I'm helping a friend with a fairly basic woodworking operation. I need to inset a round metal doorbell push button into a piece of wood and I'm going to use a plunge router with a straight bit and a guide bushing.
The problem is creating the template. The template needs to be 2.5 mm wider than the intended cut. How can I do this? It's made a bit more awkward by the doorbell not being perfectly round - I'd like the template (jig?) to match this imperfection so that the flaw isn't obvious after insetting it into its wooden panel.
The problem is creating the template. The template needs to be 2.5 mm wider than the intended cut. How can I do this? It's made a bit more awkward by the doorbell not being perfectly round - I'd like the template (jig?) to match this imperfection so that the flaw isn't obvious after insetting it into its wooden panel.