Of course, if the template is designed to be used with a template bit, the
bushing will leave the routed hole too small by the distance between the bit
and the outside of the bushing. Check with Stew-Mac about this, and get a
template guided bit, if needed. It will route to the same dimensions as the
template.

Kevin
"Doug Miller" wrote in message
om...
In article , "Ed B."
wrote:
I'm adding some active electronics into a solid body electric guitar and
I
need to route a hole into the guitar ... [snip] The other option is
to put some kind of bushing or bearing on the router shank and let that
hit
the template sides, but that only works once you've got the hole deep
enough
to where the router bit is past the template. I'm thinking there's some
easy way to do this that I'm missing.

You're almost there, but not quite. You need three things:
1) a guide bushing that attaches to the router base,
2) a router bit that's the same diameter as the bushing, and
3) a starter hole in the middle of the area to be routed out.

Extend the router bit to the full depth of the cut. Drill a starter hole
*larger* than the router bit by at least 1/8", the larger the better.
Place
the bit in the starter hole before starting the router. Then enlarge the
starter hole to the full width and length of the template by nibbling away
at
the wood around it, until the guide bushing rubs against the template.

--
Regards,
Doug Miller (alphageek-at-milmac-dot-com)

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