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Ok so the next morning I removed all of the clamps. The insert plate came with some pre-drilled holes for non plunge type routers like Porter Cable which are more common but like I said, I had this nice one not being used and it is a more powerful one then my Hitachi. I removed the small cover plate from the bottom of my router and discovered I had room to drill out the holes and tap new ones to allow for a bigger machine screw. I then matched the adapted router base up with the insert plate and drilled holes on my drill press. I went with a nice countersunk machine bold that is tightened with a allen wrench.
1. and 2. Attaching the router base to the insert
3. I added a locking nut so the machine screw can't accidentally vibrate loose.
4. Here is a closeup of the pattern cutting bit on my Hitachi router. I used my sabre saw to cut the area that would not be needed and would leave a lip to be cut with a rabbet. I then clamped my plywood pattern and used the pattern bit to cut the rabbet. The ball bearing above the cutting tips runs along the pattern. It took 2 passes to get the correct depth.
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