small recessed panel advice

[condeesteso]

I need to make these things (to take a nameplate). Size is around 50mm x 30mm but i'll need a smaller one also. My best guess would be a very small bearing guided cutter in a hand-held router, with bearing at top and a tempate. I want the tightest radii at corners possible, but could always go in after and sharpen with a chisel. There may be another way but I'm stuck. The ground needs to be flat of course. Help appreciated.

 

[Paul Chapman]

How about a router plane rather than an electric router? Go round the edges of the recess with a knife first, then take out the waste with the router plane.

Cheers :wink:

Paul

 

[condeesteso]

Thanks Paul, I'd not properly considered that (and I do have a nice RXH router plane too!). I need to drop the ground about 3mm in and the length being 50mm-ish, i suspect I'll be taking v short cuts each way and maybe remove centre area with a chisel. I will test on some scrap. I need the walls really crisp too and no overcutting depth with a knife or chisel - the recess is bigger than the plate which is not rectangular... so everything shows. I've done these by hand before with just chisels, and it's tricky to get bang on!

 

[xy mosian]

Final trim with scratch stock? Flat blade of course.
xy

 

[Jacob]

Wos the problem exactly? Have I misunderstood - you have a plate approx 50 x 30mm to set in a piece of wood?
You drop the plate on, draw the outline with a sharp scribe pin of some sort, and cut out a recess to the marks. Doesn't have to be accurate in depth as it is all covered by the plate but has to be tight at the edges. Er wos the problem?
NB you wouldn't bother with router for such a little simple job.

 

[condeesteso]

Jacob, the problem is the plate is not rectangular, more the shape of a small boiler plate with concave rad corners. So i want the recess say a mm or so bigger all round. And hence the edges are visible and need to be immaculate. Not a problem, more a slight challenge!
The scratch stock is a good one for ground but I still reckon the edges to be a bit tricky. I know I'm supposed to be a bit hand-toolie but doesn't someone make a machine that'll do this while I go for tea? Have to be a cheap one mind :lol:

 

[xy mosian]

doesn't someone make a machine that'll do this while I go for tea? Have to be a cheap one mind :lol:

Sounds like a fly press job to me!
xy

 

[AndyT]

I think there's someone near you spending all his spare time on a home made CNC set up which will turn them out by the score! Have you not been watching his YouTube videos?

 

[Jacob]

Jacob, the problem is the plate is not rectangular, more the shape of a small boiler plate with concave rad corners. ...

So you need to be able to pick out the curves - ideally with a gouge of the same radius - but if not it's perfectly possible to nibble at it with a gouge of smaller radius

 

[condeesteso]

I never managed to explain this very well - what I wanted was even clearance all round but it's hard to explain, should have sketched it. Anyway, sorted - I have an old trim router with custom guide bush (made on lathe from brass tube) and a 6mm cutter set to depth. The template is corian - it took a while to make accurately and still needs a slight tune:

Those plates are made by Richard at Abbey Casting, measure about 35mm across. This one is a brass alloy but he did me some in gunmetal, very tasty indeed. (It's not pinned on yet).

Thanks for help, sorry I hadn't explained well, and sorry for using a router (not very sorry, it works and it's fast).