URGENTLY need bushing guide larger than 30mm !!

[Intex]

I dont want to make a story long, but...
I need to route a piece of hardwood at least 3/4" in some areas, using a router jig that uses a 30mm router bushing to seat the router on its carriage. I purchased everything and tried it, and found that my OF-1010 router was not powerful enough to work correctly with 1/4" bits. So I purchased the larger router with a 1/2" shank, and a bowl/tray bit with a 1/2 shank.

When I went to assemble everything, I found that the collet for the 1/2" bit would NOT fit thru the inside diameter of the 30mm Bushing Guide. SO... I purchased 2 collect extensions, but found that neither of them would fit thru the bushing guide, so I am left with just the 2 1/2" long bit, that will only cut about 1/4" into the wood, before the collect hits the bushing, and will not go down any more. This is further hindered by the fact that the jig carriage sits 1 1/2" above the wood surface top start with.

My options are : ???
1. Get a larger bushing guide and then drill out the 30mm carriage hole to fit the larger guide - My problem is I can not find a larger guide than 30mm

2. Get a longer shank bit - Also can not find one longer than 2 5/8"

3. Find  a CNC machine that can do this and have someone else make it for me - this defeats the whole purpose of making this

ANY recommendations would be greatly appreciated, since I cant think of how to solve this?

 

[RKA]

The jig is 1.5”??  Is there any way to reduce that?  Templates aren’t usually that thick for this reason, it eats up your plunge depth.

 

[nclemmons]

Not clear what you are trying to cut.

Could you not use a top bearing guided router bit with a template?

Something like this -
https://www.toolstoday.com/v-9812-45489-s.html

 

[Intex]

It is not just a template, but a template with travelling plate, and it is used to cut grooves in wood kitchen countertops, so it has bottom rails that are tapered, so both the rebate and groves are cut at an angle. I tried making a makeshift jig, but it didnt work out as well as this has for other woodworkers

 

[Intex]

See attached pic

 

[ear3]

Festool makes a 40mm guide bushing
https://www.amazon.com/Festool-492186-Template-Guide-40/dp/B0017V9HKA

 

[Cheese]

I’d take issue with the fact that the 1010 is unable to handle a 1/4” router bit. The 1010 is designed around the the 1/4” and 8 mm router bits. So if it can handle a 8 mm router bit it will certainly handle a 1/4” router bit.

I’ve used the 1010 to mill aluminum stock and it wasn’t a problem.

If you need to hog out a 3/4” depth, do it in steps. I’d do that depth in 1/4” steps.

The 1010 is definitely an over achiever...not an under achiever as you suggest.

 

[Intex]

There is a misunderstanding, I did not mean the the 1010 could not do 1/4" bits, I meant it could not do 1/2" shank bits, which is what the manufacturer of the jig recommends.

 

[Intex]

Ear3:
I did not see that 40mm guide bearing. Unfortunately it only works with the OF-1400, and I have the OF-1010, and just purchased a Titan router just for this job. I could not justify the cost of the OF-1400 just for this job, as I usually am fine with the OF-1010 for handheld use and Bosch for the table router.

I can not find a 40mm bushing for the titan or any other popular router such as P-C, Makita, Bosch

 

[ScotF]

https://www.amazon.com/Festool-486034-Template-Guide-Model/dp/B001JBIYV6/ref=sr_1_20?keywords=40mm+router+guide&qid=1564118975&s=hi&sr=1-20

Looks like they have one for the 1010 too.

 

[AlexThePalex]

My options are : ???
1. Get a larger bushing guide and then drill out the 30mm carriage hole to fit the larger guide - My problem is I can not find a larger guide than 30mm

2. Get a longer shank bit - Also can not find one longer than 2 5/8"

3. Find  a CNC machine that can do this and have someone else make it for me - this defeats the whole purpose of making this

        4. Drill holes in the router carriage so you can attach it with screws to the base of your router.

 

[Cheese]

If you have a lathe, metal or wood, you could make an adapter.

If you have a drill press, you can also make an adapter using various sized hole saws.

If the difference between the guide bushing you have and the guide bushing that you need isn’t that different, then several wraps of electrical tape may work.

Again, Kapton tape, which is a hard plastic, comes in varying thicknesses and widths, is not as soft as vinyl electrical tape and has a very aggressive adhesive. It could also be used for incremental diameter changes.

FWIW...I’ve used a 3/4” diameter Whiteside bowl bit on my 1010 for routing out HVAC covers. I also have a 40 mm bushing for my 1010.

Another option is to purchase a Musclechuck for the 1010 which is capable of holding a 1/2”
diameter bit.

 

[Intex]

Does anyone know what the size diameter is on the collet nut n the OF-1400 router .
I would like to see if the collet will fit thru a 30mm guide bushing.

I investigated online and found that a Triton and Bosch would fit, so I purchased one of each, only to find that the dims online are incorrect, and would not work with my jig

I am now thinking that instead of mounting a 30mm guide bushing on the router base, I will see how I can attach the router base not the jig’s carriage plate, after all the bits are installed, thereby avoiding having 5o use a guide bushing to attach 5o he carriage plate

 

[Stone Message]

I am 99% certain that the Festool 1/2" collet fits inside the Festool 30 mm Guides for both the OF1400 and OF2200 - I am unable to get at either right now.

Peter

 

[Bob D.]

Mine measures 29.70mm, so yes its less than 30mm but that's the OD of
the bushing correct?

 

[Stone Message]

The body of the collet fits into my 30 mm guide bush but the nut part of the collet does not.

Peter

 

[Michael Kellough]

I looked at the manual for the Trend DG/Pro. It’s pretty good as far as manuals go (light years beyond Festool manuals).

There is a list of compatible routers that fit Trend’s universal sub-base UNIBASE.

“Fits following router models
Atlas Copco OFSE2000 Bosch GOF 1300ACE, 1600A, 1700ACE Casals FT2000VCE DeWalt DW625EK,
629 Draper R1900V Elu MOF 31, 77, 98, 131, 177(E) Felisatti TP246(E), R346EC Festo OF2000E Freud FT2000E Hitachi MI12V, M12SA, TR12 Makita 3612BR, 3612(C) Metabo OF1612, OFE1812 Performance Pro CLM1250R >11/2003, CLM2050R Ryobi RE600N, R600N, RE601, R500, R502 Skil 1875U1 T-TECH TT/R127 Wadkin R500”

“To obtain a perfect accurate close fitting joint, a 30mm guide bush must be used. The guide bush must always be fitted concentric with the cutter. This can be achieved using a Universal Sub-base and 30mm outside diameter guide bush ref. GB30/A.”

The troubling thing about the Trend DG/PRO Jig manual is that the copyright date is 2018 and the only Festo router in the list went out of production years before.

The manual also lists Trend router bits suitable for the jig’s purpose.

Seems like you just need a longer router bit. You haven’t revealed what kind or size cut you want to make or how far beyond the jig’s design you want to push.

 

[Stone Message]

I was not quite clear before about the collet and the guide ring. I hope the following pictures help. It is the nut that fits inside the guide ring and the circular boss which does not - it means that there is no issue using the collect shown with the 30 mm UJK guide bush.

View attachment 1

View attachment 2

View attachment 3

View attachment 4

Peter

 

[Michael Kellough]

Good on UJK for including such clear and comprehensive dimensions with the kit.

 

[Mike Goetzke]

Good on UJK for including such clear and comprehensive dimensions with the kit.

If only it came in Imperial..... [big grin]