I dont want to make a story long, but...
I need to route a piece of hardwood at least 3/4" in some areas, using a router jig that uses a 30mm router bushing to seat the router on its carriage. I purchased everything and tried it, and found that my OF-1010 router was not powerful enough to work correctly with 1/4" bits. So I purchased the larger router with a 1/2" shank, and a bowl/tray bit with a 1/2 shank.

When I went to assemble everything, I found that the collet for the 1/2" bit would NOT fit thru the inside diameter of the 30mm Bushing Guide. SO... I purchased 2 collect extensions, but found that neither of them would fit thru the bushing guide, so I am left with just the 2 1/2" long bit, that will only cut about 1/4" into the wood, before the collect hits the bushing, and will not go down any more. This is further hindered by the fact that the jig carriage sits 1 1/2" above the wood surface top start with.

My options are :
1. Get a larger bushing guide and then drill out the 30mm carriage hole to fit the larger guide - My problem is I can not find a larger guide than 30mm

2. Get a longer shank bit - Also can not find one longer than 2 5/8"

3. Find  a CNC machine that can do this and have someone else make it for me - this defeats the whole purpose of making this

ANY recommendations would be greatly appreciated, since I cant think of how to solve this?

Not clear what you are trying to cut.

Could you not use a top bearing guided router bit with a template?

Something like this -

https://www.toolstoday.com/v-9812-45489-s.html

See attached pic

I’d take issue with the fact that the 1010 is unable to handle a 1/4” router bit. The 1010 is designed around the the 1/4” and 8 mm router bits. So if it can handle a 8 mm router bit it will certainly handle a 1/4” router bit.

I’ve used the 1010 to mill aluminum stock and it wasn’t a problem.

If you need to hog out a 3/4” depth, do it in steps. I’d do that depth in 1/4” steps.

The 1010 is definitely an over achiever...not an under achiever as you suggest.

Ear3:
I did not see that 40mm guide bearing. Unfortunately it only works with the OF-1400, and I have the OF-1010, and just purchased a Titan router just for this job. I could not justify the cost of the OF-1400 just for this job, as I usually am fine with the OF-1010 for handheld use and Bosch for the table router.

I can not find a 40mm bushing for the titan or any other popular router such as P-C, Makita, Bosch

My options are :
1. Get a larger bushing guide and then drill out the 30mm carriage hole to fit the larger guide - My problem is I can not find a larger guide than 30mm

2. Get a longer shank bit - Also can not find one longer than 2 5/8"

3. Find  a CNC machine that can do this and have someone else make it for me - this defeats the whole purpose of making this

        4. Drill holes in the router carriage so you can attach it with screws to the base of your router.

Does anyone know what the size diameter is on the collet nut n the OF-1400 router .
I would like to see if the collet will fit thru a 30mm guide bushing.

I investigated online and found that a Triton and Bosch would fit, so I purchased one of each, only to find that the dims online are incorrect, and would not work with my jig

I am now thinking that instead of mounting a 30mm guide bushing on the router base, I will see how I can attach the router base not the jig’s carriage plate, after all the bits are installed, thereby avoiding having 5o use a guide bushing to attach 5o he carriage plate

Mine measures 29.70mm, so yes its less than 30mm but that's the OD of
the bushing correct?

I looked at the manual for the Trend DG/Pro. It’s pretty good as far as manuals go (light years beyond Festool manuals).

There is a list of compatible routers that fit Trend’s universal sub-base UNIBASE.

“Fits following router models
Atlas Copco OFSE2000 Bosch GOF 1300ACE, 1600A, 1700ACE Casals FT2000VCE DeWalt DW625EK,
629 Draper R1900V Elu MOF 31, 77, 98, 131, 177(E) Felisatti TP246(E), R346EC Festo OF2000E Freud FT2000E Hitachi MI12V, M12SA, TR12 Makita 3612BR, 3612(C) Metabo OF1612, OFE1812 Performance Pro CLM1250R >11/2003, CLM2050R Ryobi RE600N, R600N, RE601, R500, R502 Skil 1875U1 T-TECH TT/R127 Wadkin R500”

“To obtain a perfect accurate close fitting joint, a 30mm guide bush must be used. The guide bush must always be fitted concentric with the cutter. This can be achieved using a Universal Sub-base and 30mm outside diameter guide bush ref. GB30/A.”

The troubling thing about the Trend DG/PRO Jig manual is that the copyright date is 2018 and the only Festo router in the list went out of production years before.

The manual also lists Trend router bits suitable for the jig’s purpose.

Seems like you just need a longer router bit. You haven’t revealed what kind or size cut you want to make or how far beyond the jig’s design you want to push.

Good on UJK for including such clear and comprehensive dimensions with the kit.

Hi @Intex

I have had a thought...

Is your dilemma due to the fact that the cutter you want to use is bigger than the clear space within the guide bush? This would mean that you have to be able to access the collet nut with the cutter already below the guide bush.

Peter

I suspect that the jig has been designed to work with cutters that fit through the 30 mm guide. I have never seen the jig before and would probably make something up of my own if I only had one or two jobs to do that needed it.

Peter

FWIW, I made a jig to do our draining board. I only had 18mm MR-MDF at the time so I ended up having to work around the loss of plunge depth... and I only had the 1010 at that time so I was starting from not the greatest of places.

Wealden do some 8mm long shanked core box bits which got me there in the end. With light passes the grooves turned out surprisingly well considering the 100mm long shank.