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Hands-On Fabrication Tip: Using the Fukuda Router Tool Perfect Cut-Outs on Inside Square or Rectangular Shapes – in less than 5 minutes Overview The sequence in this feature shows the Fukuda Router Tool performing the cutting guide for an EXACT FIT cut out on a square or rectangular shape in less than 5 minutes from start to finish. This is a time saving method to produce excellent results when compared to routing with MDF strips, using a jigsaw or Dremel, or even manual filing. This process allows for attractive flush mounting, even in “zero clearance” situations. It’s a great way to shave precious time out of the custom fabrication process – especially for the quick jobs that usually end up taking an hour when you did not plan it. You can also use this process to develop your own templates for repetitive tasks so the subsequent jobs take even less time to cut the perfect opening! In the example shown, a trim ring for an LCD monitor is demonstrated. Process
Position the tool around the object you for which want to build a “snug” fitting panel. (Figure 1)
Push the rails in until the tool is tight against the object. At this time tighten the plastic thumbscrews. (Figure 2)
Now take the tool over to your substrate material (MDF, plastic, etc.) and lay it over the material (upside down) so you can mark the opening for rough cutting. Mark the opening with something that will show up adequately during the rough cutting steps like a pencil or black Sharpie. (Figure 3)
Use the appropriate eye protection at this time (safety glasses, etc.). Drill a hole in each corner of the marked area leaving about 1/8”-3/16” spacing from the marked line of the edge. Using your jigsaw, carefully cut out the middle section leaving that necessary spacing of 1/8”-3/16” around the edge. This will be the trimming job of the router bit once the router tool is in place as the guide. (Figure 4)
Prepare your substrate for attachment with the tool by wiping away any residual dust from the rough cutting operation (Figure 5). Peel and stick 2 sided tape to the tool first and press it firmly into place on the aluminum arms (Figure 6). Once completed, peel away the second layer of the tape, flip the tool over, and position over the rough cut opening. Take your time when doing this part because the 1/8”-3/16” edge does not leave much room for error. Press and stick the tool firmly to the substrate material. Note: It is not advised to stick the tool down to the substrate and lift it again for repositioning. If the tool must be repositioned, use new 2-sided tape.
Take the tool and substrate combination over to the router table and lay the open area over the router bit. Adjust the router height so the flush trim bearing RIDES ON THE ALUMINUM of the tool arm (Figure 7). After the router is sufficiently adjusted, pull the tool away from the router bit and hold it firmly in place while you start the router. Remember you should be wearing eye protection before turning on the router!!
Once the router is turned on, follow the pattern shown to coordinate your cutting movements. Begin at the bottom edge of the tool, moving to the left, then up across the top, and back down the right side (Figure 8). Complete trimming by going around another pass to ensure you did not miss any material. Beginning at the bottom (closest to you) lets you safely align the bearing on the tool.
After the opening is finished, you can move on to completing the panel in whatever fashion you wish. It can be trimmed and integrated into a dash or door panel, it can be finished on the edges like a trunk panel, or it can be further modified on the outer edges for a trim ring.
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Step 2: 
Step 3: 
Step
4: 
Step 6:
Step 7:
Step 8: Once completed, remove the tool from the substrate and
test fit your part. It should fit perfectly if you have used the
correct diameter bit for the corners. Remember a ½” flush
trim router bit gives you a ¼” radius (Figure 9) and
a ¼” flush trim router bit gives you a 1/8” radius.
It’s recommended to use a ¼” flush trim bit
on tight corners like headunits and monitors to duplicate the radius
correctly without filing (Figure 10).
The finished example was further trimmed on the outside edges
with another template for a video screen trim ring (Figure 11).
In actual practice, the opening could be for virtually anything
that is square or rectangle in shape including: