How to Duplicate a Shape with a Plunge Router

What You'll Need
Plunge router
Template (to be duplicated)
Wood slabs
Router bits
Marker or pen

A plunge router is essentially used for woodwork, and are mainly used to cut out, design and craft pieces of wood which can then be used in the interiors of your home or office. One of the main advantages that plunge routers have over other routers is that they are portable and do not have to be fixed upon a flat surface when being used. Hence, this makes it relatively simple for them to duplicate a wide variety of shapes with the right tools and materials in hand. Follow the detailed instructions to learn how to duplicate a shape using a plunge router.

Step 1 – Safety and Precautionary Instructions

For your own safety and protection, it is essential to keep a small number of items on hand when performing this activity. Ensure that you wear rubber gloves and eye goggles, as this will protect you from any potential damage to your eyes and skin when the router is in operation. Moreover, it is pertinent to read through the safety manual of the plunge router before using it. This will contain all kinds of warnings and instructions that must be kept in mind when using the router.

Step 2 – Trace Template Shape onto Wooden Slabs

Now coming towards the focal part of the activity, the wooden piece or the template whose shape is to be copied must be traced out onto the wooden slabs. Simply place the template onto the wooden slab and trace out its shape using a pen or a marker. The number of tracings to be done on the wooden slab shall depend upon the number of duplications required.

Step 3 – Insert Router Bit

Once the tracings of the template are complete on the wooden slabs, the next step is to ascertain the type of router bit that will be used for carving out the wood. A wide variety of router bits are available in the market, but for this purpose a flush trim bit would prove to be effective. Using a wrench, install this router bit and secure it inside tightly. Once done, adjust the depth of the router according to the depth of the wooden slabs which will be placed inside it.

Step 4 - Clamp Wood and Adjust Depth

Since the router will be operating at an extremely high speed, it is essential to fix the wooden slabs onto a flat surface using a clamp. Once clamped, the desired shape can be carved out easily. The next step is to adjust the depth of the router which should be set according to the depth of the wooden slab to be cut.

Step 5 – Start Operating Plunge Router

Now that all the steps in order to duplicate the template have already taken place, it is time for the router to finally cut through the wooden slab. Plug in the router and hold it from both the handles. Carefully, start carving out the tracing done on the wooden slab. Keep pressing the plunge button, as this will give you considerable control over the speed of the router. Run the router all over the tracing, and you will soon have the exact duplication of the template before you.