Router guide bushing is too long...

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Forum topic by mpounders posted 05-11-2011 10:15 PM 1944 views 0 times favorited 7 replies Add to Favorites Watch
View mpounders's profile


894 posts in 3065 days

05-11-2011 10:15 PM

Topic tags/keywords: question router jig

so can I just sand it off shorter? Someone gave me a cheap Central Machinery dovetail jig and my daughter would like me to make a couple of drawers for a cabinet she is re-doing. I picked up some cheap router guide bushings at Harbor Freight and the bushing that fits the comb on the jig extends a bit past the bottom of the comb. The comb is 1/4” thick aluminum and the bushing is a little longer. I figured that I would mark it while in the jig and then just grind it down so that it would work with a 1/4” thick template. Othe than being maybe 1/16th too long, it seems like it will work fine.

Having never used a bushing, or a dovetail jig, I figured I better ask before making the bushing shorter! Am I on the right path here?

-- Mike P., Arkansas,

7 replies so far

View Mark A. DeCou's profile

Mark A. DeCou

2009 posts in 4575 days

#1 posted 05-11-2011 10:40 PM

Mike, I’ve sanded off guide bushings before, didn’t hurt a thing. I just used a metal cutting file, and made a few quick swipes and it was short enough for the jig I was using.


-- Mark DeCou - American Contemporary Craft Artisan -

View mpounders's profile


894 posts in 3065 days

#2 posted 05-11-2011 10:49 PM

Thanks Mark. I will give the file a try first.

-- Mike P., Arkansas,

View Dick, & Barb Cain's profile

Dick, & Barb Cain

8693 posts in 4469 days

#3 posted 05-11-2011 11:20 PM

I just used a hand hacksaw, and then sanded it smooth. It works fine.

Brass is real tough filing.

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

View bubinga's profile


861 posts in 2837 days

#4 posted 05-12-2011 01:04 AM

I have done this before
I used a die grinder , fine cut file ,and sand paper to smooth it.

-- E J ------- Always Keep a Firm Grip on Your Tool

View Richard's profile


1922 posts in 2860 days

#5 posted 05-12-2011 04:08 AM

And even if you don’t get it perfectly flat it is no big deal as your only useing the sides of the bushing anyway, just need to get it shorter than the template.
Also check out this link for some tweaks to help make adjusting that dovetail jig a little bit easier. The jig is from HF as well.

View mpounders's profile


894 posts in 3065 days

#6 posted 05-12-2011 05:07 AM

Thanks for all the input and especially for some tips on tweaking the jig also….you have probably increased my chances of success!

-- Mike P., Arkansas,

View Popsnsons's profile


387 posts in 3151 days

#7 posted 05-12-2011 06:15 AM

Mike, Could you make an auxilary base plate for your router that is thicker? This way you can keep the guide bushing in tact in case you need to use it as is in the future.

-- Pops ~ In So Cal...

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