Thread: easy to build router insert plate WIP video

not sure if the MDF is going to be stiff enough as the router is heavy so it will start to sag.

Originally Posted by Gaza

not sure if the MDF is going to be stiff enough as the router is heavy so it will start to sag.

I made one like that a few years ago and it wasn't stiff enough, but I screwed lengths of aluminium angle to the MDF each side of the router base and that fixed it.

The opening seems to be too large for that small straight bit. Got to be extremely careful that the work piece or worse the fingers don't get into that hole while the router is spinning!

4mm perspex is much better than MDF in my opinion as you can see the work while you route. I made 1 down at the community shed only last week (after i broke the old one trying to get a stripped head screw out!) 4mm perspex is nice & stiff too. I used essentially the same method except i didn't cut out the router bit hole manually, i loaded in first a small pointed bit & plunged the router thru the perspex then chucked in a larger bit & repeated, 1 more larger still bit & the hole was done. The key with routing thru perspex is VERY SLOW SPEED & slow gentle plunging. Don't forget protective eye glasses (should be wearing them anyways!), the router can throw out hot perspex chips especially if you plunge too fast. Then finish up by cleaning up the rough edges & you're set to go!.