Now I feel like David Marks with all the templates, but it was the only way I could think of that was fool proof. By fool proof I mean that you can’t wander with the router and cut off what you didn’t want to.
I needed to make three paper patterns. One for each of the cuts I will be making. Here are two of them taped to the template before cutting.
.
.
.
.
.
.
These were made from the corners of MDF like the one for the outside. I had to leave more material on the outside edge so that when I applied pressure with the router if didn’t flex away. They don’t look pretty but they turned out pretty good where they counted.
These gave me a chance to use my scroll saw which sits neglected in my shop most of the time. Then some sanding and filing and the edges were perfect (as far as I could make them anyway).
.
.
.
.
Then since I wouldn’t be able to see my lines in the top, once I starting removing material, to line things up I drilled a hole to allow me to see through. Then just extended my line into the hole. This is one of the reasons I am going to save cutting the outside radius until last. Otherwise it would remove my lines from the outside edge.
.
.
.
.
Here you can see part of the rough cut just to make clearance for the other bits. I just used the flat router bit with one of the wider templates. Now here I don’t want to remove too much material from the surface because I still want to use it to support the router base when I route the outside radius. That will be the last thing I do before removing all the material from the inside.
.
. 
.
.
Here’s one of my 2 rarely used plunge routers, set up with my router guide insert and flat bit. You can also see why I left so much material on the templates. I have to have room for the clamp.
.
.
.
.
Now because of the diameter of the 1/4” radiusing bit I couldn’t use a router guide insert like a did above, so I had to do something different.
I had to add a bearing to the bit. Luckily the bearing from the other bit I am going to use would work. See the larger diameter shank on the blue bit? Well, that was because the inside diameter of the bearing was 5/16”. So to get it to work on my 1/4” shank red bit I had to make a sleeve to the shank to increase the diameter. Now I just happen to have a metal cutting lathe so I just made one.
.
.
.
.
The next time you see this I should have the entire inside edge done and show you how I remove the rest of the material from the inside.
-- Gary, East TX -- The longest journey begins with a single step.
15 comments so far
pommy
home | projects | blog
978 posts in 590 days
posted 207 days ago
outstanding gary as always but then i can only dream of being half as good as you thank you for the posts and please keep them up i’m learning so much for your work
Andy
-- cut it saw it scrap it
PurpLev
home | projects | blog
2764 posts in 547 days
posted 207 days ago
nice progress. templates ARE the safe way to go… make it once. and it’s good for a while
-- When in doubt - There is no doubt - Go the safer route.
a1Jim
home | projects | blog
17115 posts in 476 days
posted 207 days ago
Looking good Gary I can’t wait to see the finished top. Great work
-- Jim from Heirloom Woodshop, custom furniture ,maker, woodworking school, heirloomwoodshop.com
Greg
home | projects | blog
227 posts in 207 days
posted 207 days ago
Templates and jigs add so much versatility to using a router. Your table wil look so very unique and nice when completed.
-- Each and Every step of any project should be considered your masterpiece if you want the finished product to reflect the quality of your work. Greg Little
patron
home | projects | blog
2462 posts in 240 days
posted 207 days ago
oh the things we learn through our ( and each others ) mistakes !
nice save .
cant wait !
-- david ,new mexico ,allheart
Bob #2
home | projects | blog
3055 posts in 920 days
posted 207 days ago
Looking good Gary.
How did you figure out the pattern fit for the circle diameter or do you have to fudge the edges a bit to get a fit?
Bob
-- A mind, like a home, is furnished by its owner
TopamaxSurvivor
home | projects | blog
3070 posts in 574 days
posted 207 days ago
Very interesting process. Nice to see a master in the act :-))
-- Debt is nothing more than the 21st Century's form of slavery.
Rj
home | projects | blog
570 posts in 530 days
posted 207 days ago
I was wondering how you were going to do the recessed area of the top ? Looooking goood .
Thanks again for the step by step.
-- Rj's Woodworks,San Jose & Weed Ca,
GaryK
home | projects | blog
9539 posts in 887 days
posted 207 days ago
Bob – I always figure things out with AutoCAD first. Then I print one or more pages in 1:1 scale and tape them together as required.
-- Gary, East TX -- The longest journey begins with a single step.
Scott Bryan
home | projects | blog
20784 posts in 720 days
posted 207 days ago
Gary, you have an innate ability to take a complex process and reduce it to a seemingly simple step wise approach. This has been an interesting series to follow.
-- With God's help all things are possible- even woodworking. Woodworking is not just a hobby, it is an (expletive deleted) expensive hobby.
lew
home | projects | blog
4506 posts in 654 days
posted 207 days ago
Great Blog, Gary!!
The idea of leaving material on the outside edge of the template is something I will have to remember!! Now that you have the templates, you will have to make more than one table! (unless you’re like me and have a shop full of one-of-a-kinds)
Lew
bluchz
home | projects | blog
143 posts in 272 days
posted 207 days ago
Amazing Gary, thanks for posting the process.
Russel
home | projects | blog
2065 posts in 838 days
posted 207 days ago
Remarkable work. I wish I had your meticulous nature.
-- Working at Woodworking http://www.VillageLaneFurniture.com
Les Hastings
home | projects | blog
953 posts in 672 days
posted 207 days ago
Great project and blog Gary. Good to see your getting some quality time in.
-- Les, Wichita, Ks. (I'd rather be covered in saw dust!)
Woodhacker
home | projects | blog
1145 posts in 622 days
posted 207 days ago
Good stuff Gary. I actually have autocad software…just haven’t taken the time to learn to use it….This makes me rethink that. Going through this blog series, is providing fuel for various ideas for using these techniques.
Thanks for taking the time to post this series.
-- Martin, Kansas