I'm close to doing 100 guitars with this binding jig and have been happy with the results but...
This thread and the associated Flickr set have had consistent activity since I posted it so I thought I'd do this update about my most recent upgrade on the binding jig set up.
An issue that I have been having is the fiddly router base that I used with the Bosch Palm Router. The adjustment don't reliably work and there is too much play in the set base. So if you are contemplating making this jig set up or already made one with the Bosch Palm Router and the standard little router holder I recommend upgrading to the Bosch Plunge Router Base:
The handles come off easily and it works like a charm. The router base has the same base screw pattern as the standard base so you don't need to drill any new holes in your jig.
The Plunge Router Base holds the router much more accurately and securely. The router attaches and releases from the base much more easily if you use the router for other work. Additionally, you can have the plunge feature that makes setting depth settings effortless. I set the depth stop on the router base for my deepest cut which is for my standard binding and purfling.
When attaching the new base I was careful to be sure the router bit was properly aligned. The center of the cutting bit should be dead on with the center of the dumb bell guides. When this is done correctly you will get a consistent depth of cut because it will remain the same depth if the guitar tilts one way or the other along the path of the cut. This tilting can be unavoidable in tight places like the inside of a cut away. Generally when properly set it is just one less thing to worry about while routing.
Bosch has an alignment tool that is helpful when attaching the base to the jig:
It is 1/4" for the router side and 1/2" for the dumb bell side. When it is attached you can easily center exactly where the base should be tightened down to the jig:
If you are using a different brand router it's likely they have a plunge router base as well and you may want to consider the advantages. The plunge router bases usually costs over a $100 so certainly the expense may be a consideration. For me I would have been willing to pay the extra buck for every guitar I've done to not have to fiddle around with that stupid little router base I've been fighting with all these years!