This is a quick and dirty router table insert for the Bosch trim router with matching templates.
The router is quite powerful, so it works relatively well as a table mounted router even when cutting hard wood, albeit taking shallow passes.
Materials you will need:
- Bosch AdvancedTrimRouter 18V-8 (other makes and models may be compatible)
- Flush trim router bits: 13 mm with bearing on top, 16 mm with bearing on the bottom
- Sheet of wood, at least 8 mm thick, I used 20 mm plywood
- Jigsaw
- Power drill with a drill bit large enough for the jigsaw blade
- 7x countersunk wood screws, 4 mm x 20 mm
- All printed model files, I suggest printing the base plate in a stiff and strong material (ABS) at 100% infill
Optional:
- Paper backed tape/painter's tape and superglue
Instructions:
- Use the inner template to mark the inside hole, drill at the four corners and cut the inner part with the jigsaw by connecting the four drilled holes. Be sure to leave enough stock (2-5 mm) to later clean up with the flush trim bit

- Fix the templates to the wood to flush trim them: The idea is to glue the template temporarily to the wood by using the tape as a barrier to not glue wood and plastic together. Apply tape on the mating surfaces on both the template and wood, then using a small amount of superglue on the tape, glue the parts together.
Here's a video for clarity: https://youtu.be/3Gw3Z3yt1v0?t=76 - Flush trim the inside from the back side using the 13 mm flush trim bit and check the fit of the router holder that came with the tool. It should be quite tight.
- Once you are happy with the fit, remove the inner template and cut the 5 mm recess with the 16 mm flush trim bit and the outer template.
Finished product:

- Remove the clear stock base plate, swap it out for the printed one and screw it to the table using the countersunk wood screws.
- Have fun making stuff!
Disclaimer:
Power tools are dangerous and can cause serious injury or death. Make sure you read and adhere to the safetey instructions that came with your power tool. You are solely responsible for your own safety and the safety of others while using these tools. Any damage, injury, or loss resulting from the use of these tools is at your own risk, and the creator of this model assumes no liability for such occurrences.
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The author marked this model as their own original creation.