Quote Originally Posted by totoblue View Post
I now use my router using an ordinary 16mm router bit. I have a Makita 3612 (very common). I made an MDF jig to do the holes using a standard 16mm router bit...

The jig is just MDF with a circle cut into it...

If you want the hole to be 35 mm, then you need the jig hole to be 35-16 = 19mm bigger than the base of the router (assuming the router base is round).

So if you have a 3mm nail in the centre of a piece of MDF (that's 19mm minus the 16mm router bit), and hold your router hard up against the nail, you will get the correct sized hole...
Thinking about this some more, it's clear that the nail or drill bit you use (when cutting the hole in the jig) needs to be the wanted hole diameter (35mm) minus two times the diameter of the router bit.

e.g. 35mm hole and 16 mm bit: 35-2*16 = 3
35mm hole and 12 mm bit: 35-2*12 = 11

For other sized holes
25mm hole and 6mm bit: 25-2*6 = 13