Anyone ever use a router and pattern bit?

[kynetx]

I was thinking that making some Masonite templates for tricky stuff like jack baffles and driver rings and using a router and pattern bit would yield more consistent results. Anyone try anything like this? How did it go?

[Harley]

I use a top bearing bit and make my patterns out of ply.

You have to be diligent using them and ensure the router has stopped before lifting it out of the workpiece.

Be prepared to damage your patterns at first until you get the hang of it. Using ply means you just use a bi of bondofil to repair the damage and 15 minutes later you're back in business.

I used the collar type template followers and found they were too much of a hassle and too inaccurate. Making the patterns was also difficult as you had to deduct or add the 2mm distance between the collar side and the blade of the bit.

[DJPhatman]

I was thinking that making some Masonite templates for tricky stuff like jack baffles and driver rings and using a router and pattern bit would yield more consistent results. Anyone try anything like this? How did it go?

Leland @ speakerhardware sells router templates for handles, OTop ports(built-in handles) and jack plates. I use the Jasper Circle cutting jig on my router, and AntonZ built his own jig. The circle cutting jig is the way to go for any round cut. Very easy to set up and use.

[Radian]

At the last fab shop I worked at, we used just this method for cranking out detail aircraft parts (angles, brackets, mounting plates, zigzags, widgets, etc...) We used a freakish pneumatic router (circa 1940's) that followed patterns sculpted out of 6061 aluminum plate. The pattern sandwiched the workpiece against the cutting table, which meant if you weren't totally on the ball that day, the router might just flip up out of the clear blue and take a nice notch out of the fancy template. The tool and die machinists loathed me for the first year I worked there. A visit from me meant another F'd up pattern. So Harley's got a point....make a few copies of your templates right off the bat (easy enough to do) , if you decide that templates are your bag.

Welding department didn't seem to mind as much....must have been the complimentary beer I offered up in exchange for the extra work orders generated.

[LelandCrooks]

Anyone try anything like this? How did it go?

Constantly. I have patterns for damn near everything that requires something more than a table saw. I sell some, that were designed by Tim. They're currently off the site, as some more need to be made.

Make a master, then make another. Set the master aside, never use it unless you screw up your work template.

My current favorite bit. It requires you to drill a hole and cut through the top of the workpiece and work blind with the pattern, but it's better. Cuts 1/2 ply like butter. It's also a $100 bill for just the bit.

[bzb]

I use Masonite/hardboard templates quite a bit. For the driver ring, I made a jig like this:

http://www.woodworkingtips.com/etips/etip102000sn.html

Used just like a compass. After I made the first one, I figured I'd be doing it more, so I just made another out of plywood as a template. Unfortunately, I burned up my top bearing pattern bit, so I've been using flush trim bits like Leland has above.

For the handle, I have a double-sided template that has a 1/2" edge on one side. This is so that the handle cutouts are equidistance from the corner.

[SoundInMotionDJ]

Make a master, then make another. Set the master aside, never use it unless you screw up your work template.

+1,000,000

The master template is made with excruciating precision...and is NEVER EVER used to make a part.

--Stan Graves

[kynetx]

OK, cool. Now I just gotta get a router. =)