Template routing with a plunge router is how shops copy hinge mortises, inlays, curved parts, and identical cutouts without reinventing the path each time. A plunge base lets you enter inside a closed template, set depth stops for safe multi-pass work, and keep the cutter vertical while a guide bushing or bearing follows the pattern. This guide walks through template design, bushing offset math, clamping, and the plunge sequence that keeps edges crisp instead of chewed.
Guides
How to Template Route with a Plunge Router
Learn how to template route with a plunge router using bushings or bearing bits, secure templates, and multi-pass technique for clean, repeatable shapes.
Bushing follow versus bearing follow
With a guide bushing, a straight or spiral bit rides inside a collar that tracks the template edge; you must account for the offset between bushing OD and bit diameter when you size the pattern. With a bearing-guided flush-trim or pattern bit, the bearing rides the template directly and the cutter matches that edge — simpler mentally, but you need the right bit style for whether the template sits on top or under the work. Plunge routers shine with bushings for interior pockets because you can drop into the waste and work out in controlled stages.
What you need
- Plunge router with a centered bushing port or a quality bushing set
- Template material: MDF, Baltic birch, or acrylic thick enough not to flex
- Straight or spiral bit matched to the bushing, or a pattern/flush-trim bit for bearing work
- Clamps or double-sided tape that will not let the template creep
- Depth stops set for roughing and finish passes
Step-by-step template routing
01
Build a template that will not flex
Cut the master carefully — bandsaw and sand, or CNC the blank — because every error copies forever. Keep walls thick enough that clamp pressure and bushing pressure do not bow the edge. Mark orientation so you never flip a non-symmetric pattern. For interior openings, make sure the bushing can enter and travel without binding at tight radii; inside corners cannot be sharper than the bit allows.
02
Calculate offset if you use a guide bushing
Offset equals half the difference between bushing outside diameter and bit diameter. Enlarge exterior templates or shrink interior openings by that amount when designing the pattern, depending on whether the bushing rides outside or inside the template wall. Test on scrap: a small surprise on a hinge mortise is a ruined door. Write the bushing and bit combo on the template so you repeat the same setup next month.
03
Secure template and workpiece as one unit
Align registration marks, then clamp outside the travel path or use quality carpet tape across a large contact area. The template must not lift when the bushing presses sideways. Support thin work over a spoil board so the bit does not break out underneath. Confirm the bushing is concentric and seated fully in the base — a cocked bushing cuts ovals that look like bad templates.
04
Set plunge depths for roughing then finish
Dial a final depth that just clears the waste or reaches the mortise floor. Use turret stops or marked intermediate depths so each pass removes a controlled amount — often 1/8 in. or less in hardwood. Keep a last skim pass of about 1/32 in. for a clean wall. Zero the bit against the surface with the power off before locking numbers you trust.
05
Plunge, follow, and keep lateral pressure steady
Start the router, plunge to the first stop inside the waste, then move until the bushing or bearing kisses the template. Maintain firm contact without leaning the base. Feed against bit rotation for the main removal; a light climb pass can clean tear-out only when depth is tiny and the template is solid. Complete the perimeter before deepening, or work in laddered depths if the pocket is large.
06
Retract, clear chips, and inspect before the next pass
Raise the bit fully before moving the router off the work. Vacuum the track so chips do not lift the bushing off the template edge. Check for burn, wander, or a shiny glazed wall that hints at a dull bit. Only then drop to the next depth. On the final pass, slow the feed and keep the base flat through the exit so you do not leave a divot at the stop point.
Common template failures and fixes
- Undersized or oversized part: wrong bushing offset — remeasure OD and bit diameter
- Wavy edge: template flex or intermittent bushing contact — thicken the pattern or improve clamps
- Burned walls: dull bit, too deep, or dwelling — sharpen and lighten passes
- Blowout on exit: unsupported grain — backer board or careful exit on the last skim
- Oval mortise: bushing not centered or base tipped — check centering and keep the base flat
Production tips for repeat parts
Number templates, store bushing notes with them, and keep a dedicated bit for that setup when possible. A stop block or pinning system speeds alignment on batches. If you switch between bushing brands, re-verify offset — same labeled size is not always the same OD. For deep pockets, leave the finish pass until roughing has removed heat-building bulk.
FAQ
01
Do I need a plunge router for template work?
A plunge base is ideal for interior cutouts and mortises. Fixed-base routers can follow edge templates when you can start from the outside, but plunging into a closed shape is awkward and less safe.
02
Guide bushing or bearing bit?
Bushings are flexible with any straight bit and great for interiors. Bearing pattern or flush-trim bits are simpler when the template can sit where the bearing rides.
03
How thick should a template be?
Thick enough that the bushing or bearing has a full, stable wall — often 1/4 in. to 1/2 in. MDF or plywood. Thin stock can flex under side pressure.
04
Why is my copy not matching the template?
Usually bushing offset math, a non-centered bushing, or template creep. Test the exact bit and bushing pair on scrap before the good workpiece.
05
Can I template route hardwood in one pass?
Rarely wise. Multi-pass plunging keeps the bit cooler, the walls straighter, and the router easier to control.
06
What bit works best with bushings?
A sharp straight or spiral sized to leave proper clearance inside the bushing. Spirals clear chips better in deep pockets.
07
How do I prevent template shift?
Use wide clamp pads or strong double-sided tape, and keep side pressure steady rather than slamming the bushing into the wall.
08
Should the template go on top or underneath?
Top templates are common with bushings and top-bearing pattern bits. Bottom templates pair with flush-trim bits that have a bottom bearing — choose based on bit geometry and access.