I started fabricating Karl's 'J Rail design for the Floor Section and Seat Base and wondered how I could achieve it with just a hand router. So I designed the following parts to use after 3d printing them as router guides use a 12mm Follow Cutter. The Corner Radius Guide is for the Seat Base which accurately places the hole at each corner for the Swivel Truck Assembly. I will refer to the 2 small stops seen below as 'Edge Stoppers' which fit into the various Guide which ensures when clamped are flush to the edge of the panel.
The stoppers shown above are removed and inserted. Once the Guide is clamped down these are removed and gives the full outer edge for the router to follow.
I also made a Guide so the multi radius corner section could be done in one go. Again utilising the Edge Stoppers accurately getting the Guide flush to the edge. Same process clamp down, remove the Edge Stoppers for the router to follow unimpeded.
Finally the J Rail Guide. This was printed in 2 parts but was designed so each overlapped along the straight section and using some dowel posts and holes aligned the 2 parts together accurately, then simply glued them together creating a single solid guide.
Some strengthening sections outside the slot also stopped any flexing from the pressure of the router once screwed down to the floor section where clamps were unable to be used. This worked very well and was happy with the result. The router cut all 4 slots accurately and were all aligned to one another.
The 'Edge stoppers' were only used to position the initial front inner slot on the floor base. The plugs were used to accurately align the seat base in the slot Guide and allowed the other 3 holes from the seat base to be drilled into the floor. The floor base was then moved to the retracted J end of the guide and again the other 3 holes were drilled into the floor base from the seat base holes. Once these were done it was a simple process to put a plug in both holes for each J slot which then aligned the Guide screwed and clamped down then plugs removed and slot routed out. Repeat same process for remaining slots.
End result all slots were aligned with one another accurately and the trucks once assembled followed the slots without showing any binding at all.
If anyone would like these STL files happy to share just message me