I finally settled on some radiator covers--got a great deal on pre-maid ones, made to measure from MDF, and then I assemble.
The only downside is that I have to router slots in the top plate. The ones we're getting look like this: [www.lowes.com]

So, slots in the front, but not on top. I want to router slots on the top to match, so roughly 4 slots on each of 9 tops, each slot maybe 3/4 of an inch wide, maybe 18 to 50 inches long. So 36 slots in all.

I'm trying to figure out which plunge router to buy. This is the only time I'm ever going to use it; I'll sell it after the journey of 36 slots. So on the one hand, I try to buy nice tools, because they often make the work much less of a hassle. On the other hand, this is at most a week of work and done, so I'm loathe to buy a $200 router when a $100 one will do. Decisions, decisions....

Anyway, it seems to come to these three: the Wen, the Bosch, and the Dewalt (and anything else that anyone here raves about. So either talk me out of the Wen (my likely first choice) or into the Bosch (my likely splurge choice). My one thought so far is that the Wen is likely to be fine, if I get a good one--the item to item variance seems higher for the Wen (and cheap but decent power tools generally) than for the Bosch.

Thanks!

[www.amazon.com]

[www.amazon.com]

[www.amazon.com]

Pay a local handyman to do it?

Hmmmm.....

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MikeF
Pay a local handyman to do it?

There's nothing worse than a subpar plunge router. A good one will set you back $250-350. I'd rent one, or if you've never used one, have a handyman do it like MikeF says. Routers can be dangerous if you're new to them, especially a powerful one like you'll need.

Either way, get a very good bit from an outfit like McMaster Carr. Composites will dull a bit quickly and the cuts will not be clean.

I learned these lessons the hard way.

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Would be nice to have a router table for a job like that. How about a standard router mounted upside down in a quick DIY plywood board with a fence, all clamped to a table. Make it long enough so that you could use stop blocks to mark the beginning and end of your cuts. A 3/4 inch slot might require a few incremental passes. Just a thought.

Edit: Wouldn't have to be too long — just mark starting and stopping lines on the fence.

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Northern California Coast



Edited 1 time(s). Last edit at 01/30/2021 12:29AM by steve....

How about a drill, 3/4 inch spade bit, a jigsaw, clamps, and straight edge?



Edited 1 time(s). Last edit at 01/30/2021 05:06AM by RE:up.

If you have a DeWalt outlet near you, you could save quite a bit of money on a DeWalt plunge router.

A router is best if you are going to cut an unusually shaped contour, but if you're just doing straight, vertically-sided slots it may not the best tool for the job because you have to deal with its tendency to turn away from the desired track, and will need a good fence setup and steady hand. If the slots are long enough I think I would do it with a table saw and dado blade cranked up through the piece then use a drill to cut the rounded ends of the slots. A hand saw, jigsaw or even a multitool could be used to finish up the part between the saw cut and drilled holes.

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"In science it often happens that scientists say, 'You know that's a really good argument; my position is mistaken,' and then they would actually change their minds and you never hear that old view from them again. They really do it. It doesn't happen as often as it should, because scientists are human and change is sometimes painful. But it happens every day. I cannot recall the last time something like that happened in politics or religion." (1987) -- Carl Sagan

Harbor Freight is my go-to for use them once tools. In my experience their power tools work fine for a while and then go south.

I'd buy this one for $60 after a 20% coupon: [www.harborfreight.com]

It has a 90 day warranty. Buy a piece of MDF from HD and practice (no matter what kind of plunge router you buy). If you don't like the outcome with the Harbor Freight, take it back and buy higher-end router. And then practice with that one.

Regardless of the router you buy, don't skimp on the quality of bit you use.

I would consider cutting the slots out with a jigsaw and using the router to clean up/finish the slots.

I have the Dewalt. Mounted in a Bosch table most of the time. No complaints. It doesn't particularly stand out, but it always works, has plenty of power, and had spare parts I've never even needed to use.

It was a replacement of a Ryobi that literally burnt up. POS that was.

I'd go with the Bosch. They know how to make motors, and that is primarily what a router is.

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C(-)ris
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I would consider using a drill bit to make a starting hole, and the router to make the rest of the cut. Then you don't need a plunge router, which is expensive.

MDF kills blades - plan on using a couple of bits.

How wide are the slots going to be?

Do you already own a drill and circular (or other saw)?


Use a drill to cut holes in the surface and then a circular saw for simple straight cuts to join the holes. Use a clamp on guide to ensure straight cuts.

I don't, but I'm thinking about this. The problem is that I'm starting the cuts in the middle of the board, not the end. These are slots, which start maybe 3" in from each end.

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testcase
Do you already own a drill and circular (or other saw)?


Use a drill to cut holes in the surface and then a circular saw for simple straight cuts to join the holes. Use a clamp on guide to ensure straight cuts.

I'd got with the drill a hole then run the router method. Best would be to build a jig - in this case just a rectangular frame the keep the router from sliding around.

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Embarassing myself on the Internet since 1978.

Thanks. I’m definitely planning on the frame.

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raz
I'd got with the drill a hole then run the router method. Best would be to build a jig - in this case just a rectangular frame the keep the router from sliding around.