Keith MacKenzie

Pin Router

A cheap inlay router table that works great

Two sets of computer drawer slides from Home Depot and a Dremel+ router base is the main expense.

This has enough travel to do an entire fingerboard inlay.

Note:(The table could also be used to duplicate bridge outlines even copying the saddle slot.)

The two knobs behind the router allow the cutter and pin holder to be moved for

convenience and then clamp securely to the top table.

The pin is made by chucking a piece of .125 steel rod in a Dremel and running it against

the edge of a running belt sander until it is the size of the chosen cutting bit.

Then finish by running it against a wet stone to end up with a slightly undersize pin.

About .003" under size works well, but you can experiment.

 This picture shows the Cutter, pin, and "Custom Inlay Inc." Template.

In this case the Cutter Bit is .031" and the Pin Dia. is .028"

(Template seems like Corian and is well made)

Set the pin depth to ride almost to the bottom of the template and make sure

it can move freely throughout the pattern. Then set the cutting bit to the required depth of cut.

In the Custom inlay case .062"

On this table I flex the table top up while the router is running and lower the pin into the largest open area

in the template.Something more elegant than flexing the table top could be done but hey it works.

Slowly move around the template making sure to follow the edges and the clear interior areas.

Repeat the process for each area and you're done.

 Tip:  when cutting your own patterns, one easy and fast way to make a 1:1 template is with "Friendly Plastic".

FP is available in hobby stores and online you can do a search.

Hide glue your finished inlay to a small square of wood and spray with WD-40.

Place a quantity of beads enough to cover the inlay 1/4" thick in a glass of water.

Microwave to a boil then remove with a stick and press over the inlay with another square of wood

on th top and kept parallel to the bottom piece.

Let this cool off for a few minutes then carefully tease the plastic away from the inlay

once it reaches room temperature you will  have a template to put on the router table.

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