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Bearhawk #982
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Date:  10-21-2008
Number of Hours:  0.00
Manual Reference:  
Brief Description:  My Formblock System - A how to (part 4)

9. Counter sink at jig pin locations on “lower” layer of router block to allow 2 1/2” long bolt head to sit below surface of MDF while routing.
10. Using a flush trim router bit, shape rough layer to match finished layer.
a. Only rout around outer edge of pieces as lightening hole requirements differ per layer
11. Using drill press and circle cutter, cut lightening holes in 1 piece designated top layer
a. Clamp your work securely to drill press table, hand pressure is not enough
b. Holes are sized per plans + 3/8” or 1/4" radius (to allow for flange width) for this block
12. Using offcuts from lightening holes (I label each offcut as I cut it with LH location), resize circle cutter to create a plug of MDF that JUST fits into the upper layer. The plug should fit loosely but not too loose. (It should go in and out of the hole with very little pressure)
13. At router table with a 45 degree bit installed and adjusted to give a 3/8” flange (or whatever the plans call for at that location), rout 45 degree bevels on all lightening holes in the MIDDLE layer (both sides of layer)
a. Both sides are done for left and right hand ribs. The layer will be “flipped over” and used for each side.
b. NOTE: if properly set, the router created flanges will not intersect on the for block. If both 45’s meet in the middle of the form block, your bit is too high
14. Use router table again and CAREFULLY rout 45’s on plugs created in step 11.
15. See my kitlog for images of my blocks for further clarification
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