Author Topic: Plexiglass router template  (Read 1220 times)

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Offline ear3

  • Posts: 4108
Plexiglass router template
« on: January 19, 2020, 05:33 PM »
Working on a commission where I have to do a bunch of spline joints in 2" thick boards, so since I have the Shaper, thought I'd work up my own version of the Routing Aid OF-OH 2200, which these days goes for $365 [eek].

Materials were a 12x36 sheet of 1/2 cast acrylic, a bag of 1/4-20 dowel nuts, with a thickness of .472" so that they didn't protrude from the sides, and some 1/4-20 knobs, all from McMaster Carr.  Total materials cost was $90 before tax and shipping.

Did holes in two positions each for the 2200 and the 1400 router, and made the opening 30mm, enough for a 1" bit.  I was considering making the opening wider to accommodate a 1 1/4" bit, but I don't know when I might want to edge rout a groove that wide -- if I ever need to, I can knock off another jig base now that I have the design.

Made the design in Fusion 360.  I didn't have exact measurements for the OEM jig, other than knowing that the material was 1/2, but I saw enough pictures to eyeball reasonable proportions and positioning.  Ended up making mine 14x7, with 3 1/2" sides.  The only tricky part was getting the positioning right on the drill press to add the holes into the edge of the sides for the knobs.  I initially hit the mark on only 2 of 4, and so had to expand the hole on the other two with a 17/64 bit to make sure the knobs lined up with the dowel nuts.  I also should have ordered 1 1/4" long knobs, rather than the 1 1/2" ones I ended up using -- instead of cutting them off shorter, I simply lengthened the hole on the underside of the cross-dowel nut.  I figured this would make the fit a bit more snug in any case.

I didn't include the extra vacuum hole in the back -- I figured that if dust collection were an issue, this could always be added later assuming I can get a similar dust port part as on the OEM jig (they don't seem to sell this as a separate part).  In any case, tests with the 2200 thus far have shown superior dust collection, so I'm not sure I'll even need to make the modification.

The one additional feature I added was a notch on center at the front and back of the jig to line it up with the center of the board.  I didn't add any kind of scale with which to set the sides, but I figure I will almost always be edge routing on center, and on those rare occasions where I have to go off center, I'm sure it will be simple enough to set the jig manually.

Tests thus far have been a success -- real application will begin sometime next week once I finish dressing the boards designated for work with this setup.

I'll probably be adding a post to the Shaper Origin forum with all the specs and files, but feel free to send me a PM if you want the files directly, which I'd be happy to share. Here's a link to the Project Files on the Shaper Forum.  It includes the original .dxf file if you want to modify anything.
« Last Edit: January 19, 2020, 10:40 PM by ear3 »
Kapex KS 120 w/UG Cart and Extensions • CXS Set • T 18+3 w/Centrotec Installer's Set • PDC 18/4 • TID 18 • TS 75 • TSC 55 • HKC 55 w/250, 420 and 670 FSK rails • Carvex 420 w/Accessory Kit • Domino 500 Set • Domino 700 XL • OF 2200 w/Base Accessory Kit • OF 1400 • OF 1010 • MFK 700 EQ Set • LR 32 • MFS 400 w/2000, 1000, and 700 extensions • Rotex 90 • Rotex 150 • LS 130 • ETS-EC 150/5 • ETS-EC 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • RS 2 • HL 850 • Vecturo OS 400 • AGC 18-115 • CT 26 w/BT module • CT Sys w/Long-Life Bag • MFT/3

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Offline rvieceli

  • Posts: 1224
Re: Plexiglass router template
« Reply #1 on: January 19, 2020, 05:49 PM »
Nicely done Edward.

Ron

Offline Svar

  • Posts: 2151
Re: Plexiglass router template
« Reply #2 on: January 19, 2020, 06:11 PM »
Well done with jig manufacturing.
However, I don't understand the purpose of the Routing Aid, if stock rods and 2 router edge guides on opposite sides provide exact same function at a fraction of the cost.

Offline ear3

  • Posts: 4108
Re: Plexiglass router template
« Reply #3 on: January 19, 2020, 07:30 PM »
Fair point. There might be certain operations, like routing an edge vertically (say a groove on the underside of a door that you have to lay flat), where the router aid provides more support?  Dunno, haven't worked with two edge guides so I'm not sure how it compares in those situations.



Well done with jig manufacturing.
However, I don't understand the purpose of the Routing Aid, if stock rods and 2 router edge guides on opposite sides provide exact same function at a fraction of the cost.
Kapex KS 120 w/UG Cart and Extensions • CXS Set • T 18+3 w/Centrotec Installer's Set • PDC 18/4 • TID 18 • TS 75 • TSC 55 • HKC 55 w/250, 420 and 670 FSK rails • Carvex 420 w/Accessory Kit • Domino 500 Set • Domino 700 XL • OF 2200 w/Base Accessory Kit • OF 1400 • OF 1010 • MFK 700 EQ Set • LR 32 • MFS 400 w/2000, 1000, and 700 extensions • Rotex 90 • Rotex 150 • LS 130 • ETS-EC 150/5 • ETS-EC 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • RS 2 • HL 850 • Vecturo OS 400 • AGC 18-115 • CT 26 w/BT module • CT Sys w/Long-Life Bag • MFT/3

Offline Michael Kellough

  • Posts: 4823
Re: Plexiglass router template
« Reply #4 on: January 19, 2020, 08:50 PM »
Well done with jig manufacturing.
However, I don't understand the purpose of the Routing Aid, if stock rods and 2 router edge guides on opposite sides provide exact same function at a fraction of the cost.

For making sliding dovetail joints, I’d much rather have a big jig like this.

Offline Cheese

  • Posts: 7514
Re: Plexiglass router template
« Reply #5 on: January 20, 2020, 10:47 AM »
Nice Edward...very nice. What size router bit did you use for the centering notch?

Offline ear3

  • Posts: 4108
Re: Plexiglass router template
« Reply #6 on: January 20, 2020, 12:23 PM »
Thanks.@Cheese I created the notch in the original design to be on center and it was milled in the original profile of the base. But of course, due to slight variations with router positioning, ive discovered that it is about 1/64th off center of my 2200. Going forward ill probably just compensate by drawing the center line off by 1/64th.

Theoretically, I suppose one might design one specifically for the 1400 or 1010 that incorporated the hold down features of the LR32 such that it would allow centering the collet on the hole, and therefore assuring dead on center alignment.

Quote author=Cheese link=topic=61784.msg598144#msg598144 date=1579535232]
Nice Edward...very nice. What size router bit did you use for the centering notch?
[/quote]
« Last Edit: January 20, 2020, 12:29 PM by ear3 »
Kapex KS 120 w/UG Cart and Extensions • CXS Set • T 18+3 w/Centrotec Installer's Set • PDC 18/4 • TID 18 • TS 75 • TSC 55 • HKC 55 w/250, 420 and 670 FSK rails • Carvex 420 w/Accessory Kit • Domino 500 Set • Domino 700 XL • OF 2200 w/Base Accessory Kit • OF 1400 • OF 1010 • MFK 700 EQ Set • LR 32 • MFS 400 w/2000, 1000, and 700 extensions • Rotex 90 • Rotex 150 • LS 130 • ETS-EC 150/5 • ETS-EC 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • RS 2 • HL 850 • Vecturo OS 400 • AGC 18-115 • CT 26 w/BT module • CT Sys w/Long-Life Bag • MFT/3