Just wanted to show my template off that Timoe inspired me to make. With space being an issue in my shop, I make all of my templates small (this one is about 8" square) and fasten everything with double sided tape. I'm in love with the stuff now...
Also, while Timoe made his template for a tight fit, I sized mine to make about a 1/8" space all the way around. This allows for a bit of wiggle room. I made a set of templates for Sanwa joysticks too, but they're going to change so I won't show them just yet.
The template. I made mine out of 1/2" baltic birch plywood. I love how smooth and stable this stuff is. It's my template making material now. I like how the edges don't compress in whan I use a bearing guided bit (anyone who used an MDF template with a flush trim or pattern bit knows what I mean) and the fact that it can be had for pretty cheap if you know where to look. Here's
a good source.
The finished recess.
And making the template is not hard at all. Don't let it discourage you.
"Now if you were to expand upon the idea and make jiggs of various common layouts (to enable a person to only use the router and eliminate those tiresome drill bits for the button holes) then that might be more useful and time saving. Of course then you have to drill holes for the buttons anyway to get the trim bit in, so it might be more trouble than it's worth. "
It is possible to rout the holes without drilling starter holes. All you need is a plunge boring router bit. It's designed to plunge into a workpiece just like a drill bit. That actually sounds like a good idea. Not as fun as using a drill press though! j/k
I just really want a drill press...
This needs to be stickied.
And you should post more of your jigs in here Timoe