Templates by numbers

You can make a template to fit a router insert plate in a matter of minutes with Templates by numbers.
To make the template we did the following:
1 Make the template plan in two halves (see the seperate article)
2 Piece the two halves together and place on the workpiece
3 Transfer the positions of the 'Mortice jig cutout' guidelines from the template plan. These guidelines have the offset for the router bit/guide bush combination you choose to use when you made the template plan.
4 Align scrap straight edges on the Mortice jig cutout guidelines
5 Start routing out the cutout.

Guide to using the template

Template for 12mm router cutter and 24mm guide bush

TBNFittingRouterInsert

	Transferring template dimensions direct to the workpiece. Place the template on the workpiece, weigh it down flat using the router table insert and transfer the mortice jig positions through to the workpiece with a sharp nail and a few gentle taps with a hammer. Repeat for all four mortice jig corners.
	Align scrap straight-edges to the nail marks.
	Tack the straight-edges using pins or double sided sticky tape.
	Ready to start routing. Using a router equipped with the cuttter and guide bush specified when making the template (in this case a 10mm cutter and 24mm guide bush), zero the cutter on the workpiece and then plunge route to a depth of 3mm.
	Starting the routing.
	After the router first pass. The outline routed should correspond to the dimensions of the router insert plate.
	Setting the final depth of cut. The aim is to get the router insert plate flush with the router table top. Here we use the router insert plate itself to get the routing depth.
	Removing the centre waste. We use a jigsaw to cut out the centre of the router table to make space for when the router is attached to the insert plate. Notice the scrap piece of MDF - which is the same thickness as the jig MDF - under the jigsaw baseplate to prevent tipping.
	Centre waste material removed. We are now ready for a first fit.
	After a little bit of easing the insert plate fits snugly into the table top. We kept the mortice jig scraps in place so if it was necessary we could have made cutting depth modifications after the first fit.