Plexiglas Router Template DIY

[Mauri Motti]

After I found this thread from 2008 I was thrilled. Ordered a 12 mm lexan A4 sheet from ebay UK and went to work. Still waiting for a 20 mm lexan sheet for the fences.
Four knobs and the jig bolts I ordered from my Festool dealer (EKAT). Although I'm obviously not ready yet, I am so eager that I had to post it.  [embarassed]

I have cut the A4 sheet to size using my TS 55 on the MFT. Furthermore followed almost all instructions by member Cannuck (Rob, for which many thanks!) from Canada. What I did different was drilling a 30 mm center hole and I scribed my lines, drilled the hole and routed the slots with the plastic protection cover on the lexan sheet. Also, I used the OF 1400 with the parallel side fence instead with the parallel guide, which I do have but I figured that the shorter the distance from the side of the plastic sheet to the to be routed slots, the better. This worked very well but as Cannuck mentions in his post, clamping the sheet down firmly is a must! If I would have to do one again, I would do all these slight differences again.

Also useful readings I found were this and this one

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Kind regards, Mauri   [big grin]

 

[Frank-Jan]

Looks nice sofar.

I like how you put the hole in the centre of the jig, on the original there's a 30 mm difference between the centre of the routerbit and the different edges of the jig.
I use mine almost exclusively on door-edges, (multipoint locks, automatic doorsweeps, groves for pocketdoor bottoms, and also, frontplates for standard doorlocks).

When I do the frontplates I mark the edges of the lock, then I mark the edge of the OF FH on the door, so I can easily see where to start/stop. When doing multiple doors it's nice when you can just mark those lines, measured relatively to the centre of the handle. But, due to the off-centre-ness, you have to be carefull which way you put the jig on the door.

 

[justinmcf]

hi mauri.
that looks like a beautiful job you are doing!

what blade did you use for cutting the 12mm lexan sheet?
was it the fine tooth blade or aluminium blade?

which drill bits did you use for the 30mm centre hole?
was it the forstener bit shown in the photo?

and did you use a spiral up cutting bit for the slots?

thanks for sharing, justin.

 

[Mauri Motti]

hi mauri.
that looks like a beautiful job you are doing!

what blade did you use for cutting the 12mm lexan sheet?
was it the fine tooth blade or aluminium blade?

which drill bits did you use for the 30mm centre hole?
was it the forstener bit shown in the photo?

and did you use a spiral up cutting bit for the slots?

For cutting the lexan: Ts 55 with Festool 48Teeth blade.
I have used the groove cutter HW D6/14 bit (#461689) that is one of the bits in my Festool BOX-OFS8 router bit set (495478), the only router bits I own. Although I'm very, very happy with the set (is NAINA right?) But... there are many more bits I'd like to have.
Indeed, the forstner bit as shown in the image I used for cutting the center hole, with my T12. A drill press would have been perfect for the job but I only have a hand cranked drill press and it wasn't sufficient enough.

thanks for sharing, justin.