Bosch Colt Offset Router Jig

[Splint Eastwood]

Well, I finally got around to making something from the haul of plastic goods that Amy Dowden scored for some of us awhile back.

It's an Offset Router plate/jig for the Bosch Colt(already broken in) :

I don't think Bosch sells these, I know they have a router plate, but not an offset. There are some folks who sell but want anywhere from $30 -50 depending.

This one cost @ $3 in materials. I turned a 1.5 X 1.5 X 2 piece of hard maple for the handle and used 1 1/4in20 nut and bolt to connect to plate.

I loved milling this plastic. Easy to cut (a bit brittle) but once I got the rough cuts done, I just used a circular sander to finish shape and used up to 1200 grit to finish sand. Easy Peasy! Drilling it was also easy.

Thanks for looking!
Matt

 

[Tarhead]

How'd you make the cuts? I've drooled over Pat Warner's version but hard to spend more on the base than the router.

 

[Splint Eastwood]

How'd you make the cuts? I've drooled over Pat Warner's version but hard to spend more on the base than the router.

I used 10in sliding miter saw with an 80 tooth blade. I think 80 teeth is the minimum you need to make clean cuts. Make straight angular cuts around the base (doesn't need to be too close) Then used a 10in circular sander with 80 grit to shape sand to the line. It mill sands pretty fast and clean.

Just be careful when cutting! I tried to cut small pieces and it just shattered and frags went everywhere (Eye protection crucial). But just dont take to small a cut, especially around the round part of base.

Lemme know if you have any other questions!

This was fun and easy. Took only an hour or two. I took longer because I turned the knob, instead of buying one.

 

[Tarhead]

Thanks!
I'll need to try that. I have some 3/8" plexiglass but been hesitant to hack it up. Now to figure out how to center the hole...:icon_scra

 

[Ken Massingale]

Nice Matt. That looks every bit as good as Pat Warners.

 

[Splint Eastwood]

Nice Matt. That looks every bit as good as Pat Warners.

Thanks Ken,

Who is Pat Warner, and does he have a web-site? Is he a member?

Forgive my naivette.

Thanks,

 

[Tarhead]

http://www.patwarner.com/index.html

 

[TracyP]

Good looking jig!!!

 

[Splint Eastwood]

http://www.patwarner.com/index.html

Good looking jig!!!

Wow, nice website. I need to get a better camera!:gar-Bi.

Thanks for the link.

Thanks for the kind words!

Matt

 

[Canuck]

Matt!!!

that is a really close imitation of the Pat Warner version!!!

Can you make me one? (Just kiddin' ya!!!!) I too have that sheet from Amy. You have latched onto a cool idea! :icon_cheers:icon_cheersThere have been times where I wish I had that offset for my Colt too!!!

Thanks a bunch for the inspiration!!!:eusa_clap:eusa_clap

That sure looks like a very useful add-on and am sure that it will see some really great use in the shop!:gar-Bi:gar-Bi

You are really stepping the shop a few notches!

Thanks for sharing!!!

Wayne

 

[Splint Eastwood]

Matt!!!

that is a really close imitation of the Pat Warner version!!!

Can you make me one? (Just kiddin' ya!!!!) I too have that sheet from Amy. You have latched onto a cool idea! :icon_cheers:icon_cheersThere have been times where I wish I had that offset for my Colt too!!!

Thanks a bunch for the inspiration!!!:eusa_clap:eusa_clap

That sure looks like a very useful add-on and am sure that it will see some really great use in the shop!:gar-Bi:gar-Bi

You are really stepping the shop a few notches!

Thanks for sharing!!!

Wayne

Wayne,
You can use mine as a template. Your welcome anytime to stop by.

Thanks for the encouraging words! I really appreciate.

Matt

 

[garymuto]

FWIW I read somewhre that you can use a propane torch (lightly :wink_smil) to smooth the sawn edges of plastics like Plexiglass®.

 

[thrytis]

Thanks!
I'll need to try that. I have some 3/8" plexiglass but been hesitant to hack it up. Now to figure out how to center the hole...:icon_scra

Mount your router without the center hole cut. Then just use your largest bit and plunge through. If it isn't a plungeable bit (e.g. has a bearing on it), use a smaller bit to drill out a clearance and then expand with the bit.

 

[Sully]

FWIW I read somewhre that you can use a propane torch (lightly :wink_smil) to smooth the sawn edges of plastics like Plexiglass®.

Yes, you can. I would recommend some practice with scrap pieces first though. It can be a fine line between smoothing out the edges and setting the whole thing on fire. :elvis: DAMHIKT

J

 

[Joe Scharle]

Mount your router without the center hole cut. Then just use your largest bit and plunge through. If it isn't a plungeable bit (e.g. has a bearing on it), use a smaller bit to drill out a clearance and then expand with the bit.

However, if you want to create a hole for PC style bushings, you could make a pointy dimple instead to use as a pilot hole for bore/counterbore with forstner bits.

 

[jhreed]

I have some 1/4" plexiglass. Is this thick enough for this project?

 

[Splint Eastwood]

I have some 1/4" plexiglass. Is this thick enough for this project?

Maybe, not sure. The Colt is not a heavy router, so minimal flex with thinner plastic.

Just don't make the jig too long and don't "lean on" router, should be ok.

Give it a try, not much material at risk.

:icon_thum

 

[ScottM]

Kewl,,,, I saw the WIP but the final version is way better. Maybe Matt needs to host a mini workshop some evening or week-end. :widea:

 

[Splint Eastwood]

Kewl,,,, I saw the WIP but the final version is way better. Maybe Matt needs to host a mini workshop some evening or week-end. :widea:

Scott,

Thanks for the vote of approval, It's much appreciated. Anytime you want a mini workshop for this, let me know!