So I spent a few hours reviewing old threads about making templates and found a ton of good info but not the exact thing I was looking for.

Ive always just popped the plug in the holders and used it as a guide, but i have some plugs that I cant/dont want to take apart, or have off center holes.

My main question is how much material do you leave on the base of the plexi/other material template that is held in the dupe??

I figured i would just measure the plug and kind of visualize how big overall the template needed to be.

and are you guys adjusting the depth of the cutter blade based on each plug or leaving that pretty much looked in place and adjusting the template or stylus??

Would like to build a template and some jigs for my own designed plugs so I can reproduce them easily and consistently.

Thanks guys

Mine have 3/4 to an inch of plexi before the end of the plug profile begins to jut out. I keep a turned master of each so I can verify that the stylus is set to proper depth by mounting it in the lathe and adjust plexi (left/right) then stylus depth accordingly. This is why I like to trade the turned master blanks.

Chris I cut a 1/4" piece of plexi approx 3/4" longer than plug and 3 inches wide. Use either a body to trace the plug on the paper plexiglass glass coating from the stylus converted cutter with a pencil and wood follower I stead of cutter or lay plug on plexiglass secured and trace. Cut out with band saw living line and get final shape with file and sanding block.