Make a Larger Router Baseplate for Safer, More Accurate Routing
A router is one of the most versatile tools in the woodworking shop, especially when you're using templates and guide bushings to shape parts or cut joinery.
But there's one drawback I've run into with many routers: The factory baseplate doesn't always provide enough support.
When routing along the edge of a workpiece or following a template, a small base can make it difficult to keep the router flat and stable. And if the router tips during a cut, it can leave an uneven surface or damage the workpiece.
An easy solution is to replace the factory baseplate with a larger, clear router baseplate.
This shop-made version is cut from plastic and includes a stepped opening for Porter-Cable-style guide bushings. The larger surface provides better support, while the clear material makes it easier to see the workpiece and follow a template.
Make a Clear Router Baseplate
The baseplate starts with a square blank of 1/4"-thick acrylic or polycarbonate plastic.
Both materials provide a clear surface that lets you see the work beneath the router. Polycarbonate is generally tougher and more impact-resistant, making it a good choice for a shop-made accessory.
Cut the blank large enough to provide additional support around the router, particularly when working near an edge.
The exact size will depend on your router and the type of work you do.
The important feature is the opening in the center of the baseplate. It needs to accept the threaded body and flange of a Porter-Cable-style guide bushing, along with its locking collar.
Rather than using a simple through-hole, the opening is stepped so the bushing flange sits in a shallow recess.
Cut the Stepped Opening for the Guide Bushing
The stepped opening can be made using two different hole saws.
Secure the plastic blank to a sacrificial backer board on the drill press. Make sure the blank is clamped firmly so it can't spin or shift while drilling.
Step 1: Cut the Recess for the Bushing Flange
Start with a 1⅜"-diameter hole saw.
This first cut creates the shallow recess, or rabbet, that accommodates the flange around the guide bushing.
The recess should be as deep as the flange is thick, or slightly deeper, so the flange doesn't project below the bottom surface of the baseplate.
Take care not to drill all the way through the plastic.
Step 2: Cut the Through-Hole
Leave the plastic blank clamped in place and switch to a 13/16"-diameter hole saw.
Drill through the center of the first recess to create the opening for the threaded portion of the guide bushing.
Work slowly and clear the chips frequently. Excessive heat can soften or melt the plastic, leaving a rough opening.
Once the hole is complete, remove any burrs and check the fit of the guide bushing and locking collar.
The bushing should seat properly in the recess and tighten securely without rocking.
These hole saw dimensions suit the bushing arrangement shown here. Check your actual guide bushing dimensions before cutting, since bushing styles can vary.
Center the Baseplate on Your Router
Accurate alignment is especially important when using guide bushings.
If the guide bushing isn't centered around the router bit, the distance between the bit and the template can change as you rotate the router. That can affect the accuracy of the cut.
To locate the mounting holes, install a guide bushing in the new baseplate.
With the router unplugged, use a suitable centering pin or alignment tool in the router collet to position the bushing opening concentrically with the spindle.
Then use the router's existing mounting holes to mark the screw locations on the plastic.
Drill and countersink the mounting holes as needed so the screw heads sit below the bottom surface of the baseplate.
Before using the router, confirm that the baseplate is securely attached, the guide bushing is centered, and the router bit has adequate clearance.
Why a Larger Router Base Makes a Difference
An oversized router baseplate offers several advantages over a standard factory base.
Better stability. The larger surface helps support the router when part of the base extends beyond the edge of the workpiece.
Improved visibility. Clear plastic allows you to see the workpiece, template, and cutting area.
Accurate template routing. The stepped opening accepts guide bushings for following templates and routing precise shapes.
More control. The extra support makes it easier to keep the router level throughout a cut.
The result is a simple accessory that makes a noticeable difference when routing along edges, working with templates, or cutting joinery.
A Simple Upgrade for More Accurate Routing
You don't need an elaborate jig to improve the way your router handles.
A larger baseplate made from clear plastic gives you more support and better visibility without adding much complexity to the tool.
And by adding a properly sized opening for a guide bushing, you can use the same baseplate for a wide range of template-routing tasks.
It's an inexpensive shop-made upgrade that can help you make cleaner, more consistent cuts.
More Shop-Made Router Accessories
A larger router baseplate is just one way to make your router more versatile. From edge guides and specialty bases to template-routing accessories, a few shop-made additions can make challenging routing operations easier and more accurate.
Explore the Woodsmith Auxiliary Router Bases woodworking plan for more practical ways to expand your router's capabilities.
GET THE ROUTER BASE PLANS → Get More from Your Router with Custom Bases and Jigs
