woodworking and dust washers

[armax]

Anyone with experience in routing for dustwashers?  Any methods or tips would be greatly appreciated.  thanks!

[spystyle]

I haven't actually done it,

but I suppose you mark the wood, then calibrate the height of your router by turning it up-side-down, laying the washer next to the cutting bit on the router's base, and adjusting the height until it is equal to the washer, then carefully route out what you have marked.

Practicing on a piece of scrap wood is a good way to verify the router's depth is correct.

Dig it?
Craig

[SirPeale]

You can't just trace the dust washer, otherwise it won't have anywhere to move.  What I've done is temp install the joystick with just a couple bolts, and throw the joystick as far in all directions as it will go, and mark the edge of the washer.  Then take a compass and draw your circle based on the center and the outside edge.

Or you could set the compass for the inside/outside of the joystick base.  That'd likely be easier.

When you adjust the router height, make sure to put a piece of boxboard or similar thickness on top, to make sure you route out enough space for the washer to move.

[RandyT]

Here's a simple formula:

(Throw of the stick + Radius of dustwasher) x 2 =  Diameter of clearance hole.

Just to be account for the "nobody's perfect"  law, add an extra 1/8" to the throw of the stick. 

RandyT