WOOD Magazine – October 01, 2019

66 WOOD magazine October 2019

Create identical parts

Bushings excel for pattern routing. Shape a

template from plywood, hardboard, MDF,

or acrylic and use it over and over to pro-

duce identical pieces. Because of the offset

between the bit and bushing, the bit traces a

slightly larger version of the template [Photo

C]. To calculate this offset, take the guide

bushing’s O.D., subtract the bit diameter,

and divide by two. Note that to create identi-

cal pieces, you must use the same router bit

and bushing each time. Switching either, or

both, changes your results.

Rout inlays

Create beautifully fit inlays with an inlay kit.

It pairs a guide bushing with a collar matched

to a specific-diameter bit. The collar compen-

sates for the bit diameter and the offset

between the bit and collar. Inlays routed with-

out the collar [Photo D] fit perfectly in recesses

routed with the collar in place [Photo E]. Sand

or plane a slight chamfer on the bottom of the

inlay, then glue it in place.

Rout shelf-pin holes

Make perfectly spaced holes for shelf pins

with a shop-made template and a plunge

router. To make the template, drill a series of

holes matching the bushing O.D. into a

piece of plywood, MDF, or acrylic. Space the

holes as desired for the shelf pins. In your

plunge router, install the bushing, and a

spiral upcut bit that matches the shelf-pin

diameter. Set the router depth stop so the bit

reaches the desired depth below the tem-

plate. Clamp the template onto a workpiece,

register the bushing in a hole, and plunge

the bit down to create a dead-straight shelf-

pin hole [Photo F].

Create a template to shape the recess and inlay. This one creates a bowtie inlay to

accent a door panel. Either rout through the material or resaw to release the inlays.

Slip the collar onto the bushing, and, using the same bit and template, rout the

recess. For straight-edged inlays, such as this one, chisel the corners straight.

Make your own template to fit a guide bushing, customizing the template to the

number of holes and the hole spacing desired.

D

E

F

Template

Workpiece

Template

Calculate the offset between the bit and barrel, then size your template to
account for that offset.

C

Template

Learn more about

choosing straight bits

on page 58.