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Making a Plastic Shield for our Router Mortising Machine

By: John Doyle
One of my favorite tools happens to be this shop-built tool from Woodsmith. It’s a Router Mortising Machine, but I made a slight improvement — it’s the addition of a clear safety shield in front of the router to protect my fingers when the router is both running and turned off.

Get the step-by-step plans to build this Router Mortising Machine from WoodsmithPlans.com.

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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.

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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.

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Bend. When the plastic starts to droop, use another board to bend the warmed plastic down, making an even bend.

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When the plastic is formed to your liking and cooled, it’s a simple matter of mounting it to the router clamping block.

Published: Jan., 14 2021
Topics: None
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