DIY Adjustable Router Template

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An Indispensable Router Accessory: DIY Adjustable Routing Template

I made this adjustable router template based on Festool's MFS Multi-Routing Template http://amzn.to/1QaqWtM.

Building this thing out of plywood keeps the cost down SIGNIFICANTLY compared to the commercial aluminum model, but fulfills the same features and works with the same clamps!

Specifically, these clamps:

The ratchet-style http://amzn.to/1Qarfos
The screw-style http://amzn.to/1Qarn7j
(technically, you don't even need these special clamps as long as you don't mind a clamp directly on the surface)

This system offers the most versatile template routing setup that I am aware of, and it can be had with just a couple hours in the shop + a few bucks worth of plywood.

Stuff you'll need to build this:

Some 3/4" plywood
4 of #10-32 x 3/4" machine screws
4 of #10-32 hex nuts
A router (preferable in a router table)
1/2" keyhole router bit http://amzn.to/1Qassfp
3/8" keyhole router bit http://amzn.to/1o27rGW
Pocket hole jig http://amzn.to/1QasqEu

How It Works

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T-tracks on the edges of each profile provide the size adjustment, and pocket holes (with machine screws) lock in any specific size.

The hardware used is:

#10-32 x 3/4" machine screws
#10-32 hex nuts

For a detailed look at the profiles, check out the SketchUp model in the next step!

SketchUp Model

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Here's a dimensioned view of the profile.

You can download this SketchUp model from my website: http://fasteasysmarttool.com/template/

Cut the Plywood

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Now to build it! Ripping an 80mm wide board off a sheet of 3/4" plywood.

Sand the Plywood

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I take this opportunity to smooth the plywood. Best to do this now, as the surface becomes too intricate after all the T-tracks are cut in.

Route T-tracks on the Faces

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Using the 1/2" keyhole bit (http://amzn.to/1Qassfp), I make T-tracks for the clamps.

Test Fit the T-Tracks

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The clamp should fit in the slot and slide freely (when not engaged, of course).

Route T-Tracks on the Edges

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Pockets holes are on a 15° angle, so I set up a 15° fence on the router table for this step.

Now I'm using the 3/8" keyhole bit (http://amzn.to/1o27rGW).

Drill Pocket Holes

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It may take some trial and error to get the position of the pocket holes just right so it fits in the T-tracks. Just be patient.

Pocket hole jig: http://amzn.to/1QasqEu

Cut to Length

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Make as many of these as you want, and cut them to any length.

Assembled and Complete

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You're awesome!

Thanks for reading :)