How to make a rotary tool Router. This is a attachment for a dremel/ rotary tool that automatically makes it a router. This is my own design, and I have made many of these before. So today i'm showing you how to make one! This is probably one of the most simple designs and projects I've ever made, so no matter what skill level you're at, this can easily be made. So the first thing you want to do is have all your materials ready.
1/2 in. thick Plywood (
1 in. thick pine wood
Cut all the wooden pieces to the given lengths:
1. 1 in. pine: 5 In. x 1 1/2 in. x 1 (This will be Piece A)
2. 1/2 in. plywood: 1/2 x 1/2 in. x 2 (These will be pieces B, and C)
3.1/2 in. plywood: 1/2 in. x 5 in. x 1/4 in. x 1 (H, L, W) (This will be piece D)
4. Veneer: 5 in. x 1 1/2 in.
Step 1: Drill Your Holes.
After you've gotten all your pieces cut to length; drill all the holes shown. The first hole will be drilled on Piece A. with a 1/4 in. bit; then Counter-Sink it with a 1/2 bit. After doing that on BOTH sides of the piece as shown, drill a 5/8 in. hole in the middle of the piece: This will be where the rotary tool attaches.
Tools needed for this Step:
1. 1/4 in. Drill Bit
2. 5/8 in. Drill Bit
3. 1/2 in. Drill Bit
4. Drill/ drill press/ hand-crank drill.
Step 2: Add Some Pizzazz!
Now that you've drilled all your pieces, add some pizzazz by gluing some Veneer on top of Piece A. I chose to use Honduran Mahogany for this. Try not to be skimmy on the glue, because this veneer won't stay if it doesn't have a good glue bond. Make sure before gluing the pieces, to drill SMALL holes through the veneer, so that way we can clean it up later on... One important thing though is to clamp it together, because it will try to peel off as shown in the image above.
Once the glue is all DRY, use a Rotary tool with a burr or sanding sleeve to remove the excess material of the veneer that's covering the holes.
Tools and Materials used in this step:
1. Wood Glue
2. Veneer (any kind will work)
3. Rotary tool/ Dremel (and burr or sanding sleeve)
Step 3: While the Glue Dries...
While the glue on the veneer dries, drill your holes into Pieces B and C. You want to drill a 1/4 in. hole for the screw to go in, and then counter-sink it with a 1/2 in. bit; that ensures that the screw won't bother you while using the router.
Tools used in this step:
2. 1/4 in. Drill Bit.
3. 1/2 in. Drill Bit.
Step 4: Trace, Cut, and Round It.
Now that the glue on the Veneer is dry; trace a simple line along Piece A and make it 'round', i used a small container to trace it. After doing that, I cut it out to shape. The shape is easier to understand on the last picture above. When everything is cut, clean up the edges and round the piece up with a File/ sandpaper.
NOTE: Try not to round the top of it too much, because you still want to keep the veneer showing at the top of the piece.
Tools and Materials used in this Step:
1. Container (something small and round to trace)
3. Saw/ coping saw
4. Filer/ sandpaper
Step 5: Make Your Cross Piece.
To hold the two bottom pieces together I made a cross-piece ( Piece D). This cross piece will be drilled with a 1/8 in. drill bit. Drill the hole a 1/2 in. away from the edge of the wood; the picture above shows where. Once your holes are drilled, glue in some 1/8 in. dowels. You want those to be able to lock the side pieces together later on.
Tools/ materials used in this step:
2. Piece 'D'
3. 1/8 in. Drill Bit
4. 1/8 in. Dowel
5. Wood Glue
Step 6: Make It Symmetrical.
While piece D dries, we're going to make Pieces B and C symmetrical with Piece A.. To do that we'll make sure holes align, and then trace piece A onto pieces B and C. (view images above for better understanding) After we've traced the pieces (both left side and right side) we'll cut along the line. That way when the product is done; it's perfectly symmetrical and neat. And after you've completed that; drill a hole into the top of pieces B and C. And after that, you're basically done!
NOTE: Make sure the holes are drilled the same distance away from the edge as they are on piece D. This is VERY important, because if these don't align with the holes on piece A, you'll need to drill all new holes, and possibly start over and make your pieces again. (view pictures above)
Tools/ Materials used in this Step:
2. Saw/ coping saw
3. Piece A
4. Pieces B and C
Step 7: Put It Together!
Now that all your pieces are made and complete, you can start putting it together! Follow instructions carefully(or view pictures above)
- Fit pieces B, and C to piece D. (dowels will hold them together)
- Insert screws into the bottom of both pieces B and C, and make sure they fit into your 'Counter Sink'
- Screw on your Nut to fasten the screw to pieces B and C.
- Screw on two more Nuts on top of the two screws from the previous step.
- Align piece A on the screws (as shown in images above)
- Put on Wing-Nuts after inserting piece A, to ensure piece A is fastened to the screws (view pictures above)
Tools/ Materials used in this Step:
- Pieces A, B, C, and D
- 2 screws
- 4 nuts
- 2 wing nuts
Step 8: Tap the Screw.
Now that it's put together, you need to tap your hole so your Dremel can attach. NOTE: I screwed off the cover on the head of the rotary tool, the threaded screw left is what will screw unto the piece.
Because I didn't have a tap, or screw big enough to tap it; I ended up just using the Dremel screw to tap it. This can be done by simply inserting the Dremel Head into the hole, and twisting slowly. Eventually, you should be able to screw in the Rotary tool in and out like it should.
NOTE: the ONLY reason i decided to tap it with the dremel is because i'm using Pine wood, (which is very soft) If you don't use a soft wood for piece A and try to tap it with the dremel, you'll ruin the screw on it. That's why i decided to go without a tap for this, but if you DO have a tap that'll work, then you can use any wood you want.
Step 9: Finished!
Now your Rotary Tool Router is complete! This is a small, portable router that is no doubt simple. It is powered by a Rotary tool, and it is removable from the attachment. This is basically just a Jig/ Attachment that can turn it into router. It also requires Bits to rout what you need, just like any other router would. I loved making this project, it was quite fun. If you've made it, have questions, concerns, or suggestions, feel free to comment below. But 'till next time, thanks for stopping by; and Create Something.
Runner Up in the
Build a Tool Contest 2017
maKACS made it!