In an attempt to eliminate rust from my router bit shanks this is what I came up with. I started with the festool foam insert for storing my router bits. Though rusty shank became an issue with this setup so I switched to bit holders from Lee Valley. Didn't care for the combo bit shank option from Rockler, though less expensive. Sent them back.http://www.leevalley.com/us/wood/page.aspx?p=50697&cat=1,46168,69435,46180
I use AutoCAD to create my insert/hole layout templates. Then print at 1:1 on 13' x 19" paper using my large format printer. I cut the insert base from 3/4" birch plywood using a 1/4" hardboard template. Cut with jigsaw and cleanup with template bit on router table. I drilled the bit holder mounting holes on a drill press. I tape my printed hole layout to the insert base and drill my holes directly through the paper template. Coated the plywood insert with 4 coats spray Spar poly.
Router Bit kit: Router bits (of course) 1/4", 1/2", 8 mm shank. Pitch/resin remover, rust/stain remover, brush, bearing lube, scotch bright, allen keys & bearings/screws (in an old pill bottle) and a small rag. My remover solutions are Boeshield stored in small spray bottles I found at a local Walmart. As a rust prevention I use Zerust Plastab cards with great success. Each 1x3 card has a protection radius of 7" for 2 years.http://www.zerustproducts.com/products/electronics-tools-parts/plastabs/
I use AutoCAD to create my insert/hole layout templates. Then print at 1:1 on 13' x 19" paper using my large format printer. I cut the insert base from 3/4" birch plywood using a 1/4" hardboard template. Cut with jigsaw and cleanup with template bit on router table. I drilled the bit holder mounting holes on a drill press. I tape my printed hole layout to the insert base and drill my holes directly through the paper template. Coated the plywood insert with 4 coats spray Spar poly.
Router Bit kit: Router bits (of course) 1/4", 1/2", 8 mm shank. Pitch/resin remover, rust/stain remover, brush, bearing lube, scotch bright, allen keys & bearings/screws (in an old pill bottle) and a small rag. My remover solutions are Boeshield stored in small spray bottles I found at a local Walmart. As a rust prevention I use Zerust Plastab cards with great success. Each 1x3 card has a protection radius of 7" for 2 years.http://www.zerustproducts.com/products/electronics-tools-parts/plastabs/