs, a a calipr, a ar squar, a a prciso protractor
for accurat agls Tos tools o't com cap, ut ty av crossovr
possits i fwooworig macitool stup a quaty cotrol
Template Uses and Types
O y fact is tat tmpats ca us a sris of stps to crat asurprisg varity of tais ca gt iffrt typs of cuts from a crc
tmpat, as wll as myria variatios y cagig coars, arigs, cut
trs, a cuttr pt First I j ust camp t is oto t wor a rout
t wor full ticss wit a pattr it I sift t tmplat
ac a ic a cut alf t ticss of t wor Fially, st t tm
plat ac agai a wit a collar a straigt it cut a oamtr
corativ patway
So, a tmplat ca us to sap t tr worpic ticss,
ay fracto of it alog a g, or to cut a or troug s cava
tio Tat muc vrsity is wat mas t tmpat so importat
A ful -ickness fl s-rim med coy of e rofile Sifing e em lae back rous a c rved rabbe
Tempate Uses ad Types
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Taking Out the Guesswork
To simplify making straight MDF
templ ates us ualy create only
one straight edgewith two ends
square to the edge on t he maste
stock. The opposite edge is bandsawn
and thu s never mi staken for a work
edge I aways indicate the ps ide
(work face) with a b ig felt-tip pen
Usin g op poste faces of the same
tempate may introduce un expected
error. Becase 'm using MD, se a
machine d edge as the straight edge
and carefly square up the two adja
cent edges o n the table saw
174 Template Routing
All three possibities of the template: ful thckness fractional thickness, and the ine
M aking Basic Templates
A straightedge with two square corners s in some ways the mother o
templates. Wthout it you certanly cant ae much n the way of ot
templates Make one as a preliminary step to makng a basc comb tem
plate (Ths kind of template s used for box jo ints and dovetai ls ) For
bility use MDF for the nitial straightedge. Then two different pattern
are used to mae first a single slot thats 1 in. wide. This serves as a
guide to mae the series of 5-in. slots for the comb template
The key concept used in translating the straght template nto aprocess s step and repeat using an accurate method to step o the n
vdual fngers use an alumnum bar to index one cut from the previo
cut thus mang the seres accurate to wthn a couple thousandths
of an nch
PROCEDURE
Before you begin prepare the MDF materals One s for the simple
straight edge; the second s for the intermedate step; and the third is f
the comb template. I use 3-n.thc MDF for the first and second tem
plate and 3/4-n for the final comb template Whatever size you use sh
be a convenent se for the job at hand. 'll also have the two router b
on hand, one with a 1 -in. cutter and a -n topmounted bearing a
the other with a %-in. cutter and a n top-mounted bearng ( Do t
n stages with a collar guide and a plunge router. A single pass in 3/n
MDF may break the bt.) Use bearng-guded cutters rather than colla
guides to ensure exact centers A collar guide can be o center enoug
mae a dfference You'll also need a pece of 1 V4n alumnum bar sto
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Ft, ue e mpe tagedge tempate o mae e eond tem
pate wi a ngle o n i en ue at o mae a et of lo on egula
and exa ente.
e one of e quaedup piee of MDF in. ) and ou te
1 �in.wide ingle lo ung e eang-guided te. Sandw wo
eang eween e two taigt-edge eion to potion tem, and out
a ingle lo tat' quae to te fae Now e imple lot guide to ,ep, and epea unil we ge e fined om templae.
Poiion e lot emplae qae to te font edge of te lan. Now
wi e 5�-in-damete te, o e eie of equally paed %-n. lot.
e two straigt tem ates are clam ed 1 in aart on to of te temate stock used
to make te comb master e stock sould be big enoug so wen it's clamed on te
master te router wont it te clams.
Use te slot temlate to rout te slots in t e master Kee it flus to te e dge of te master
for every cut.
aking Basic Templates
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176 Tempate Roung
Wit a 1 Y4in alu min um bar in dexed against te temlate ad a straig edge rout aseries of equally saced slots Remove te ar and side te temae agains te camstraigt edge for eac cut
Mov tmpla on 1 4 n ncrmns w amnm 1 4
bar Car mst b takn vr m o mak a cang I a cp so
g bwn t spacr, mplat angs p on som srac br
or o bmp , o wll tow o wol sqnc, an o mg
wll sta anw Wt caon an concnraton, o can mak a rg
spac orgnal comb tmpla a as onl onosant to wo
osants o an nc o rror n 1 t o mplatwto masrn
CURVED TEMPTE
Nxt, wl mak a smp crv mplat w a vrsng ras aga
sng MDF sock cnal a s o c a sk o o MD an s
bo t sk an sronng o" mara as stang ma
Monng a cv scton o sk ajacn to a crv scton o
ol" cras a ranson rom os to ns as a can b s
(Dpnng on ow xac o n to matc ra o ma n
actal c two skson w a slgtl sma ras tan o
to accon or cknss o k)
st mak a sk 6 n or so n am ot o �ntck M S
ol, as wll b s to mak t ns ras. Now scw
(or part o t) o a Y nck pc o M Tak a scon o o
mpla an scrw own on MDF an p agans t sk Transon om ns ras o t ots mst b mprcpb
o l a bmp o anng otr tan a smoo anson nal
tmplat wll nrt ct
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Now wih he wo emplae crewed o a lank head for he andaw
and c off he wae eaing lh in. or le o e flh rimmed Ue a pa
ern i and rm he maer een wih creweddown emplae he ro
ing emplae making (dik, ec) aemly, and andawing ake ime,
he proce eay
Cominng raigh and cred econ n he ame emplae preen
no pecal prolem. ayo and poiioning are ery imporan o he c
ce of he emplae and wil ake ome pracice o maer
Screw e subemaes emlaes used o make e maser down on e maser e
ansiion oiner) mus ave o erceibe defecs.
Bandsaw e wase rom e emlae base before rim mi ng e wo ayers flu s
Get a Dolar's Woth
Most trim mer cutters are 0
to 0004 in or so sma le
radis than their bearngs, so w
accont for this sm al "oset
oded dollar bi l ls (0004 in thi
This makes the window sightly
than the 2x4 Its transer to the
wil redce the m ortse agan-
experimentation may be necess
Makig Basic emplae
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TEMPTES FOR A SNUG FIT
2x4
178 Template Roung
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Rout a practic mortis though som scra Us a fnc scrwd to th bottom of th tmlat to idx th work cosistntly
Now wth he window emplate od out a home fo he quae na dawe bottom (o whaeve Le ' ut epea th poedue wth an
odinay tk fo a lit e paie ay a 2x
To impify he one fi in he final wokpee, fi ound ove a
fo one of the 2x with a 3-in-adi bi Make he window emplate
ng a /4-in-diamee bit o he adii of he one math up
Sew down ome -in. tagh eion of ap aond the 2x
map" a hown at ef Leave abou 0008 n op between he 2x and
the gide.
Wate the inde of he templae wih a j igaw and then flh ou
even wih he aight tempate Remove the ap gide and ae thewindow ono he wok J gaw o di ot the nde wate amp the
emplae in pae and m wth a h m bt
Making Basic Templaes
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18
Resources
Adjustable Clamp Co.417 N. Ashland AveChicago, IL 60622-6397(3 12 ) 666-0640Camps
Amana Too Corp1 20 Carolyn BlvdFarmingdale NY 1 1 735(800) 445-0077Router bits
Bruss FastenersO Box 88307Grand Rapids MI 49518-0307(800) 5360009Steel X-dowes
CMTO Box 4185Greensboro, NC 27404-4185(800) CMBitsRouter bits
De-StaCoO Box 2800Troy M 48007(81 0) 594-5600Toggle clamps
DeWat Tools701 E Joppa RdTowson MD 2 1 286(800) 4-DeWaltElectric power tools
Fein Power Tools, Inc301 9 W Carson StPitttsburgh PA 15204(412 ) 331-2325Electric power tools
Hampton House200 N Brewer StGreenwood N 46 142 -3605(317 ) 881-8601Katie Jg
Hitachi Power Tools3950 Steve Reynolds Blvd.Nocross, GA 30093(800) 706-7337Electric power tools
J&L Industrial SuppyPO Box 335 9Livonia, MI 481 5 1 -3359(800) 521-9520Machine tools
Jesada Toos, Inc3 10 Mears BlvdOdsmar FL 34677(800) 531-5559Router bits and accessories
JessEm Too Co1 7 1 Robert St East, Unit #8Penetanguishene ON L9M Canada(800) 436-6799Rout-R-Lift
Jointech1 1 72 5 Warfied StSan Antonio TX 78216(800) 619- 1288Joinery jigs and templates
Keler & Co1327 StPetaluma, CA 94952(800) 995-2456Dovetai templates
Leigh Industries, LtdO Box 357Port Coquitlan, BC U3 C 4K6Canada(604) 464-2700Dovetail and joinery jigs
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Makita Tools1 4930 otham Sta Miada CA 90638(800) 4-MakitaElectic powe toos
Micro Fence1 1 1 00 Cumpton St. #35N Holywood CA 91601(81 8) 766-4367Edge cicle guides ellipse make
Milwaukee Electric Tool1 3 1 3 5 isbon Rd.Bookfied, WI 53005(262) 781-3600Electic powe tools
Porter-Cable Corp.Box 2468Jackson T 38302(800) 368-1487Routes and othe potable electicwoodwoking tools
PRC73 1 -C Paso Robes StPaso Robles CA 93446(800) 238-6144Route bits
Reid Tool2265 Black Ceek RdMuskegon, MI 49444-2684(800) 253-0421ig hadwae
Ridge Carbide595 ew Yok AveLyndhurst, J 07071(800) 443-0992Reginding of oute bits
S-B Power Tool Co (Bosch)4300 W Peteson AveChicago I 60646-5999(877) 267-2499Electric powe tools
Taylor Design Group Inc.PO Box 810262Dallas TX 753 81(972) 418-481 1Inca jig
Veritas Tools, Inc.
1 2 East Rive StOgdensburg Y 13669(800) 871-8158Woodwoking tools, outeaccessoies
Patrick Warner1427 Kenoa StEscondido, CA 92027(760) 7 47-2623Acylic offset subbases and igs
W L. Fuller, IncPO Box 87677
Wawick RI 028 8(401 ) 467-2900Dilling tools
Woodhaven501 W 1st AveDuant IA 52747(800) 344-6657Router accessories
Resorces
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82
Index
Ix no pg frncs i ilcs ic phoogph o lusrio.
A
Accssois:
circ/lps cig, 69, 24, 1 5
cor gs, [9, 19 29-30, 1 , 32, 22, 1
ov/boxjo krs 28, 1 9 30
g guids 2, 1
nly kis 22-23, 1
pn ong, 2 8, 1
ortbs 16 27, 1, 28, 18 30, 1sbbss 9 , 19 , 2 , 6, 2
wch lss cos, 1 5
B
Brgg cus, 22-23, 2, 2, 5,
2627
Bvls, 3 , 8 , , 1 1 , 1 1 5 6
Bi�, , 82, 16 07
ccrcy of gid, 08, 19, 0 , 1 1
nickbc
bd ctng, 08, 4, 1 1, -6
bng n h midl 6, 1 1 6
brig o h boom 7 , 1 1 8, 1 1 8bng o h op 6, 1 1 6
bing yp 1 1 , 22-23 , 6 4, 1 1 ,
1 1 5
crb I l , 3 , 1 1
cu if - 2 , 1 1 3 , 1 1
dcoriv po curs 6- 7
ccy, 1 1, I I
shi 7, 7, 1 1 , 8, 1 18
u sign
highsp sl (HSS) 23 , 1 1
jory 9, 1 19 20
mulipc 20, 1, 1 1
oshr
pformnc of 07, 1 08, 18 09, 19,
0 , 1 1 pod, 1 1 22-23, 6, 4, 1 1
polycrysli iod (PCD 3
rgng cus, 2
sk of, 19
squcng s of 2
shnk d, 4
shpnss/shpning, I l , 2
spr groun
srgh 26
rou 89 159
pl oug 8
s cuttg 1 1
vbro 08, 18
Bck & Dc fxbs ours, 0,
Bln cus, 20, 29, 0, 1Bosch:
col g syst 30, 1 32
cu dph usm, 6 , 63
fxbs ous, 5 6, 9,9 , 5 1
5 3
min r routs 7, 6 83, 8
pung rours 66, 67
Box o n s 9, 1 28, 1 9 30
Bng, by cuttrs 2, 1 1 , 3
c
Chrng/cts wh bbrig crs
226
Chip colcing 6, 65 67, 30, 1Circs, 38, 9 69, 38, 18
Clmps/cms 66
Cib cuttg 9 98, 98, 99, , 15 1, 2
Col guids 8 22, 1
Cos 3, 2, 1 5 4, 15
Cop nd sck 9, 1 08, 9
Cfts Ss/Cfsn
Crossgi cug 7
Cutt phwy cool:
biggud 2223, 24, 2, 5
26-27
blin cus 20
cic cr s guid 38, 9
cor gs, 29-30, , 3 , 1 32,
dg gs 33, 3, 3, 5 36
fhd outg 40
gu sysms 1 22
sbbs s gu 36, 6 37
ool shnk s g 37 , , 38
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deph cus, 9-9, 97
determnig heght 88, 88
eecrica equipme, 8, 87
feed directin 0, 1
fence 9 , 91 92 ,9 93
ixedbase r plunge 89
hidde cutter, 9, 19
miter gauge 99, 99 00, 1
pteci frm cuter 93 9 9, 9 95
ruting cuvy w 9, 1 9 0
safety 000 , 1 1 02, 1 03, 1 1
0, 4, 17
smal w saey, 8, 18 49
sads 8 , 89
sartig ut, 0, 1 7
tablep materia, 90, 9
rappng the wrk, 02, 1 0 3, 1
twsep cutting 9 19
usg pluge ruters 2
Rutg:
appicatns, 8, 9, 0, 1 1 1
measured wasting f mateal 4, , 5
pwer equirements ,
types 2 9RuRLt 16 2
Ryb rues, 6, , 8
s
Safety 19 3
b g cuers 0, 15
chip clectg, 6, 65, 6, 30, 1
cimb cung, , 1 1 2, 1
cutters beakng 3
dry/w ces 4, 15
dust cn,
eye prtectin , 15
had ruters, 3, 1 4, 1 4, 15
46, 16 , 17health cnces , 15
hearng ss , 15
utbaance cute 4, 15
wers' mauas 1 1 4 2
puggng/unpuggng the rue, 6 165
practce cug, 68, 1 68 69, 1 69
ruter able safety feaures 93, 9 9, 9 95
sarg u n he uter table, 0, 1 7
stc preparatin, 2-3, 1
rapped cutter 4, 15
wrg hegh ad pstue,
Sears/Crafsma:
fedbase ruters, 46,
halfbld dveta jig 30subbases, 24
Shan beaingguded cuttes 26, 7 28, 8
29, 9
Shapers vs. ue abes 96
Slttng, 0, 69, 7
Spdle lcks, 6, 82
Spies, 9 1
Staring up the ruter
changig ruer bs, 6 , 1 67
feed drectn, 69 , 1 69
matera/sck peparatn 0, 1 1 8, 6 ,
165 66
pugging/upluggig, 6 , 1 65
practice cuttng 68, 1 68, 69 1 69
securng he w 66, 166 6
Sc prepaai 0, 1 1 8, 64, 16 66
Sps 0 93, 9, 95
Staight Oints 26
Subbases 36 6 3, 80, 8
Swiches 6, 6
T
eaut 89, 1 9
empae rutig 17 8, 18 9 , 40, 0, 1 7
clar gudes, 29, 32
curved template 6, 1 77
cus wih e template 3, 1 7, 1 7
edap, 36, 1 6wth ixedbase uters 6 5 9
fulthcess cuts 4
maea, 2-3
pin uting, 28, 1
pcedure - 1 7 6, 1 76
shank beagguded cuters, 26, 6
sugfttg templates, 8, 1 78, 9, 1 79
stragh empae
tabe rutig,
ts r mag templates 1 7 3
ons, , , 9, 1 69, 7 71
adusabe en maker 363, 17 , 3 8, 1 8
bts f 9
gs fr 3, 1 3, 15
gue ad gve 9, 1 08, 9
Trim ruting 6 7 2 , 3 , 1
22 0 vts 6
v
Vacuum, 6, 93
Vermnt Amecan subbases, 2
Vgrves 8
w
Wdhaven subbases 24
Wr hders, 66-6
Index
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or Evaluation Only.opyright (c) by VeryPDF.com Incdited by VeryPDF PDF Editor Version 2.6
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