Offset for Whiteside Inlay Kit

[Steve H Graham]

I got a Whiteside router inlay kit. It seems like a great set of tools, but I wanted to check my results with other people. It looks like a template has to be about 27/64" bigger than the desired inlay (in a given dimension) in order to produce the right size cavity and inlay. For example, if you want an inlay 2" wide, you have to make a template with a hole 2 27/64" wide.

Is this about what other people are getting?

[Bill Huber]

I don't think that looks right, not sure.

The collar on my Whiteside is 1/8" so it looks to be that the overall difference would be 1/4".

I am not sure where the 27/64" is coming from.

[Steve H Graham]

I tried to do the math, including the bit, bushing, and so on, but it drove me crazy. Finally I just measured the results, and that's how I got 27/64".

It's funny; I had no problems with calculus and advanced physics courses, but addition and subtraction drive me out of my mind sometimes.

[Andrew Gibson]

Steve, I measured Mine and came up with 3/8"
the inner bushing is 1/16" wider then the bit.
The larger bushing coller is 3/16" larger then the the bit. 3/16" times 2 = 3/8"

So if you want a 2" strip inlay you need to make your template 2-3/8" wide.

The easy way to check is to put your inlay bit on your router, plunge your bit through and then measure from the edge of the bit to the edge of the big bushing, then multiply by 2.

[Steve H Graham]

I wonder how I got 27/64". I'll measure again.

[Bill Huber]

I tried to do the math, including the bit, bushing, and so on, but it drove me crazy. Finally I just measured the results, and that's how I got 27/64".

It's funny; I had no problems with calculus and advanced physics courses, but addition and subtraction drive me out of my mind sometimes.

I know what you mean, I have been setting here running all around it.

You are going to use an 1/8 bit so that will always be the same.
The only thing that will change is the collar so if the width of the collar is 1/8" that should be the only difference. 1/8" on each side would be 1/4", I think.

I just brought in my template and measured it to an inlay I did and it looks like you are right, 27/64" difference in the inlay and the template.

So now I am going out to the shop and cut an inlay out and then just see how it measures out when put back into the template.

[Steve H Graham]

I'll bet I could do the calculations all day and never come up with 27/64". That's what makes me want to pull my hair out.

[Garrett Ellis]

Are yall accounting for the wall thickness of the 'tube' that the bit protrudes through? and also the space between the bit and the inner diameter of that tube?

[Bill Huber]

Ok, I just went out and cut an inlay with the Whiteside inlay set. I took it and put it in the template so that one end is against the template and measured the distance on the other end.

176436

I don't know the math but 27/64 is correct.

[Garrett Ellis]

This is going to change depending on what bushing and collar dimensions you use. I don't know the dimensions of the whiteside kit; you will have to measure the ID and OD of the bushing and the OD of the collar.

[Garrett Ellis]

FWIW, here is a "cheat sheet" for doing inlays (I found this on routerforums.com). This list is more generic and does not require you to buy a kit specific for inlays if you already have a set of bushings.

176437

[Steve H Graham]

Funny how hard simple measurements can be.

[daniel lane]

I'm sure I'll regret jumping into this, but it seems like an interesting question to me during a late at-the-desk lunch.

In my head, it sounds like the total offset needs to be [(collar OD)+(bit OD)]. If you think of only one side at a time: From the template you are offset the outer radius of the collar to the center of the bit, plus the radius of the bit to get to the outer edge of the cut - [(collar OD)]2+(bit OD)/2]. Double this for the total offset like Bill shows in the photo above and you get [(cod)/2+(bod)/2]*2 = [cod+bod]. If this is true, then based on the 27/64 offset and 1/8 radius bit above, I would guess that the collar OD is 0.296". Anyone want to check for me? :)


daniel

[Steve H Graham]

Makes my head hurt just to think about it.

[Eric Yuan]

Here's a picture explaining why the offset is 7/32" or (0.21875") for the Whiteside router inlay kit.

To Cut the Inlay piece (no outer Bushing)
1/2*Bushing OD + 1/2*Router OD
1/2*5/16" + 1/2*1/8" = 5/32+2/32 = 7/32"

To Cut the Inlay Hole (Attach outer 9/16" Bushing)
1/2*Bushing OD - 1/2*Router OD
1/2*9/16" - 1/2*1/8" = 9/32-2/32 = 7/32"


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