Router Table Adapter Plate Modification

I had a little free time this weekend and used it to address a couple of things in the garage.

1. I got my motorcycle running again

  • I’m actually very proud of this. After watching a friend do it once, I took out the carburetor, took it apart, cleaned it, reassembled it,  and re-installed it in 2.5 hours.
  • When the bike STILL wouldn’t start, I hooked it up to my truck battery and jump-started it, now it runs like a scared bunny.

2. I modified my router table adapter plate

I make the adapter plate a while back out of 1/4″ thick aluminum sheet. The center hole I cut was 2 1/4″ in diameter, which was sufficient for any router bit I owned.

But then I came across a large raised-panel bit on clearance at Rockler and bought it, only to find that it was too big to recess into the hole in the adapter plate.

I bought a set of large diameter hole saws from Harbor Freight to address the issue.

The drill press powered through the cut without any significant problems (just a lot of screeching and vibration), but the result was problematic.
Router Plate - Cutting
Router Plate - Cut
My thought had been to keep the inner portion of the cut with the original smaller hole to use as a bushing to support work pieces when using a standard sized bit; but with a large gap between the inside of the new hole and the outside of the old one, I needed a way to fill this gap and keep the inner bushing secure.

So I traced the new hole onto a piece of plywood and cut it out on my scroll saw.
Router Plate - Outer Diameter
After confirming a snug fit on the large hole, I placed the bushing on top of the plywood circle to trace it and removed the inside of the circle with the scroll saw.
Router Plate - Inner Diameter
Router Plate - bushing

After a bit of quick sanding I had a completed solution: The wooden ring fills the gap between the large hole and the inner bushing, allowing the bushing to fit securely inside the larger hole.
Router Plate - Small
Router Plate - Large

All in all, I was happy with this fix, but I may still thread a screw through the inner portion and into the router base, just to make certain the new bushing doesn’t turn into a hypersonic projectile the next time I use the router table. Although I do like hypersonic projectiles

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