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I was looking for another way to do a windshield hole on a toy truck and thought a template and pin router would work well. I made an insert for the sanding drum table insert and thought I would share.

Mark the holes and one for the center with a punch.
Mark some reference lines on the block of birch plywood before removing the template to make it easier to line up in later steps.

I have the template in Sketchup and will add a link to that later. Edit: See Post #5

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Drill the 5/8", 1/4" holes, and one for small nail or screw in the center.

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Under the finishing nail and project piece is a 1/2" piece of plywood with one table slot runner. I lined up the nail 2 9/16" from the edge of a 1/4" straight router bit and cut 1/8" deep. Remove the template before routing.

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I adjusted the lower plywood with runner away from the router bit and made a progressively larger clear area still at 1/8" depth.

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(To be continued)

I put the paper template on the side away from the routed area, cut the shape of the insert on a bandsaw and lightly sanded with the belt sander.

I held the wooden insert in the table insert with the two allen screws that come with the dust collector attachment and larger washers. Drill a 19/64" hole in the center of the wooden insert for a 1/4" t-nut.

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In this first rendition I installed a t-nut in a 5/8" countersunk hole in the bottom of the wooden insert and installed a 1/4" threaded pin from the top.
Used a metal strap, the same allen screws as above and a nut to lock it all together. I also marked one end of both inserts so the wooden insert is oriented the same way every time it is installed.

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Everything lined up and it worked with the Power Pro at 9500 rpm.

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The next picture is the second rendition.
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I countersunk the hole from the top of another wooden insert the thickness of the t-nut head and put a washer and nut on the bottom of threaded pin.
I used the allen screws and large washers to hold the wooden insert in the table insert. This eliminates the need for the metal strap.
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Hi,

Here is a related post that might be of interest to you.

https://forum.shopsmith.com/viewtopic.php?t=11612

Thanks for sharing!

Ed

Ed I remember reading that post. I liked your inserts and your right you need three hands to use the Power Pro as a pin router. I work around that by making a plunge cut to full depth, retract the bit, turn off the Power Pro, and set partial depth and lock the quill then turn it back on, rout and repeat. For the few signs, toys, etc I make I can't justify a pin router.

Here are the images but they are not to size.

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If you use the link below you should be able to print a to scale image from a top view.

http://sketchup.google.com/3dwarehouse/ ... fa6b4f45cf