4
Remove the machined rail and install another. If you have a
second router setup and your bit will reach high enough, you can go
directly to machining the pattern (for cutters with a 1/2" deep profile
max) without having to remove the rail between operations.
For safety, at least 1/8" of the bearing should ride on the template,
which also acts as a starting pin and provides
the best control of the part.
Depending on part thickness and bit design, this may require
an additional spacer between the bearing and the
cutter. You can also use a router fence, set back to
accommodate the narrowest section of the rail,
to help vacuum away cutting debris.
