Russ and I attended the same router course last year and since then he’s been using his new skills to build gaming chairs. One of the challenges for this was to fitting the nuts into the boards so that they would not stick out.
Russ: I recently had a requirement to make a hexagonal indentation in a panel to hold a captive nut, and found a simple and accurate way to do this with a router and some scrap wood
You will need
- A router with a 20mm guide bush
- 6mm and 8mm straight cutters
- Some scrap material – 9mm MDF
isfine, I used ply.
- A drill
This method will work for any size of bolt, but bigger sizes will work better as the router will round off the corners slightly.
Drill a hole in a piece of scrap the right size for your bolt. Insert the bolt and tighten so that it will not revolve freely. Setup the router with
This gives you a hexagonal hole that has a radius 13mm bigger than we want.
Lightly sand the hole to widen it a little. You can return to this step if the template is too tight to accept your bolt
Change to the 8mm cutter. Stick your new template to a fresh piece of scrap. Set the plunge stop on your router to cut the scrap slightly deeper than the flange on your guide bush. Cut around the template and remove the centre to make a shallow hexagonal indent in this second template. This will have a radius 7mm bigger than we want.
Step 4. Remove your outer template. Change back to the 6mm cutter. Cut around the outer edge of this new hexagonal indent, this time going all the way through the material. You should find the resulting hole perfectly accepts your nut/bolt. If not, return to step 2 for some more sanding. Otherwise, you are ready to cut your workpiece.
Drill the hole for your bolt through the workpiece. Put the bolt in place, and use this to locate the template perfectly over the hole. Clamp in place, then remove the bolt
Build logs for the gaming chair.
About the author
Russ likes to play Elite