ProBox Install title

The cleanliness of the installation is determined by how cleanly the hole is routed. So once again preparation is the key to success for this part of the process.

Before starting out make sure that the router bit is sharp and that the router bearing is rotating freely. If the bearing does not rotate freely it will spin against the side of the jig generating heat and melting the jig, not good!

The first step is to correctly setup the router bit in the router. The bit has a 1/4” diameter shank, a 1/2” diameter cutter, and a 5/8” diameter bearing. The cutting depth is 3/4” but it will be setup at less than this depth.

The simplest way to setup the depth of the router bit is to place it in the router, then place a jig against the bottom of the router base, then adjust the depth till the top of the cutter is a 1/16” above the bottom of the jig.

The photo shows a router bit that has been correctly set in one of our recommended routers, the Ryobi TR45K!

ProBox Install title
ProBox Install title

Routers can be very dangerous as they rotate at extremely high speeds and therefore must be handled with care. We recommend using panel routers for this reason as they are smaller and easier to handle. The key to doing a successful route is to not force the tool, let it cut at its own speed and make sure you are cutting in the correct direction. You want to be cutting against the rotational direction of the cutter.

Start out by removing the inner part of the hole before finishing by going around the inner edge of the jig. Ensure that the bearing is against the edge of the jig, a lot of force is not needed against the jig.

Once the hole has been routed there should be a lip around the inner edge of the jig, so the hole is inset from the edge of the jig. This lip makes it easier to pour resin around the box and also helps during the sanding process.

The adjacent photo shows a routed hole, the lip is visible in this photo.