Really Easy - DIY - Adjustable Router Template
Introduction: Really Easy - DIY - Adjustable Router Template
This is how I made a REALLY EASY!! - DIY - ADJUSTABLE ROUTER TEMPLATE This is a must have tool in and wood shop! This router template is used for routing dados in wood, and routing square or rectangular shapes, it is extremely useful and can be made in an hour with basic tools
Supplies
Materials used in this build (Amazon Affiliate links)
Kregg T-Track https://amzn.to/3GnmrYM
Diablo Hole Saw Kit https://amzn.to/3q5Hhq1
(you only really need the 2 inch hole saw) https://amzn.to/336TYbG
(4) Kregg Self Adhesive Measuring Tape R-L (Metric) https://amzn.to/3t9qdkO
OR
(4) Kregg Self Adhesive Measuring Tape R-L (Imperial) https://amzn.to/3n6ojO8
(4) 2.5 inch Power Tec T-Track bolts https://amzn.to/3JSwWWr
these T-bolts I had and that are listed in the materials for this are slightly too wide for this T-Track to work you will have to file them down a tiny bit. I used a disc sander and it only took a couple seconds but a file will also do the job safely.
(4) 1/4 inch hex nuts and washers
3/4 inch (#6) wood screws for attaching the T-Track
3/4 inch plywood (enough to make at least 4 pieces 3 inches wide by 24 inches long)
Tools used in this build
Table saw or track saw
Drill press
Drill
2 inch hole saw https://amzn.to/336TYbG
Self Centering Drill Bits https://amzn.to/3fgPTUy
1/4 in drill bit
Hand saw
Step 1: Cut Wood
Cut out the 4 pieces of plywood 3 inches wide.
Step 2: Cut Wood Again
Cut the 4 plywood pieces to 24 inches long or however long you want the template to be.
Step 3: Mark and Drill
Mark a line down the centre of all 4 pieces of plywood on only one end and drill a hole at least 2 inches deep in the centre of the line on each piece with the 1/4 inch drill bit. ( it is perfectly reasonable to use a slightly larger drill bit for this step too nothing bad will happen to your project )
Step 4: Mark and Drill Again
On the end of each piece you drilled the hole in mark the centre of the wood at 1 3/4 inches from the end. this is going to be the centre of where you drill with the hole saw.
Then drill the holes using the 2 inch hole saw and a drill press. 493
(only on the one end of each piece that you already drilled the 1/4 inch hole in.)
Drill only half way through the flip the wood and drill the rest from the opposite side this will prevent tare out on the plywood.
Step 5: Cut Plugs
Cut your plugs in half. Take note of where I have the saw blade placed in the photo on one side of the hole.
(you only need 4 halves so pick the best ones)
Step 6: Cut You T-Track
Only if you need to cut your T-Track to your desired length Kregg T track comes in several pre cut lengths so you can buy the correct length and skip this step.
*Aluminum is soft and will not destroy your saw blade just make sure you are wearing eye protection
Also these T-bolts I had and that are listed in the materials for this are slightly too wide for this T-Track to work you will have to file them down a tiny bit. I used a disc sander and it only took a couple seconds but a file will also do the job safely.
Step 7: Assemble Bolt Section
Assemble the T-bolt sections as per the photo
Step 8: Mount T-Track
Mount the T-Track on the edge of one side of each piece of the plywood.
Use the self entering drill bit to pre drill the holes this will help the wood to not split when you drive in the screws!
Step 9: Assemble!
Put your Template together!
Step 10: Stick on Rulers
Stick on your 4 Sticky tape rulers. They are metal but you can snap them easily by folding them over a straight edge. I tried to show myself doing this step in the photos but it makes a lot more sense if you see it in the video I have embedded at the top of this instructable.
Step 11: Used Your Template! 56