Router jig slotting templates, knobs, and fences (Marius Hornberger's Samurai jig version)

Six years ago, the young Marius Hornberger uploaded a making-of video of his version of the Samurai Carpenter's router baseplate jig. Some months ago, I stumbled across it, bought a 300*300 mm plate of polycarbonate and let it sit in the corner, like one does.

Here's the original video: 

This weekend, I finally got around doing something with it. Since I don't have a CNC, I designed templates for cutting the first slot on each side with my router, then placing the second template in the first hole to cut the second, third, and fourth.

ATTENTION: All templates are meant to be used with a bushing guide/cam ring of 10 mm and a router bit of 6 mm in diameter. For the bushings, I got this set by “Allsome” on AliExpress (looks identical to Katsu): https://s.click.aliexpress.com/e/_oFYQ0A3 and for the bit I went with this one: https://www.aliexpress.com/item/1005008541042519.html (6x22x50L).

I also made knobs out of the DXF files provided by Marius as well as a template for the middle 40mm hole. The knobs are press fit. I used my bench vise to press in the head of my M8 hex bolts (you will need 4). There is also room for a 5*3mm magnet to hold a washer. Turns out, my washers are stainless steel and not magnetic, so I just glued them on for now.

I used double sided tape to make sure the templates for the middle hole and the one for the first hole on each side stay in place. 

Further, I designed some fences in Fusion. There are tall (35 mm height) and small (10 mm height) versions, with and without threads. I decided to cut the threads myself for shorter print times (high layers don't go well with delicate threads). 

Maybe someone will find it useful. 

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