rout rectangular hole in 1" maple tabletop?

[Iwood75]

I'd like to use my OF1010 router to route a rectangular hole in a maple table top. Is the router capable and will a 1/4 bit with pilot going to do the job?
I'll be making a template (4 sided frame) for the bearing to ride against. It'll be at least 1" thick so the bearing has a surface to ride on for the full depth. OR, can I delete the frame after about 1'2" and then let the bearing follow the already routed edge the rest of the way down? Thanks for any tips! I can't afford a new top if I screw this up.

 

[tjbnwi]

Your process is fine. Use a down cut bit. Once the cut is deep enough you can use the top as the template.

Leave about 1/32" on the bottom, tap the slug out. You don't want the slug to break loose and jamb the bit.

Tom

 

[Iwood75]

Thanks Tom. Have another question... Can I get a downcut bit with a top bearing? And it would have to be 1/4" shank to fit in the 1010. Joel

 

[Green Mojo]

When I have done this, I routed into the table top and then used a jig saw to cut the center out. Then I used the router to clean up the edge. Saves some wear and tear on the router.

 

[tjbnwi]

Thanks Tom. Have another question... Can I get a downcut bit with a top bearing? And it would have to be 1/4" shank to fit in the 1010. Joel

You can get a 1/2" o.d. beraing with a 1/4" i.d., add a pair of collars, one top one bottom.

Tom

 

[Iwood75]

By "collars", do you mean bearings? And, how can it plunge cut if it has a bearing at the bottom? Sorry, but I've gotten confused by your answer. I thought I would buy a bit with a bearing already at the top. Didn't realize that you can add bearings to bits.  Joel

 

[tjbnwi]

I see how my answer could be miss read. One collar above and one collar below the bearing. They all go above the cutting area of the bit. Here is one supplier, make sure you get 2 collars.

You'll have to make your template with an offset to make up for the differences in diameter.

Other choice is use a 1/4" shank, 1/2" bit with 1/2" bearing.
http://www.eagleamerica.com/product/v196-0810k/maint_-_bearings_and_rub_collars

Tom

 

[Holmz]

Alternatively one could drill 4 holes at the corners, or use a jig saw for sharp cornered hole. A corner chistle would also help, and a rasp.

If the hole is blind, then an 8-mm shank would be stronger than 6-mm or 1/4"... if the 1010 takes 8-mm bits (?).

 

[Peter_C]

Not sure how big this rectangle cut out is but...What about using a track saw? At full plunge it will barely leave anything in the corners and will produce a fairly clean cut. It will be as square as you set it up to be. Use a stop!

You can double stick ripped 1/4" thick stock, like Lexan, MDF, etc, for use as a router template. Cut them longer than your rectangle (They overlap) and instead of using a follower bit use a template guide bushing. Just account for the difference. That way you can plunge a little at a time as you make your cuts. 1" of Maple will take at least a few passes.

Honestly I wouldn't have the most confidence in a 1/4" bit that long with a bearing on it.

 

[rvieceli]

I think it would be most helpful if you let us know exactly what you are trying to do. How big is the cut out going to be?

Depending on the finished size there are other methods that may work better. If the resulting void is big enough then you may get better results by using a jigsaw to cut it undersize and then using a router to clean up the edges.

 

[mastercabman]

Thanks Tom. Have another question... Can I get a downcut bit with a top bearing? And it would have to be 1/4" shank to fit in the 1010. Joel

I don't think you can
Most down cut bits are solid piece
So in your case you will need a bit that is 1/2"  with a 1/4" shank whitch I have never seen
You could look into using a bush guide

 

[tjbnwi]

Thanks Tom. Have another question... Can I get a downcut bit with a top bearing? And it would have to be 1/4" shank to fit in the 1010. Joel

I don't think you can
Most down cut bits are solid piece
So in your case you will need a bit that is 1/2"  with a 1/4" shank whitch I have never seen
You could look into using a bush guide

Explained the process in post #4.

Other option is 1/4" bit with 1/4" bottom bearing, mount template on bottom of table, drill hole run bearing on template. Issue with this is the sly may come loose if your not real careful.

I agree, bushings are an option also.

Tom

 

[rst]

Start with one of thesehttp://www.toolstoday.com/p-5675-dado-clean-out-router-bits  Amana 45489-S
Finish with these ww.toolstoday.com/p-5046-flush-trim-plunge-template-router-bits-w-upper-ball-bearing I use Amana 45461

 

[mastercabman]

Thanks Tom. Have another question... Can I get a downcut bit with a top bearing? And it would have to be 1/4" shank to fit in the 1010. Joel

I don't think you can
Most down cut bits are solid piece
So in your case you will need a bit that is 1/2"  with a 1/4" shank whitch I have never seen
You could look into using a bush guide

Explained the process in post #4.

Other option is 1/4" bit with 1/4" bottom bearing, mount template on bottom of table, drill hole run bearing on template. Issue with this is the sly may come loose if your not real careful.

I agree, bushings are an option also.

Tom

Tom
I read post#4
But down cut spiral bit are solid bits
If you use(let say 1/2" bit) the shank will need to be 1/4" so that the bearing slide onto the 1/4" shaft
But I have never seen a bit like that with a smaller shaft
If you can post a picture or a link to what you are referring to

 

[Iwood75]

Thanks for all the info and ideas. Seems I'm complicating it by trying to use my small router for this project. I already have a 1/2" flush cutting bit with a 1/2" shank and bottom bearing so I'm going to experiment with doing it upside down on my router table. The piece I'll be routing is a 30"x30"x1" and the hole will be 5"x15" with 1/2" radius corners. I don't prefer to move a piece this large around the table (never done it before), but I'll test it out before spending so much time and money on finding/buying bits for my 1010 router.
Does the router table seem a good idea or am I asking for trouble trying to spin such a large piece on the router table? Thanks again for your input. I really appreciate the support.  Joel

 

[Peter_C]

That is not a BIG piece, but rather a larger piece. Do it on the router table with a 1/2" shank, 1/2" cutting follower bit. Use a jig saw to precut the middle out, and maybe even the tracksaw on the long sides. Yes I do love my tracksaw. You can use a track or fence to keep from cutting too much material at once on the router table, if needed.

 

[Holmz]

The roller-bearing units look cool. Most of the time a guide bush is as good, but that was mentioned by [member=4105]tjbnwi[/member] , You cannot get a square hole with a round bit.
One usually needs a chisel, a jig saw, a drill, or a morticing machine.

I am assuming it is large for a sink cutout and does not matter, or it is small for cables or a leg to go through the table top.

 

[tjbnwi]

To achieve a 1/2" radius you need to make your template with 1/2" radius corners or use a 1" diameter bit.

I would drill 1" holes in the corners (Fostener bit, turn it backwards a few revolutions with pressure on the drill before drilling forward), place a track to cut the short sides, clamp it down and use the kick back pawl to keep the saw in place, plunge the saw until the blade just enters the drilled holes, at 5" you won't be moving the saw. Move the track to the long sides, start at one hole, move the saw forward to the next, make sure you use the pawl. Any area that did not cut through use a hand saw or jig saw to remove the piece.

If you did a neat job, you could run a top bearing bit in the router to clean up the opening, set the top of the bearing to ride right along the top edge of the cut out.

Tom

 

[tjbnwi]

Thanks Tom. Have another question... Can I get a downcut bit with a top bearing? And it would have to be 1/4" shank to fit in the 1010. Joel

I don't think you can
Most down cut bits are solid piece
So in your case you will need a bit that is 1/2"  with a 1/4" shank whitch I have never seen
You could look into using a bush guide

Explained the process in post #4.

Other option is 1/4" bit with 1/4" bottom bearing, mount template on bottom of table, drill hole run bearing on template. Issue with this is the sly may come loose if your not real careful.

I agree, bushings are an option also.

Tom

Tom
I read post#4
But down cut spiral bit are solid bits
If you use(let say 1/2" bit) the shank will need to be 1/4" so that the bearing slide onto the 1/4" shaft
But I have never seen a bit like that with a smaller shaft
If you can post a picture or a link to what you are referring to

Collar-bearing-collar.

Tom

 

[mastercabman]

Thanks Tom. Have another question... Can I get a downcut bit with a top bearing? And it would have to be 1/4" shank to fit in the 1010. Joel

I don't think you can
Most down cut bits are solid piece
So in your case you will need a bit that is 1/2"  with a 1/4" shank whitch I have never seen
You could look into using a bush guide

Explained the process in post #4.

Other option is 1/4" bit with 1/4" bottom bearing, mount template on bottom of table, drill hole run bearing on template. Issue with this is the sly may come loose if your not real careful.

I agree, bushings are an option also.

Tom

Tom
I read post#4
But down cut spiral bit are solid bits
If you use(let say 1/2" bit) the shank will need to be 1/4" so that the bearing slide onto the 1/4" shaft
But I have never seen a bit like that with a smaller shaft
If you can post a picture or a link to what you are referring to

Collar-bearing-collar.

Tom

OK
But that's not a flush cut set up
I thought the OP was looking for flush copy bit?