grbmds said:
Getting a top done using a CNC seems to me to be the only way to get complete accuracy. The Festool tops are expensive but accurate. Doing it even with a template seems risky. If any holes aren't exactly drilled right accuracy will suffer. I think we all like the concept of finding a way to create jigs and these Festool tops on our own, but I'll stick with Festool's tops for now. The dogs and clamping kits are a great idea though and, especially the clamping kit would make securement of parts easier and faster, especially for assembly but cutting also.
I myself have been able to accurately duplicate many high tolerance needed templates over onto another board very successfully ,
It's all about getting solid stable reference points , with a new MFT top & these parf dogs (or any pair of the other threaded dogs bolted from the top then the underside ) as long as there at least two reference points it can be drilled OR use of a good high tolerance trim cut router bit .
I like the trim cut bits (1" deep ones) as the cut is precisely perpendicular to the top surface . I myself have been very satisfied that I can repeat this all day long on production work , Yes I have to predrill a hole that allows the bit & bearing to enter but the way it cuts the risk of a plunge bit not staying in reference is gone .
this is where a non-plunge router is useful , I have one Porter Cable 890 router that is it's only function , the use of the trim cut-off bits at just over a $100.oo for the PC on sale it's a no brainer single use tool , with 3 flute cut-off bits , I end up with a very fine cut surface . I'm not saying this is the best way but I have been able to duplicate a template to where you can't tell which piece is the template when I'm done
Everyone has their own processes that they are comfortable with & If you feel you can't do as I do that's great go the CNC route . It's a what works for you is the best method .