Last
week, I posted this picture with the announcement that Beth and I would be starting a new
project — an "Insert Plate Garage.'
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This is what started
the idea some months ago. Marc Sommerfeld sent me a new product, the new Pocket-Pro
Joinery System developed by Marc and CMT (photo is from CMT's website.) I have used it on
a number of projects but simply clamped the base to a worktable.
But this picture intrigued me. Since these insert plates are so well made and
fit so exactly, I asked myself the question: "What other shop tasks could use this
concept?"
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I shared my thoughts with
Beth. It didn't take long to look at how we use the router table — I came up with a
practical need for 5 insert plates. And, if I need this many plates, I also need a garage
for them — one that would keep the tools safe and sound.
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Beth starts by measuring the
tools that we will mount on insert plates. You can see the CMT/Sommerfeld Raised Panel Set
in the center of the picture. I am planning the "garage" around that product and
the tasks of making raised panel doors. I want to include the following insert plates:
1) large router with speed control for the large raised panel
bit; 2 and 3) 2 smaller routers for the rail and stile bits; 4) the Porter Cable Portable
Oscillating Spindle Sander (already mounted at the right) and 5) the CMT/Sommerfeld
Pocket-Pro Joinery set, far right.
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Choosing the
right router is going to be a bit of a task. Beth is holding the PC 690. It is a gem of a
router that I have used for years, but it works only at the speed of 22,000 rpm
— great for a lot of routing jobs, but too fast for the rail and stile bits which,
because of their width, should be run at 13,000 rpm.
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This Porter Cable plunge
router model (PC 8529) is a recent addition to their lineup and sports a 2hp motor and
has variable speed and a soft start. In the back ground you can see that I have one unit
already mounted in the insert. It has the same hole sizing as the PC690 which makes it
easy to change models.
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This is the Porter Cable
Portable Oscillating Spindle Sander which I mounted during the week. I used 1/2"
Finnform which is absolutely great for this use.
I used a number of router "copying techniques" to make this insert.
I did photograph most of the steps, so here they are.
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I have cut a piece of
Finnform (see source below) on the table saw using another insert to set the fence
distances exactly to the insert dimensions. Using an 80 tooth cabinet blade gave me a very
smooth edge.
I am trying to figure out where the sander would be located on the plate.
Since the sander is long, I decided to place the hole offset so that the unit will
"fit." The number "1" is at the Porter Cable accessory that I am using
to mark the hole position. I could also use the base ("2") which I have removed.
I thought I would be leaving the base off, but I see that it is an integral part of the
unit's dust collection system and belongs on.
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I have used some double face
tape to fix the base adapter to the Finnform and am now drilling the holes that will hold
the router.
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Well, I got wrapped up with
what I was doing and did not photograph some small tasks in between. What I did was use
the holes to attach the black adapter to the base and then used the router with a pattern
bit to follow the plastic adapter. It took only a few minutes to make an exact copy of the
hole. I also used one of the other plates and the pattern bit to rout the corners
exactly.
I am holding the final product — it is perfect. But, I will admit, the
other plate on the bench is the earlier attempt. I countersunk the holes on the wrong side
— I don't want you to think that I don't make mistakes.
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Beth was admiring the
"perfect" fit and then she tried to place it in the top. It fit perfectly, but
there is not enough room under the top for the sander. I will either have to remount the
sander or remove the small cabinet inserts underneath the top.
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This is what it looks
like. I had built these storage areas to fit the Hitachi M12V exactly. Since they are
installed with pocket hole screws, I should be able to remove them and trim them down to
allow the new equipment to fit.
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