I've had this router for years and it only gets occasional use but the last time I went to use it the base broke! Having just dropped a bundle on a 3D printer, I didn't feel like replacing a router. So.... I modelled it up and it's too big for my printer! Aaargh.
So, I've split it into two halves that can be printed separately and then welded together. It worked surprisingly well. Of course, if you have a big printer skip the pain and just print the whole thing.
I printed this in ABS with a heavy infill for rigidity.
Once printed, you'll find some notches on the bases that are probably a bit oversized and rounded preventing the two parts from fitting perfectly. File the edges of the notches until they just fit inside the other component. The notches work both ways so that the base isn't relying on just the weld for shear strength.
Place the two pieces on a flat surface and using a Q-Tip apply some acetone to both surfaces. Apply pressure while both sides are wet and ensure that they stay straight. I used a set of clamps to ensure this went smoothly.
Finally, wipe down the surface with acetone to give it a smoother finish and to smooth the line at the weld. In the photo you can see this gives it a glossy finish.
The two halves aren't the same and when putting it back on the router make sure to aligned the shapes on the bottom with the vacuum port on the router.