router help

[allsorts11]

over the last 10 years I've made dozens of rocking horses out of 12mm plywood one operation is to saw 2 large intricate shapes which are roughly 1500mm x 500mm. To do this i use hand held jigsaw which is quite hard work and requires quite a lot of time and skill to get these parts exactly the same size as each other. Then one day 2 years ago my uncle tom suggested using a hand held router and a home made jig to do this job. so with his guarantee it would be quicker easier and more accurate i asked him to show me how to do this. so my uncle tom said get yourself a router then give me a call and I'll show you how. So went out got myself a router but unfortunately my uncle tom passed away taking with him the knowledge i needed. Since then i have searched and asked everywhere how to use a router and jig to cut out these shapes with no success the only info i can find is how to use router against a fence for straight pieces of wood. So can anyone give me any advice

 

[big-all]

heeelllooo and welcome allsorts11

assuming you have a fully finnished runner you can "follow"
screw the new runner to the "template" draw around the template

unscrew the template cut the next runner to within 5mm off the finnished size

screw back together and use one of these
http://www.screwfix.com/prods/62672.../Trend/Trend-Guided-Profiler-1-2-19-1mmx-50mm


or one of these
http://www.screwfix.com/prods/88874/Blades/Router-Cutters/Trend/Trend-Guided-Trimmer-1-4-12-7x25-4mm

screw the new runner onto the template raise the template off the bench or board by 12mm [same wood screw can be used through the blank /template/battons into a board or workbench to secure]
set the plunge depth so the guide wheel will follow the centre of the template

exteriour cuts clockwise interiour cuts anti clockwise

 

[allsorts11]

thanks big all be giving this idea a try as soon as i receive router cutter hopefully making this job a little easier.
Cant believe how little info there is on how to do this

 

[gypsymoth]

hi all sorts.

I have and idea for you.

You will need for this:

[1] a piece of plywood, 1/2" will do. Dimensions of which will contain
a sample of your rocking horse rocker. i.e 1500mm x 500mm.
Perhaps you have an existing rocker handy?

[2] jig saw. "Clue is in the name"

[3] Router, does your new router come with a guide bush?
normally a good make will supply a 30mm guide bush with accessories.

[4] Two G clamps.


Now for the fun part.

[a] Trace the sample onto the ply wood. Be very very careful here,
because what ever line you draw, you will cut, you will route out,
you will have as a finished product.

Copy a parallel line to the one you have just drawn.
Now for the tricky bit!
I will assume you have conmen sense and "some" carpentry skills,
over the last 10 years. So:-
Depending on how wide you want the rocker to be, will determine
how far apart you draw the second line. You have to take into
account the size of the cutter, and the 30mm guide bush on your
new router.
Perhaps experiment a little on other boards first until you get it
perfect.


[c] When you are 100% happy with your pencil lines, cut out the shape
with you jig saw. Here, you will have to be meticulous. Even the
slightest out of line cut will mean that every rocker you rout out will
have that misshape.

[c] What you are aiming for is a board with a hole in it, the shape, and
size you want. So that when you place this board, which is now your
very own bespoke jig.

[d] When you are happy with the result, you are ready to start making
as many rockers as you want, fast, with identical reproduction.

[e] Place your jig over a new piece of plywood, clamp it down with the
G clamps, and rout away.
Make sure the bottom board is secure too, because you will have
run the router along the edge of you jig. If the ply you are routing
is very thick, then just take shallow cuts between plunges. If too deep
the cutter will bite into the ply and spoil your shape.
It might be a good idea to run you router in the same direction as the
motor turns, to avoid the router from biting and drifting into your
shape.


I have a feeling this is what your Uncle Tom was going to explain to you.
My condolences. R.I.P

Have fun.

 

[xerxes]

When I made a rocking horse last year, I started by making exact-size hardboard templates for all the parts.

Then I used a flush trimmer router bit to cut the plywood pieces, having cut them out slightly oversize with a jigsaw.

The top edges of the rocker panels had to be cut at 110 degrees, which was easily accomplished with another bearing-guided bit against the rocker panel template.

I drilled and countersunk the templates, choosing places for the screw holes that wouldn't show on the finished panels. No need, therefore, for clamping.

One or two of the templates didn't turn out perfectly symmetrical. Rather than scrap them and start again I routed half the panel using the better half of the template, then carefully inverted it to finish the routing. This means that if ever I use those templates again, I'll have to remember to do the same again.