No, I don’t mean for an inexpensive skateboard. I mean for someone who doesn’t like to spend money when I don’t have to.
I’m thinking of trying FCS fusions, but I don’t feel like buying another router bit nor the jigs ($70). I figure I can make them myself, adapting to the router bit I already have. I’m just wondering how tight a fit the boxes have in the routed hole? 1/16" gap? Less? Anybody else ever go the cheap route?
no gap! a gap would more epoxy to fill in and heat up the foam, so they are really tight in there.. The install kit is only 65$. when compared to futures @170$. Find a buddy to split it with you.?
You can do it without the jig if you have a steady hand. I have installed a bunch of futures boxes, two stage route, sans jigs. Actually came out cleaner than the jig ones I studied from some boards sitting in shops. The fusions are sweet–single stage route, fit them snug with a little bit of resin. No exotherm issues if using epoxy and being able to install them in the foam pre vac bag is the trick.
That said, I have the jig for fusions if you are in the central Florida area, you’re welcome to em. If not, I’m sure there are some swaylockers close to you that could loan them for a six pack. No cheap beer though–we are cheap bastards (why we build our own boards) in other aspects of life so We can enjoy good beer 
Josh
Make your own jig. The fusion jig can be made by drilling two holes into a piece of plywood and some rubber shelf liner from Target glued to the bottom so it doesn’t slip when you use it. I think the size was 2 1/8" holes about 4" apart, and then a coping saw to clean out the center. Not sure about the sizes, it was a long time ago.
Personally, I still like the original FCS plug for the connection to the deck. If exotherm is an issue, do two pours with Fiberglass Hawaii three minute epoxy. First pour is to fill the H pattern, the second pour is to set the plug. In about three minutes it will be like silicone rubber; easy to trim with a razor. Sandable in about eight hours. Fiberglass Hawaii three minute has almost no exotherm. The mixing directions on the bottle aren’t very clear. use 100:40 by weight.
No cheap beer though–we are cheap bastards (why we build our own boards) in other aspects of life so We can enjoy good beer Josh
right on brother!
So, are the dummy jigs necessary?
No they are not necessary. You can just use an old set of fins.
thanks Mako
UMM..................
Keith and Stingray have several gigs... and Jigs and templates....You might have to drive down south..........ha, ha
We have what you need......make the drive.....lot's of surf spots on your way south.....plenty of pals when you get here
Ray
**–wait, what? Freehand a Fusion? **Dude, that’s rad. I want to see a vid of this becuase I’m claiming shenanigans reading it.
Cool Hand Luke: “No one can eat 50 eggs.”
Hi Lillebel03/J…
If you want a tight fit, some see through tape, a tray, epoxy and microballoons,knife… and time
Can make a decent mold for it.
Is the only bit you have a copy collared router bit?
or…
just buy a Fusion plug, use a pencil, and router it out by hand…
i saw an ad from fcs with their new 2013 system somewhere?
w
really, see my post up the page. Plywood and a hole saw. half hour and you have a professional template.
That new system looks sweet if you have fin-and/or-wave personality disorder or are too lazy to screw your fins down. It’s a cool design approach, same footprint as the Fusion I hear, but: that’ll prob be an $16 plug… x5 on with a knubster, the works, better make a long lasting board to pair w/a $60-$80 plug set: Fin Systems - FCS
I like the FCS stuff, it’s quality. I bought the router jig, love it. I think I could make a plywood jig but how would I be able to see my toe points? If you could make one out of acrylic, you’d be able to line-up those marks. Precision. I like to know my cut is right-on. At that point, might as well drop the $60 bucks and have the real deal.
EDIT: der…I guess you could drill 1/8" holes in place of your L-C-R points, locate these marks. Been a long work week. der…
Scrap acrylic is easy to find in any city.
Make a jig with plywood and use it as the jig to route the acrylic since acrylic is a bit harder to work with than wood if you are not used to it.
Vaeske
Neither of the new plugs are the same footprint as the Fusion
The FCSii is close to the Fusion install.
The Origins is closer to a Futures install
Easier than that. Draw your fin marks 4 1/4 long, rather than the usual 4 1/2". That way you can see the ends of the lines when you put the template down.
On the inside edge of the template, you make three dots on each end. One in the center, and one at 1/8" left, and one at 1/8" right. Just like the clear template does. Touch the correct dot to the line on the foam, and route away.
Niiice…More templates. 
Fusion definitely my favorite so far from any other plug I’ve installed.
Don’t be a cheapskate, but be frugal, wise and even crafty. Making a jig is pretty straight forward, and with a router or trim router with a straight cutting bit it shouldn’t be a big deal. If you think you can’t because your lame, and just call yourself a cheapskate, buy the jig, your already saving money making your own board, and saving time and doing a job right the first time is money.
My number one goal here is Repairs. I have free handed fin box installs for several fin companies.....It's not that hard to do without a Jig.......$70 bucks for a FCS Jig and Router Bit is not a whole lot of money.....And it's a really clean set up..........There's a video on FoamEZ.com
Yes, I can make my own plywood jig and buy a router bit from Tool Mart. At some point.....buying the kit is cheaper than making your own kit...................Stingray........