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Router Use 101

 
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pacificpainting(at)comcas
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PostPosted: Mon Nov 06, 2006 2:45 pm    Post subject: Router Use 101 Reply with quote
I hate to admit this, but since I don't have to face anyone I will. After all these years, I don't really know how to use a router. Should I buy a book? Basically what I need to know is, if I want to make a wood die so I can make some aluminum cover to seal a gap between a pipe and the surrounding metal, how do I do it? Do I cut out a metal one first and then use it to cut around or what? The question seems kind of confusing to me too. This seems really simple, but I don't get it. I would appreciate any suggestions, or at least most of them.

Dave in Salem
[quote][b]

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ron.butterfield(at)gmail.
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PostPosted: Mon Nov 06, 2006 4:26 pm    Post subject: Router Use 101 Reply with quote
On 11/6/06, Dave Ruddiman <pacificpainting(at)comcast.net> wrote:
Quote:

Basically what I need to know is, if I want to make a wood die so I
can make some aluminum cover to seal a gap between a pipe and the
surrounding metal, how do I do it?

There are three basic ways to get an exact cut with a router:
bearing
pilot
jig

The bearing mounts on (is part of) the actual bit, and rides against
whatever is used as a template.

The pilot (bushing) mounts to the router, and surrounds part of the
bit a fixed, exact amount.

The jig (straightedge, circle template, pantograph, whatever) either
mounts to the router body, or clamps to the workpiece and the router
is then run against it.

Only the first two are easily applicable to most of what we are trying
to do, and the bearing is usually simpler. The pilot is offset from
the bit (o.d. of pilot minus o.d. of bit /2) which has to be
calculated and laid out on whatever you are using for a guide.

Bearings can be either the same size as the bit, or offset. Layout
will be simpler if you choose a bit with a bearing the same size.

So, first you have to lay out on something (maybe a piece of plywood
without any voids) the design of the parts you are trying to make.
Then cut it out with either a bandsaw or jig saw, making sure to stay
outside the lines. Then, use a disk sander to smooth the cut edges
exactly to the lines. You now have a template.

Then, you cut out the blanks for whatever you are trying to make
(aluminum plate for nose ribs, form blocks for ribs, whatever) and
clamp (or bolt, or screw) them to the template.

Then, you run the router around the template to cut the blank(s) to
accurate shape. Keep in mind that the router bit spins clockwise
looking down on it (handheld router), so if you go around the template
in a counterclockwise direction the spinning of the bit will hold the
bearing tight against the template.

This guy:
http://www.bkfliers.com/
has some very detailed construction photos of doing exactly that in
his build logs.

--
Regards,
RonB

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jd(at)lawsonimaging.ca
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PostPosted: Tue Nov 07, 2006 6:03 am    Post subject: Router Use 101 Reply with quote
Ron Butterfield wrote:

Quote:
This guy:
http://www.bkfliers.com/
has some very detailed construction photos of doing exactly that in
his build logs.


So does this guy ;')

under the 'Homebuilding Tips & Tricks' section of
http://cleco.ca
Regards, J.

flying: Zenith STOL CH701/912 C-IGGY, 350 hrs.
building: Sonex #325, Jabiru 3300/6, 85% completed

+-------------------------------------------------------+
| J. Davis, M.Sc. | (computer science) |
| *NIX consulting, SysAdmin | jd at lawsonimaging.ca |
| c/o Brandywine Aviation | voice: 519.289.1527 |
| 5507 Irish Dr., Appin, ON | http://www.cleco.ca |
| N42 47.33 W081 36.50 31/13 | 2000+ x 60', elev: 740' |
+-------------------------------------------------------+

To most people the sky is the limit.
To those who love aviation, the sky is home.

A teacher once said to me, "We all bring joy to
others...sometimes when we enter a room, sometimes when
we leave...". I wonder what he was trying to tell me...

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