Miami, FL
Quoted from rosh:For the manual routing I had created templates for the routing that were basically perfect, I had found a great method for creating templates for different inserts by using the actual insert and popsicle sticks to get the spacing right for the bushing on the router, and then a flush bit to cut the template -- it worked great. In two cases I used some tape to tweak the sizing. So the reality is, it sets a pretty high bar relative to quality and fit for the CNC routed one.
I don't think you saw the manual one, it really was surprising good as far as fit and finish, the biggest drawback to the manual is there is less accuracy around positioning and alignment than with the CNC, since I have to position the template over the insert and hard to get that perfect. Other routes and cuts that were not the inserts, should be much better with the CNC, since I typically did not create templates when routing those and for various cuts, not like I am that perfect in cutting with a jigsaw. Also, a lot less stress relative to the routing, when doing it manually you know that any mistake of significance, could wipe our hours of hard work.
Josh, your game looks great! I don't have CAD, so I'm in the process of making templates for manual routing. I've hit a bit of a roadblock, though. Would you be able to post step-by-step pics on how you made your manual templates? I'd like to see the process for making them, then routing the holes to fit flush with the inserts.
I made a template from 1/8" hardboard with seven shapes, but each one has little misaligned gaps, despite a tight fit. The section on pinball makers is informative, but only has a few pictures. Hopefully you can show us. Good luck with the build!
