Anyone do this? A little worried the Friction from the router will melt the template and screw it up for second half of the forum.

not sure, only used thin plywood...only the bearing should touch it so I would think you will be good. I use a router table with a 2" long bottom bearing pattern bit, template is on top. I know others use the router without the table and use a top bearing bit..either way the cutting edge only touches the wood

tried it,definitely use plywood.  It does indeed melt.

OK, looks like plexi melted when born used it. I'm gonna make a new form in the next week or two myself.. I have some plywood to make my template I also have some lexan..will use lexan on another project.

I used it with no problem. I drew a form on the computer And had it laser cut. Made a perfect curve which I can't do by hand on plywood.

If the bearing is spinning as designed why would there be that much friction?  It worked slick for me.

Yes I can't see any reason for it to melt unless the bearing is old and running hot

Get yourself some 1/8" tempered masonite for your template

Kopper,I do the majority of the plex work where I work(alot of it) It makes an awsome template for either top or bottom bearing bits. Burt