Planning routing makes my brain hurt - advice needed.

[griffindodd]

Hi all,

First time router, first time builder.

Having never routed before I am both excited and apprehensive about the project ahead. I know what I want to do with each piece of my cabinet but I'm unsure as to the best technique to use. I'll write out here what I plan to do and maybe you guys could weigh in on your recommendations of how to attack each piece. I do not have a routing table.

Sides.
I'll be using 5/8 MDF. So my plan is to create a 1/4" template first and then route the two sides one at a time using the template. To do this I am assuming I will want to use a 3/4" top baring flush bit with my template attached to the top of my panel???

Side Laminate
I'll be using 1/16 Wilsonart matt black plastic laminate bonded with contact cement. My plan is to leave about 1/2" of overhang on the laminate and then trim using the 3/4" bottom baring flush bit assuming the laminate is on the top of the MDF.

Controller.
Controller top panel will be 5/8" MDF. I plan to Cut it out with a table saw and sand to finish. Holes cut with 1.1/8" spade bit and a 3" circle cutter. I then plan to make a perfect mated clear 1/4" polycarb top by using a 3/4" bottom baring flush bit utilizing my MDF controller panel below my polycarb as the template.

Controller Box
I do own a table saw but it's a Ryobi janky thing that I got cheap at HD and I'm not too impressed with it's accuracy. I'm trying to decide whether to do my miters for the controller box with the saw or use chamfer bits with the router. My question is will the chamfer bit give me a perfect corner or will it leave a ridge?

Controller Box Laminate
After mitering my controller box pieces I plan to use the same laminate gluing and trimming technique I used with cab sides.

Any advice on any of these techniques is hugely appreciated.

Joel

[yaksplat]

For the sides, just cut one side out, clean up any jigsaw mistakes with sandpaper or a plane, then use that as your template for the other side.  Unless you plan on making a few more side panels for other machines, i wouldn't bother making a stand alone template.  If you do decide to make a template, use thicker plywood.  1/4" warps a lot and it's not a lot of material to run a bearing on, especially since you're a routing rookie.

side laminate - that'll work

CP - Use a forstner bit if you can for the button holes.  The result will be much smoother and more accurate.

cp box - there's no need to miter.  You're just going to get aggravated if you don't have quality tools.  Just change up your design so you don't need to.  If you're going to cover the box, you'll never even see the mitered corner.  Just do a lap joint or if you've got the routing bug, do a rabbet joint.

[griffindodd]

Thanks for those recommendations.

cp box - there's no need to miter.  You're just going to get aggravated if you don't have quality tools.  Just change up your design so you don't need to.  If you're going to cover the box, you'll never even see the mitered corner.  Just do a lap joint or if you've got the routing bug, do a rabbet joint.

On the controller box, I don't want to cut the wood after I have the laminate on it as I am paranoid about chipping, so I'm not sure how I could apply the laminate to cover up the joints. I just want this to be the best piece of work I have ever done, so I really want to push myself to do it right.

Also if I decided to route my side panels, what kind of depth per pass should I stick to, assuming I am using a Bosch 2.25hp router with a 1/2 shank Whiteside straight 3/4"

[yaksplat]

For the control box:

Build the box
Apply laminate to one side
Trim laminate flush
apply laminate to next side
Trim flush
repeat

For the side panels:
You should have the piece of wood cut out with a jigsaw before routing it.  Just trace one piece on to the raw sheet and cut outside the line.  Clamp the two together, making sure that the pattern piece doesn't hang over anywhere and then you run your flush bit with the bearing on the pattern and trim off all of the excess wood in one pass.  If you have a lot of excess wood in one area, you can do that spot in a few passes.

[griffindodd]

Ok thanks that makes sense. Any tips on what to cut laminate with just to get it down to a managable size before applying to the box sides?

[yaksplat]

something like this

http://www.amazon.com/Freud-LU97M010-10-Inch-Laminate-Melamine/dp/B00006XMTY

a high tooth count blade

[selfie]

As for routing the polycarb. You will need to ensure the polycarb is clamped as tight as possible and in as many places as possible.

Polycarb is a soft(ish) material that can grab the router bit and make an unholy mess of you and the workpiece. Use a 1/4 bit if you can and go slow, let the cutter do the work without pushing.

[griffindodd]

As for routing the polycarb. You will need to ensure the polycarb is clamped as tight as possible and in as many places as possible.
Polycarb is a soft(ish) material that can grab the router bit and make an unholy mess of you and the workpiece. Use a 1/4 bit if you can and go slow, let the cutter do the work without pushing.

Good to know, thanks