Reply by Tedstor

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Posted on Clear Polycarbonate Router base

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1643 posts in 2660 days

#1 posted 04-01-2011 06:50 AM

From Ehow. Seemingly good instructions.

Make a Base Plate for a Router
Remove the original base plate from your router. Use the plate as a template to drill the holes into your new base plate material, a 1/4 inch piece of Lexan. Clamp the old base plate to the new paying attention to accuracy. The holes must align perfectly when drilled to ensure a proper fit.

Keep the two plates clamped together while you trace a pattern of the old plate onto the new. Remove the original base, turn over the new material and countersink the holes. Cut out the pattern traced on the new base plate material.

Install the new plate onto the router. Choose a bit for your project. Plunge the bit into your plate, and remove the plate from your router.

Put your new base plate template on your drill press, bottom side up. The countersinks will be facing up. To make a through-hole into your new router base plate use a 1 and 3/16 inch hole saw. Clamp the piece of Lexan firmly to the drill press, and cut a hole all the way through.

Remove the hole saw from the drill press, and replace it with a 1 and 3/8 inch Forstner bit. A counterbore will be created for the template bushing to sit into. Drill the hole the right depth so that the bushing sits just shy of the Lexan surface.

Read more: How to Make a Base Plate for a Router |

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