This past week I needed to make a notch on 3/8" acrylic rod for a client.

Problem is:

I don't have a Knee Mill/Bridgeport to make the notch, and I have to make over 100 of them.

So I used the table router and cobbled this first attempt together.

One loads the precut length rod into the rough 'blue' section.

The rod is pushed into the router bit until it hits the stop, back off, and then you remove the rod, rinse, repeat. Too slow and vibration was too great which caused crush cavitation in the cut and harmed the finish and appearance.

The next tool eliminated the hinge for a solid design, put more acrylic in contact with the rod. The larger mass of the tool reduced vibration and the cuts were up to snuff.

I don't get paid enough.....