Fitting Bosch POF 1200 AE router to FSN OFA guide rail adapter plate

1 Jan

Long ago I bought a DIY green line Bosch router POF 1200 AE which served me well for all the years. Recently, I bought a plunge saw with guide rail for perfect straight cuts and found out, there’s an adapter plate FSN OFA for a router that can be fitted to the guide rail, with which one can achieve those perfect straight lines with the router, as well. I briefly checked the manual for the adapter plate to see if I could fit my POF 1200 AE router to the plate. Unfortunately, the manual listed only professional blue line GOF router models (and some models from Festool, Mafell, DeWalt, and Makita) but I decided to buy it anyways, as I was sure I find a way to fit a POF router to it, as well.

After I unpacked the adapter plate, I thoroughly checked all the pre-drilled holes marked from A to I on the plate only to find out, that none of the holes align with the screws on my router’s base plate. The closest I could fit was one C hole, but it was putting the router slightly off center. That meant I have to either modify the adapter plate or the base plate of the router or manufacture a new base plate for the router. I found a model for a modified base plate on the web to be either 3D printed or CNC milled, but I do not have access to either of those so I ditched that idea. Instead, I decided to go the simpler route and drill new holes through the FSN OFA adapter plate.

I positioned the base plate as in the picture bellow and drilled three 4.5mm holes through the aluminum adapter plate.

After that I countersunk the holes to keep the screws flat with the surface.

Since the bottom hole was located under the blue plastic and brown composite part, I reattached them to the plate and drilled through with 4.5mm drill. Then I used larger 10mm drill bit to widen the holes in the plastic and composite part. Finally, I marked the new holes with green permanent marker as a homage to the green DIY line.

My old POF 1200 AE router has five screws, so I can keep the base plate tightened to the router with the two remaining screws, while leaving the three screw holes open for fitting to OFA adapter plate (the holes should fit also the old POF 1400 ACE model).

However, as I checked the images of the new POF 1200 AE/POF 1400 ACE routers, the current models have only three screws (the ones I used for fitting the router to OFA plate). So you will have to undo all three screws every time you want to fit the router to OFA adapter plate if you have the new model, or drill the two missing holes (I believe the two threaded holes in the aluminum plate of the router are still present – please leave a comment below to confirm if you have the new model).

The next project will be upgrading my POF 1200 AE model with fine adjustment depth knob as featured on POF 1400 ACE model. Will post an update how it goes.

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