Need advice

[Chris In Milwaukee]

Nope, doubt it will ever be an issue. Once everything is bolted together for routing, friction will hold it all together nicely.

Yep, no need to drill the corners when routing. The corner will be naturally round.

[MNBenny]

Well I ko'd the router


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[MNBenny]

Not cutting them by hand. So I guess it's on hold now.





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[Chris In Milwaukee]

I went through one myself.

[MNBenny]

Went out and bought a new 2hp router from harbor freight. It can hold bit sizes up 1/4" - 1/2"


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[Bcone1381]

Bushings...I inserted bushing into my form blocks and made them from a $5 piece of generic steel brake line. I think I used 3/16" jig pins to hold the form blocks and the rib blanks together. I cut my 2.5" long 3/16" DIA jig pins from a long piece of steel rod I got at the hardware store. The Brake line fit the jig pin nicely. I think the brake line was 1/4" Ouside Diameter. I would insert the bushing again into my form blocks, but I would want the bushings in place before I drilled the jig pin holes into my aluminum rib blanks.

[Chris In Milwaukee]

Bushings...I inserted bushing into my form blocks and made them from a $5 piece of generic steel brake line. I think I used 3/16" jig pins to hold the form blocks and the rib blanks together. I cut my 2.5" long 3/16" DIA jig pins from a long piece of steel rod I got at the hardware store. The Brake line fit the jig pin nicely. I think the brake line was 1/4" Ouside Diameter. I would insert the bushing again into my form blocks, but I would want the bushings in place before I drilled the jig pin holes into my aluminum rib blanks.

Thinking outside the box. Good stuff

I'm thinking about the jig pins in question. Did you have your forms pinned together before routing? Seems like you'd want to squish them together to hold them firmly together. I used 3/16" screws with washers and wing nuts.

[Bcone1381]

Yes Chris, you are right, When routing I used 3/16" screws with the head countersunk below the surface of the MDF pattern instead of the pins. I think I had the steel inserts in place for piercing the rib blanks to prevent hole enlargement during the drilling action.

[Chris In Milwaukee]

Gotcha. Good idea. I tried a few things but didn't find anything that worked as a bushing. I just tried to be careful. Now I know for future projects :-)

[MNBenny]

That's the new router I bought. $48 at harbor freight...not bad.

I will look for generic brake lines tomorrow provided the hardware store is open...1/4" outside diameter 3/16" inside diameter

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[MNBenny]

Ok new problem...looks like we can't mount that one upside down....


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[Chris In Milwaukee]

Your going to want a laminate bit, not that one. Laminate bits have a bearing on the end that will follow your pattern. You'll chew your pattern up with that bit.

[MNBenny]

I have a quarter inch laminate bit already. I was just showing what came with it. Is anyone else using this exact router? Were you able to mount it upside down?


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[Chris In Milwaukee]

Ok new problem...looks like we can't mount that one upside down

You can route from the top, but it'll take some thinking to make sure everything stays put and doesn't move around while routing.

[Chris In Milwaukee]

I have a quarter inch laminate bit already. I was just showing what came with it

Ok, cool

[MNBenny]

Dad was just saying that very same thing. He's thinking of away to secure it all. I'm only going to do one at first to see how it works before stepping up to 3. Let me see..........to get a 1/2" router bit or not to get a 1/2" router bit.....that's the question


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[MNBenny]

I just hope I don't have to remake these


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