Router Offset Jig

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Project by Karson posted 11-04-2008 12:20 AM 4558 views 5 times favorited 17 comments Add to Favorites Watch

While working with making the counter tops for my kitchen out of Corian, I became aware of my inability to hold the router flat on the surface for the entire time that I was doing pattern routing and edge routing.

So I figured it was time to make an Offset jig.

Since I have a surplus of Corian from the kitchen project, I decided to make the jig out of Corian.

I took the base off the router and cut the Corian 1” wider than the base.

I used double faced tape to stick down the router plate to the Corian and used Vix Bits to start drilling the holes in the center of the current holes in the base.

I took it to the drill press and drilled the holes that the head of the bolt would be recessed into.

I then drilled the holes all the way through with a hole to match the bolt size.
I then took a hole saw and cut out a hole in the middle.

Mounted it on the router and found that all the holes fit.

I then drilled a hole at the other end and put in a knob. Used a forstner bit to cut space for the bolt head and washer and then the center hole for the 5/16” bolt.

I then used it to hold the router steady while I routed the counter top.

If you don’t have one make one. There easy and quick and help with the accuracy.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware †

17 comments so far

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Dan'um Style

13789 posts in 2926 days

#1 posted 11-04-2008 12:31 AM

Good job Karson … hope you had fun making this one ! Fun to read and follow. You are a teacher and a half.

-- keeping myself entertained ... Humor and fun lubricate the brain

View Dick, & Barb Cain's profile

Dick, & Barb Cain

8693 posts in 3243 days

#2 posted 11-04-2008 12:36 AM

Very nice Karson, the Corian looks like its nice to work with.

-- -** You are never to old to set another goal or to dream a new dream ****************** Dick, & Barb Cain, Hibbing, MN.

View itsme_timd's profile


688 posts in 2774 days

#3 posted 11-04-2008 12:38 AM

Thanks Karson, very informative post!

How is the Corian for weight? Does it make it cumbersome at all?
I know it’s heavy stuff but in this application I could see that as a benefit in keeping it flush and square.

-- Tim D. - Woodstock, GA

View Karson's profile


34951 posts in 3344 days

#4 posted 11-04-2008 01:01 AM

The Corian is just a few ounce’s under plate steel in weight. Very heavy and hard to move around. Because, it’s fragile like glass. It can shatter and chip if it hits something the wrong way. You want to make sure that all of your cabinets are level, because a bow or sag in the middle can cause it to crack and break.

I put a block of wood on a 2 wheel Dolly so that the edge of the Corian is supported on the wood. I then have the back or bottom against the metal of the dolly. That allows me to transport it from the shop to the house and back and forth. In the smaller pieces I just carry them.

On this jig I’ll probably polish the back to make it slide easier. I didn’t do it today. it was just a quick shot, less than an hours time, to make it and use it.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware †

View Richard Williams's profile

Richard Williams

162 posts in 2735 days

#5 posted 11-04-2008 01:03 AM

I’m thinking of a TV show and you as the Presenter of all these wonderful ideas. Sound good?

-- Rich, Nevada,

View Karson's profile


34951 posts in 3344 days

#6 posted 11-04-2008 01:07 AM

Whats the pay Richard. If we can get over that hump. Then I’m all for it.

That’s if I don’t get elected President on my write-in campaign

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware †

View Grumpy's profile


20354 posts in 2794 days

#7 posted 11-04-2008 02:12 AM

That kit leaves a nice finish Karson. Looks easy enough to use.

-- Grumpy - "Always look on the bright side of life"- Monty Python

View lew's profile


10438 posts in 2698 days

#8 posted 11-04-2008 02:43 AM


Neat!! You said the Corian is heavy and fragile. How is it on the tool blades and bits??


-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View Karson's profile


34951 posts in 3344 days

#9 posted 11-04-2008 03:53 AM


I’m using regular carbide tooling. The saw blade that I was using maybe was a little dull, but It started to chip the surface of the Corian on the top edge. I swapped out a resharpened Triple Chip blade, about 80 tooth and it cuts great.

Cutting some MDF it just runs through the blade and doing the same with Corian it is real slow. A tough cut.

The router bits when doing the pattern cuts and the round over, I get pieces that look like Ivory Snow, a nice billowy fluffy cut (saw dust), The edge with the Ogee has what looks a straight line scratch pattern. It was a brand new router bit that I tool the covering off. So it was never used. it cuts fine but slow and I’m getting the scratches. I don’t know if they make regular Solid Surface router bits, but I’m using what I have and I’ll be done soon. It might be a bad sharpening job on the new bit and if used on wood you’d never notice, but it’s noticeable on the Corian. Sanding paper, through the grits makes it shine.

So if it kills a $35.00 router bit, I’m still ahead of having someone else do it. and the saw blade can be resharpened. So time will tell.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware †

View Callum Kendall's profile

Callum Kendall

1918 posts in 2646 days

#10 posted 11-04-2008 10:17 AM

Great idea Karson!

Thanksforthe post


-- For wood working podcasts with a twist check out

View Dusty56's profile


11772 posts in 2631 days

#11 posted 11-08-2008 09:18 PM Link to 10”x 48 tooth Corian blade $49 Sounds like it will help with the issues you described above if you have a lot more to cut or just for future reference : ) Thanks for all of the detailed info on your posting , Karson , and I’m going to make one of your jigs as well . It does sound like you had a bad grinding job on that router bit right out of the package : ( Have a great weekend !

-- I'm absolutely positive that I couldn't be more uncertain!

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22 posts in 2354 days

#12 posted 02-08-2009 04:49 PM



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#13 posted 07-02-2009 08:26 PM

Nice job and durable material .


View a1Jim's profile


113368 posts in 2520 days

#14 posted 07-02-2009 08:31 PM

Hey karson
A great idea and well photographed thanks.

-- Custom furniture

View PurpLev's profile


8477 posts in 2592 days

#15 posted 07-02-2009 08:51 PM

Fantastic! Thanks for sharing Karson, another great idea I’m going to utilize from you.

-- ㊍ When in doubt - There is no doubt - Go the safer route.

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