Routing New projects

“There is a need to re-think how the router can be used”. When designing a project we must consider how the material is to be held secure.

One method I have developed, is the ‘Jig Holder’, capable of holding the material and the template securely in position, without nailing them both together. Jig holders are designed to suit the size of the material to be cut. Some are long and narrow others are small rectangular or square. Other ‘Special’ Jig Holders and Jigs are constructed for special projects i.e. inserting hinges,/ routing mortice and tenon joints,/ cutting circles with the router,/ routing elliptical shapes,/ Routing a tapered leg, etc. Each jig is designed to make routing Safer, and produce the project quicker and more accurately, and in most instances with a better ‘finish’ eliminating a great deal of sanding. It will be necessary to have a number of template guides at your disposal to complete the projects.

Photographic samples of projects are published here simply to demonstrate there is a need to construct the Jig Holder (Box) to hold the jig,/ material,/ and template secure, if you wish to produce projects of this type. (How else can it be achieved?)

Cams: In many of the projects shelf supports have been shown to hold the material secure during the routing process. Latest method of securing the material is to produce eight ‘Cams’ and place two at each corner. The development of the cams will enable a greater variety of material of different sizes.

Here the cams are positioned in readiness to rout the twelve sided clock. (See the article on the 12 sided clock)

Small Cabinet doors
The CNC router has introduced a number of projects which were considered impossible to achieve with the standard plunge router. The kitchen cabinet doors are a typical example of one of the projects. With an increase in the size of the standard jig holder shown previously, it is possible to produce doors 720mm high and 450mm wide. Once the use of the template guide has been mastered there are numerous other designs to choose from. The procedure adopted is the same no matter what size of door is required.

Small Boxes
The construction of the small boxes will require a number of templates and a number of new routing techniques if they are to be constructed with safety. See the article on routing the small boxes

Partitioned ‘Heart’ shaped boxes can be cut from solid timber with the aid of the same standard 400 x 300mm Jig holder. This box requires a number of template to be produced to complete the project

Making or Buying Jigs:
Jigs may not be available for purchase to complete the project you may wish to produce, therefore it will be necessary to design and construct you own. Jigs templates and template guides will introduce greater Safety Awareness and improve the standard of finish on many projects.

Support your Router

There are a number of simple jigs suitable for providing this support, which will assist in obtaining a better finish to your work and also add safety awareness to your routing procedures

Consider the problem
When starting and finishing a cut, less than 25% of the base of the router is supported, and during the stroke less than 50% is resting on the material. (This is another advantage of having a circular based router, you will have the maximum support, but it is still not enough.)

What are the alternatives?
1 Screw a piece of material to the base of the router, this material is the same thickness as the piece to be routered. This method is illustrated in many books and magazines and is considered standard procedure for supporting the router.
(The procedure is used, only when routing the external edges of your material on a flat surface)

2 Place a strip of material the same thickness as the material to be cut along the side to rest the router. If the material is loose it has a tendency to move. (Unless a large piece is used and can be clamped in position.) The support material should be longer than the project material to give maximum support to the router at the start and the completion of the cut.

3 Router Support:
Make a ‘Router Support’ that can be easily attached to the router, one that will be suitable for a greater variety of material thicknesses. This support is easier to adjust and saves time locating and screwing a piece to the base of the router .
(You will always have constant support for your router.)

4 Simple Router Support
Routing the edge of the material with such cutters as the ‘Rounding over’ bit or ‘rebate cutter’, it will be necessary to ensure the router has maximum support. The ‘Router Support’ illustrated can be attached to the ‘Side Fence Attachments’ supplied with a number of routers. Prepare a suitable piece of material that can be added to the fence support with the screw provided.
The shape can be cut with the band saw, scroll saw, bow saw, or coping saw, and the slot can be drilled and completed with the chisel. The support can be adjusted to suit a greater variety of materials thicknesses. With the ‘Router Support’ in position it will be easier to control the router and also easier to adjust the plunge depth

5 Router Support New Design
This support will also give more stability to the router and it will not be necessary to use the side fence attachment supplied with the router. Purchase two rods 300mm long with the ends prepared as shown in the diagram. The space between the slots are designed for the Makita and Hitachi ½” routers and therefore it will be necessary to make the alterations to the design to suit the router that the support is to be fitted to. The distance between the slots should be made to suit the rods for the router to be used.

Having the support in position will also assist in applying equal pressure to the two router columns, therefore improving the ‘Plunging Mechanism’. Material suitable for the support can be cut from 16/18mm M.D.F., 19mm solid timber or Plywood. There are still other means of supporting your router for consideration.

Constructing a set of ‘Skis’ will add greater safety awareness and produce a better finish to the project.

Skis in use
Once the cutter has been locked at the required depth, the router with the skis attached, can be controlled from the support position which will give greater control of the router.
Sectional view through the ski mode in action to trim the external edge when routing the final stages for the base of the Elliptical Trinket Box. This is an alternative method of trimming the material, no need to place the router in the router table.

Basic Routing Procedures

strong>Routing a rebate or trench, is possibly one of the first processes you will attempt with the router. Take time to follow the proper procedure, to introduce safety with the router.
If you do not have access to a router table, rebates and grooves can be cut with the aid of the Side Fence Attachment.

Before attaching the side fence add a piece of timber 400 x 25 x 19mm to the fence. Secure the modified side fence attachment with the two thumb screws located on the router base. The side fence should be inserted from the right hand side as you face the front of the router. Plunge the router until the cutter is in contact with the material and lock the motor carriage.
Place the router on its side and set the depth of cut required by placing a piece of material (the same thickness of the depth of cut) between the plunge stop and anvil. (Note; Drills can be used to regulate the depth settings).
Grooving: This is the term used when a groove is made parallel to the long edge of the material, usually cut with the grain. (Trenching refers to grooves cut across the grain).

Select a Suitable Cutter: The cutter selected for this process will depend on the thickness of the material to fit into the groove. Setting the depth of the groove is the same procedure for routing the rebate. Once the depth of cut has been set the distance in from the edge of the material is set before releasing the cutter into the safety of the router housing. (Make any fine adjustments with the ‘Fine adjustment screw’)

Cutting the Groove: With the router base resting on the material and the side fence tight against the edge, plunge the router with the cutter clearing the end of the material. Push the router away from you to begin cutting the groove. Do not pull the router towards you. >strong&gt

Have the Cutter in View: Position yourself to have the cutter in full view as you rout the groove. Inspect the cut for any imperfections and if necessary repeat the procedure to make any corrections;

Safety Procedures

Routers can be considered dangerous if mishandled. Follow basic safety instruction on the use of the router will help to ensure your safety and those around you.

On / Off Switch
Before making any adjustments to the router such as inserting a cutter, switch the router off, and isolate the machine from the power supply. All machines should be connected through a ‘Safe’ outlet such as the ‘Ring Grip’. .Safety with the Router
Eye protection should be worn at all times, such as ‘Safety Glasses’ or a full ‘Face Visor’ Some form of protection for your ears, such as ‘Ear Muffs’ or ‘Ear Plugs’ should be worn at all times. Dust Masks should be worn, especially when using such materials as Medium Density Fibre. MDF. 

Rotation of cutter
It is important to make yourself familiar with the rotation of the cutter. This is usually displayed on the surface of the router body or base. Feed the router in an ‘Anti-Clockwise‘ direction when cutting an external edge. Feed the router in a ‘Clockwise’ direction when using Female Templates and Template Guides (Guide Bushes).

‘Push’ or ‘Pull’ the Router.
From personal experience, you have more control of the router when it is being pushed away from you. It is also Safer to push rather than pull. Place yourself in a position to see the cutter in action. Avoid moving the router across your body from left to right and certainly not from right to left on the front edge of the material.

Safety procedures
When the cutter is projecting below the base of the router, care should be taken when laying the router on the bench. This usually is the situation when the cutter has been locked at a certain depth of cut. Routers when used in the ‘Below Bench Position’ are usually switched in the ‘ON’ position and therefore when it is removed from the router table and it will be necessary to turn it ‘Off’ before making any cutter changes. It is necessary to check the on/off switch position each time before use, as some switches can be accidentally switched on when storing the router after use. As standard procedure the switch should be checked each time before re-connecting the router to the mains supply.

Try to do most of your routing in the ‘Plunge Mode’, and return the cutter into the body of the router before it is switched off. The depth of cut can be controlled with the aid of the ‘Turret’ and Depth Stop. To select the depth of cut place material between the stop and anvil, the thickness of the required depth of cut.

Turret.
Most routers have a ‘Three stage turret’, which will allow you to control the depth of cut each time. The turret can be rotated to select the depth of cut required. Check that the screws on the turret are tightened and locked properly each time before routing, as they have a tendency to vibrate loose when in use. It is important that ‘Small’ cuts are taken to reach the ‘Final’ depth. The final cut should be 1/2mm to remove the imperfection from the previous cut.

Show at least 5-10mm of ‘White metal’ of the cutter shank. It is important to ensure that at least 3/4 of the cutter’s shank length is held in the COLLET.

Pushing the cutter too far up into the COLLET engaging the ‘Fillet’ of the cutter, will damage the end of the COLLET and may cause the cutter to drop out.

Routers supplied with two spanners.
Care should be taken not to damage the columns of the router when changing cutters. Construct a simple jig to rest one of the spanners on. With the aid of this simple jig, the spanner is not in contact with the router columns.
Holding the material secure.

There are a variety of methods of securing the material during routing procedures.
(1) Clamping to the bench
(2) Special holding devices.
(3) Router mats (not always a sure method of holding material).
(4) Double-Sided Tape . Take care there are a variety of tapes available.
(5) Constructing a Jig holder. (This will hold the material and the Jig secure when in use)
(6) The ‘Mini Mach Vacuum Bed’ not only holds the material steady, it grips itself to the workbench, when in use.

 

Purchasing a New Router

Plunge or Fixed Base:
A router is basically, a high-speed motor fitted with a chuck for holding a cutting bit securely in position. The ‘Housing’ surrounding the motor and cutter, support the router and the accessories that can be fitted to it.
Making the decision to buy:
Before purchasing a router speak to someone that can advise you on how the router functions, and how the various accessories that are available will increase your routers’ potential.

Reason for the router we have today;
(1) A friend recommended the brand name and model.
(2) There was a ‘Special’ on at the time.
(3) Observed an interesting article in a magazine, that looked easy to make, which required the use of a router.
(4) It was given as a present on retirement, on your Birthday, at Christmas or handed down from family or friend
(5) I was told the large router would be too heavy
(6) I always purchase the same brand of Tool.

When selecting a router some users select the same brand of tools they have been using for years, because of the success they have had with such tools; Jigsaw / power saw / planer etc.

‘What I look for’ when selecting a router

Plunge Router;
The plunge router will enable the cutter to retract into the body of the router when it is not in use, therefore adding safety to your routing procedures. First preference would be to purchase a router with 1/2” chuck suitable to take 1/2” shank cutters.
The 1/2” Router when used in the plunge mode with the aid of template guides and jigs has maximum support for the weight

Circular Base:
Select a router with a Circular Base. Circular based routers will provide greater support when routing the edge of the projects. The base of the router can also be used as a template guide. (Some router bases are not circular and have two flat sides with curved ends)

Template Guides. (1)
The router should have the ability of attaching ‘Template Guides’ to the base of the router. Some guides are screwed in position others are attached by means of a Bayonet fitting.

40mm Template Guide:.(2)
It is important, the router should be capable of accepting a wide range of template guides. The 40mm Template Guide illustrated should be readily available for purchase

Router Table The router should be easily adjusted for height when fitted to the router table. If your choice of router is to be placed in the router table exclusively then it is strongly recommended that the Triton Router should be the used for this purpose.(1).

The position of the on/off switch The switch should be located in a convenient position with easy access when holding the router with the handles/knobs. 
Note; Some on/off switches also have a safety button incorporated in the switching on/off mechanism. Special arrangements must be made to hold the switch in the “ON” position when the router is being used in the ‘Below Bench Position’.

Router Base Opening:
The size of the opening on the base is important. Too small will restrict the size of the largest cutter that can be used. Too large  will reduce the support to the router especially at the beginning and the end of the router cut. The opening should be large enough to fit a 40mm Template guide to the base. There should also be a clear view of the cutter during the process.

Position of the Locking Lever:
The locking lever should be easily accessible, without having to remove your hand from the handle to lock and unlock the router carriage. This locking action will hold the cutter at a selected depth with the aid of the ‘Turret’. (When the router is used in the ‘plunge mode’ the locking lever is not required to be locked)

Three Way Turret:
The turret stop has been designed to rotate, to allow the operator to control the depth of each cut in stages. Routers with a six way turret are now available to allow the operator to rout each cut in a greater number of stages. If your router has a three way turret as illustrated it is strongly recommended that the two longer screws illustrated in the photograph are reduced in length to leave a difference in height of 3-6mm.

Variable Speed Routers:
Since the introduction of variable speed routers has added greater safety awareness enabling the reduction in speed when large cutters are used, or when other materials are required to be cut such as plastic or aluminium. These routers usually have a ‘Soft’ start and a ‘Braking’ system incorporated.

Dust Extraction:
Consideration may be given to what type of dust extraction system is incorporated in the router. Some routers have a system where the dust is extracted through one of the router columns and others are attached to the base with the aid of two screws. The shape of the base may be altered to accommodate the system through the column.

Introduction to the use of the template guides

“For years we have been ignoring one of the accessories supplied with our router when it was first purchased”. Tom O’Donnell
Template Guides (Guide Bushes)
We have seen a brief mention of how the guides are used when routing dovetails, producing a Mortice and in the construction of a number of trenching exercises. They have also been illustrated when working with templates to reproduce an article which would be slightly larger than the template (Male template). Very little information has been published on how the template guide is used with ‘Female Templates’. It is simply a matter of understanding how to calculate the ‘Offset’ and the various templates that require to be constructed.
Template guides are manufactured in a variety of diameters, and each manufacturer has devised their own method of attaching the guides to their brand of router, some are screwed in position others are fixed with a bayonet type fitting. ‘Special’ Template guides may be required for that special project. (30mm guide with an added bush to change the diameter to 35mm)
Trend ‘Unibase’ ‘Unibase’ suitable for most routers (hence the number of holes in the base) manufactured in the U.K.  by ‘Trend’ is available for purchase with a selection of Template Guides,
The Unibase is capable of accepting a large range of template guides. (Template guides are supplied separately)
Template Guide Survey From a number of recent independent surveys conducted, the smaller guides 16.17.18mm, are used most frequently. The 40mm guide is seldom used. [40mm (1-37/64”) Template Guide:] With this introduction I hope to encourage greater use of the guides.
Four good reasons for the purchase of the 40mm Guide:
Most cutters are visible to the operator during the process.
There is a greater selection of cutters that can be used, therefore increasing the variety of projects that can be completed.
The ‘Swarf’ will clear more readily. There is less danger of the cutter overheating. (Photograph below)
The chuck from most routers will penetrate through the template guide to give the extra plunge depth required using small ¼” cutters.

The cutter can also be inserted into the chuck with safety, without the need to ‘Crimp’ that extra bit to achieve the desired depth of cut. There are a number of projects that can be completed with greater safety if the template guide is used with the router in the ‘Plunge’ mode. It will be necessary to consider alternative methods of routing to hold the material and prepare jigs and templates. The template guide is used with a ‘Male’ or ‘Female’ template. The templates are constructed from 9-12mm Medium Density Fibre Board (MDF) The templates can be laminated with such material as ‘Laminex’ ‘Formica’ on both sides to add strength and reduce wear when in use.
Jig Holder In all routing procedures it is necessary to hold the material firmly during the process, this can be done by constructing a simple Jig Holder. Internal dimensions of Jig Holder 400mm(15-3/4”) x 300mm (11-15/16”) x 40mm (1-37/64”)
The Jig Holder can be used for a great variety of projects.
Small cabinet doors with raised panel, Inlays, Curved legs for a wine table,12 sided clocks and bowls, Elliptical trinket boxes and frames, Heart shaped boxes and frames etc etc etc.
The complete write up is available free of charge on how to construct the rectangular picture frame all I require is an email address and I will forward your copy. Note; This has also been published on My CD-ROM 2

Note: This now available for downloading in Why Template Guides

Why Template Guides

http://templatetom.files.wordpress.com/2006/12/xxx-intro-to-template-guides-a5-size.pdf
The Template Guide supplied with the side fence attachment, and the trimming guide was one of the accessories included with my router at the time of purchase. There has always been a limited amount of information available with the publication included with the router, on how each accessory was to be used. Many books and other publications are readily available to gain information on how the side fence attachment and the trimming attachment are used. Unfortunately the template guide had been neglected and in most instances was placed in a drawer or cupboard, and seldom if ever used by the average router user.

Because we have neglected to pursue the potential of the template guides we have not been able to achieve the best results from our router. With access to a large collection of template guides of different diameters will ensure a greater number of projects that can be produced, such as the trinket box.

Template guides are used regularly when working with templates to produce the final section slightly greater than the template produced. The template has to be secured to the material with either nails or screws which leave holes to be filled when completing the project. Some double sided tape can also be used depending on the strength of the selected brand.

To calculate the various off-sets that are required when using the guides, measure from the external diameter of the guide and the external diameter of the cutter. Working with Metric guides and cutters is more convenient. Selecting the 40mm guide has a number of advantages which has been explained in the chapter ‘Introduction to Template Guides’.

Producing projects with the aid of the template guides will introduce a greater safety awareness to the use of the router.

Click on the url above This has been printed as an A5 brochure

Get More From YOUR ROUTER

http://templatetom.files.wordpress.com/2006/12/blogs.doc

As the heading states ‘Get more from your router’

In my opinion this is only possible with the aid of the guides. One of the guides I use on a regular basis is the 40mm diameter. To this extent I persuades Makita Australia to return the guide as an accessory with their New Router 3612 (This was a few years ago) I am convinced that those who may have purchased that model still do not know how to use the guide because Makita did not include instructions on how it was to be used. Read the article on Why template Guides and hopefully it will give you all the information you require to get the full benefit from your router.
I have produced CD-ROM 2 and CD-ROM 3 to give further examples as to how the guides are used introducing a number of great projects. I am also in the process of producing the same material on DVDs for those who are not into computing

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