Get the step-by-step plans to build this Router Mortising Machine from WoodsmithPlans.com.
FORMED ACRYLIC. Molding a piece of acrylic into a shield is pretty straightforward. I started with a flat piece of stock, and drilled the end locations for the mounting slots. Then, I routed the slots at the router table. After rounding the corners at the band sand and sanding them smooth it's to start shaping the shield.
Heat. After clamping the acrylic in between a pair of boards, use a heat gun on low heat to slowly soften the plastic along the board.
Bend. When the plastic starts to droop, use another board to bend the warmed plastic down, making an even bend.
When the plastic is formed to your liking and cooled, it’s a simple matter of mounting it to the router clamping block.