Are you facing the challenge of creating precise cutouts on workpieces too large for your CNC machine? For tasks such as modifying electrical enclosures, achieving accurate and repeatable shapes is crucial. While CNC machining is ideal, the initial investment in larger equipment can be prohibitive. A practical and cost-effective alternative is utilizing a Router Template Guide in conjunction with a handheld router. This method allows for the creation of custom templates, often from MDF, which then guide a handheld router to produce accurate cutouts of any desired shape.
This approach is particularly useful when dealing with materials like electrical enclosures where modifications like rectangular or custom-shaped penetrations are needed. While drilling round holes is straightforward, achieving milled rectangular cutouts expands capabilities significantly without requiring immediate large capital expenditure. By creating a template using a CNC machine from MDF, and then using this template with a handheld router and guide bushing, you can effectively bridge the gap until upgrading to more advanced CNC equipment becomes feasible.
When using this technique, tooling considerations are important. Carbide tooling, commonly used in CNC machining for aluminum, is suitable for template creation and subsequent cutout operations. However, be mindful of chip evacuation, especially when using upcut spiral bits which are common in CNC. These can potentially draw chips upwards into the guide bushing area.
Router speed is another critical factor. Routers often operate at speeds too high for materials like aluminum. Mitigation strategies include using a variable-speed router at its lowest setting, employing smaller diameter end mills (like 1/8″), and maintaining a consistent and appropriate feed rate. This controlled approach ensures cleaner cuts and better results when using a router template guide system for precision cutout tasks.
