[quote name='Ou7shined' post='1215281' date='Apr 29 2011, 08:16 PM']It's gotta be wood if you are routing it out again.[/quote]
intit. stick your over sized bit of wood on some mdf, carpet tape straight edged mdf squares around it, remove said wood, rout out the centre using bearing guided bit, voila, template. tape template over desired area. rout the sucker out, brush a bit of wood glue round the sides and bottom, whack it in and rout it flush. job done.