Router Second Pass To Enlarge Dado

You want tc make a series of inch-deep dadoes in some cabinet sides. As every routerhead knows, the machine is a trimmer, and you shouldn't really cut deeper than about Y* inch per pass. Your router is a fixed-base machine, so for each dado, you set the depth of cut to V inch and make a pass, then advance the setting to * inch and make a second pass. When you are done, you assess the process. Adjusting the router twice for each dado took a lot of time. And it didn't...

IL Drawers with a Different Dovetail

The assembled drawer is clean and functional. The sliding dovetail joint is a natural for this application, since its shape mechanically resists the tendency of the front to separate from the sides. And assembly is quick no fasteners or clamps required. common size of dovetail bit, too, being the size any router bit ser includes. Adjust the cutting depth to V* inch. Sci the fcncc so the slot's ccnterlinc will be Y* inch from the end of the drawer front. Test it by slotting some scraps of the...

With Chip Out and Tear Out

As the bit cuts, it tends to tear wood strands (tear-out) and lift chips (chip-out) along the edges of the cut. Tear-out seems to happen most along the shoulder of the cut. while chip-out occurs along the bottom edge. The explanation is depicted in the drawing. When you arc feeding the router in the proper direction, chip-out occurs as the cutting edge of the bit sweeps off the wood. Because the cutting edge is almost perpendicular to the work's edge, it's...

Swinging on a Template Guide

Worried about your slotting jig drifting off the fence while you're cutting slots A momentary lapse in concentration, a slightly errant push can produce a skewed slot. A botched job. Here's a way to eliminate the problem Modify the jig to work in conjunction with a template guide bushing. Then you can eliminate the fence entirely. The jig will swivel around the guide's collar but will always be in the correct alignment with the cutter. Moreover, this approach eliminates the need to add fences...

Try This

You can save some money if you cement backer to the bottom side of the tabletop. Backer is laminate without the color layer, and it is designed specifically for sealing the bottoms of counters and other laminated surfaces. Backer is kraft-paper brown and only half the thickness of regular laminate, but it nonetheless has the same moisture-resistant qualities, works the same way, and is bended with the same contact cement. An advantage backer has over laminate is that it isn't ts slippery, so...

Is a Table Mounted Router a Shaper

A more gracious answer would be sort of. Broadly, the two rigs do the same jobs. But when you become specific, the capabilities diverge. A true shaper is a stationary tool. It isn't as versatile as a router You can't run it over the work, you can't make plunge or piercing cuts. But it's got mass and power. In the woodworking shop, a quarter-ton stationary machine has it all over a 15-pOunder. Moreover, the practical power of a 3-horscpower shaper far exceeds thai of a 3-horsepower router. The...

Constructing the ideal top

Plywood Picnictable Pattern

The ideal tabletop has a 1- to Wi-inch-thick plywood core with plastic laminate on both sides. The dimensions of it. other than the thickness, arc pretty much irrelevant. It can be small enough (say, 14 inches by 24 inches) to use for a bench-top router table, or large enough (say. 48 inches by 30 inches) to serve also as a table saw outfecd (or as a multirouter workstation). The materials used and the method of construction remain the same. 1. Cut two pieces of plywood to size. Standard fir...

Will Plunger Router Work With Tracing

The easy, economical, sensible answer is Use what you've got. You already have it, so you don't have to spend any money for it. Your bits fit it. You probably know its foibles. Here are several alternative answers. Pick the one that works for you. Get a midsized Bosch, Elu, Porter-Cable, or other manufacturer's fixed-base router with a 3l i-inch-diametcr motor. Buy an extra base for it. Buy Porter-Cable's plunge base, too. Mount the extra fixed base on the router table's mounting plate and...

Rabbeting with a piloted bit

The first choice for the average rabbeting operation is the rabbeting bit, which has a pilot. It minimizes setup The only adjustments you can make are the depth of cut and the angle of attack. The measurement between the bit s cutting edge and its pilot governs what 1 call the width of the rabbet. (A lot of bit manufacturers call this the depth of the rabbet.) You insert the bit, adjust the depth setting, and rout. It is simple, but because it is, it doesn't allow much variation. Freud offers...

Fixing The Fence

The fence is easily the most frequently used router-table guidance system. You use it to direct the movement of the workpiece to the bit. You use it to position the cut. and sometimes to control how deep the cut is or what its profile will be. The fence itself can be a straight, Hat board, a sophisticated, multipan construction, or something in between. (See tl ie el laptei Router Table Accessories for fence designs.) It's not unlikely that the more you use your router table, the more...

What Pilot

The solid pilot is an integral part of the bit. It's about M* inch in diameter and extends about 'A inch below the cutting edges. This extension rubs directly against the surface of your work to guide the tatter and control its direction. The main disadvantage to the solid pilot is that it requires a gentle, steady hand on the router to get consistent results without marring the surface where the pilot atbs. The hall-bearing pilot is a bearing mounted on the tip of the bit. This bearing is...

Router Bit Dimension Lingo

There arc three essential components to success. One is the router itself. Another is the woodworker you. The last is the bit. A sawy woodworker using good bits can do a lot with a lousy router. But the best woodworker with the greatest router will be stymied by a dull, poorly balanced bit. So the bit is easily the most important part of the whole routing operation. The bit is doing the cutting. The router only powers the bit. The thing about woodworking with a router is that the more bits you...

Doors and Windows Continued

USE COPE-AND-3TICK JOINERY TO ASiEMftlE MUNTINS. Making windows. The difference between making doors and making windows is the bit. A window sash bit (or bit set) will rout sticking with a profile and a rabbet for glass. The setups and steps hc the same as with cope-and-stlck bits Do the sticking cuts, then cope the ends of the rails. The drawing shows a 12-light storm window Fred made using a sish cutter. T*o different window sash bit configurations are available. Cascade's SV window sash bit...

Safety First

The router may he the safest tool for surfacing small workpicces. Maybe the piece is small and blocky. Maybe it's thin. These are the pieces that the jointer tends to jerk around or demolish, mauling your fingers in the process. Avoid this hazard. Joint the piece on the router table. that's too big to maneuver, think seriously about using the router. You can do the job on the router table with an easily made jointing fence, or using a hand-held router guided by a straight edge. And how do you...

Controlling The Workpiece

Freehand routing on the router table may occasionally be appropriate though I can't think of a good example of such an occasion just now. In ever)' operation that may comc to mind, you use either a starting pin or a fence, even a sled, a template guide, or an overhead pin, to help you guide and control the workpiece. Small as it may seem, a router bit does generate a lot of forcc. As die size of the bit increases, of course, the force gets greater. The gotcha in routing lies in the multiplicity...

Flush trimming

Tnic or false Flush trimming is an operation used only when working with plastic laminates. Flush trimming is an operation done only with a (lush-trimming bit. Both false, thanks to the only in both statements. Flush trimming is an operation used when working wirh plastic laminates. Bu it also is done in order to machine edge banding, trim plugs and keys, and level all manner of lumps and projections in otherwise flat surfaces. And, set up with the proper jigs and baseplates, you can do the job...

Alternatives

To realize its full potential, a router table should be carefully designed. You can make a router table as simple or as complex as you want. Most of the Build-Your-Router-Table plans you'll see are for fullblown (even overblown) industrial models that do everything and have options for even more. But don't feel that you have to have a 24-inch by 36-inch Formica top mounted on Need to conserve space in a small shop Hang a router from your table saw's extension wing. This homemade table extends...

Spline And Dovetail Keys

What we're looking at here is a paradox of woodworking. Fitting spline keys or dovetail keys is an operation that gussies up one of woodworkings really elegant joints, the miter joint. Why would we want to do this The miter joint, after all, is the one you use when you don't want the end grain to show. We go to a lot of trouble to conceal the end grain, then we rout grooves in the corner and glue keys in them so their end grain shows. Looks like dovetails, you know Why wc do this is not...

Template Guide Centered

You don't have to use a fence to cut box joints with this jig, so long as you modify it to fit over a template guide bushing. As you know, the guide bushing is a metal fitting that mounts in the router baseplate. It has a low collar that surrounds the bit. If you widen the slot in the jig's base, it will drop over the collar. The jig is trapped It can slide back and forth as far as the slot will allow. It'll pivot around the collar. But unless you lift the jig. it is in the control of that...

Offset Base Laminate Trimmer

If you find yourself doing a lot of counter installations, and you get tired of hand trimming the few inches on either side of an inside comer or at the wall, you can buy an offset-base trimmer. This little gem is the only router with the collet not mounted direcdy on the motor. In this instance, the arbor and collet are out on a comer of the router base. What this does is allow you to rout well within an inch of most obstructions, which really cuts down on the nibblc-and-file work. But you'll...

Decorative Treatments

Decorative edge treatments are elementary, ihe most elementary router operations there are. Choose a cutter, tighten it in the collet, set the desired cutting depth, and you can run all around your project with a design-unifying. aesthetically pleasing, decorative edge. It's that simple. Though a fair number of woodworkers never get beyond this use of the router, the natural extension is to use the router to cut design-unifying, aesthetically pleasing decorative grooves on the work. And to use...

Woodworking With The Router

Bill Hylton and Fred Matlack Illustrations by Frank Rohrbach Photographs by Mitch Mandel THE READER S DIGEST ASSOCIATION. INC. Plcasaniville. New York Monlreal THE READER S DIGEST ASSOCIATION. INC. Plcasaniville. New York Monlreal v 1993 by The Reader's Digest Association. Inc. Illustrations v 1993 by Frank Rohrbach All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or any other...

Routing Curves And Circles

Working in circles is considered a waste of time, but you'd be surprised how often you really need to. In fact, there's been a lot of time wasted by people who couldn't figure out how to cut a good, clean circle (or arc) when they needed one. To cut a circic with the router, the basic need is to get the router to move smoothly around a given point. You'll find that there are numerous way's to accomplish that and that each of the ways has advantages in certain applications. Almost always, you'll...

Trimming laminate

Laminate can be trimmed either flush or to one of several bevel angles, depending upon the purpose of the edge. For example, if you are applying laminate to plywood panels that will be joined together into a cabinet, you will trim the laminate flush with the plywood's edges. However, if the laminate is the top surface of a counter, you will probably bevel it. TRIMMING SEQUENCES FOR THREE EDGE TREATMENTS li -2S BtVEL-TRIMMIW BIT FLUSH-TRIMMIM amp BIT TRIMMING SEQUENCES FOR THREE EDGE TREATMENTS...

Setting The Bit Height

After the bit is firmly chucked in the collet, you need to set the height. This isn't a diflicu It task by any means, but a couple of tricks can make the job easier and the result more accurate. First of all. use a steel ruler rather than a tape measure. The hook riveted to the tape makes the first inch of the tape virtually unusable for measuring purposes. Of course, the first inch is the most important in setting the bit height. A practical measuring device is a 6-inch steel rule, which you...

Construction

Pastic Router Mount

Start by cutting out the plywood parts. All the parts listed as being birch plywood can be cut from a single sheet. Fred used good-quality A serious router and cutter generate enough chips and dust to warrant a no-nonsense dust collection system. A pickup on the fence captures some dust from the table surface, hut the bulk of it is drawn from the router compartment through the 4-inch hos '. cabinet-grade birch plywood because it takes paint well. Since they aren't exposed, the two case tops can...

Cabinet Router Table

Router Jigs And Tips

This router table will handle most anyjob. It was designed and built by Fred Matlack at the behest of American Woodworker magazine. The goal was to incorporate features that make routing easier and safer, while keeping the design as simple as possible. The niftiest feature isn't worth much if it's too complicated or cumbersome to use. So the complete project has features like an adjustable fence, dust collection, an casy-to-rcach switch, and convenient storage for bits, accessories, and even a...

The Basic Process

Cutting mortises and tenons with a router has a lot in common with cutting dovetails or box joints. The b isic process is to cut a cavity in one piece of wood that will accept a projection that you've cut on another piece. Joining the pieccs is the primary motivation. The big difference is that in mortise-and-tenon joiner ', most of the joint is invisible. That means that as long as the joint is Structurally sound, you don't have to worry too much about cosmetic fit. In fact, with many of...

Edge Laps

Dividers Using Lap Joints

The edge-lap is formed by notching two boards halfway across their faces, then slipping them together. It's the joint used to create egg-crate-likc drawer dividers, for example. Depending upon the girth of the stock, this can be dealt with using a router. On the router table, the edge-lap notch can be cut as though it were a box-joint notch. See the chapter Box Joint. In this approach you use a bit that matches the stock thickness. Set the bit height to half that of the stock being notched....

Routing Laps

Mitered Haif Lap Joint

Conceptually, cutting laps is a lot like cutting rabbets and dadoes. Don't reach for the rabbeting bit, though. Laps are usually much wider than cuts we typically think of as dadoes and rabbets. In some cases, a lol wider, and therein lies whatever nib there is. But I'll get to that. Because of their similarity to dadoes and rabbets, the techniques for routing laps mimic those for cutting dadoes and rabbets. You use some variety of straight bit straight, shear-cut. spiral, what have you. And...

Cutting Denticulated Strips

Used witm wcore-box bit. it produces V ' flutes Making dentil molding Is as simple as dadoing a board and then ripping it into strips. The challenge lies in cutting crisp, evenly spaced dadoes. The router produces the crisp cuts, and this simple-to-make baseplate generates the even spacing. The trick is the little strip on the baseplate. When you make the first cut. the strip slides along the end of the workpiece, positioning the cut. When you make the second cut, the The denticulating...

Jlc Woodworking

Here's how to fine-tune a fence setting, fine-tune you're asking. I use a little steel rule to measure from bit to fence. What's to fine-tune Well, how about a sliding dovetail setup. You've cut the groove, and you're closing in on the fence setting to cut the pin. The test cut yields a pin that's just a little tight. You need to move the fence a little more. Just enough to take a shaving off the pin. Any more than that and the tail will be too small and will rattle in the slot. Your steel...

Sources

Here are addresses of selected router and bit manufacturers. This is our way of acknowledging the help of these businesses in developing this book. Without the routers and bits they graciously provided, we would have been hard-pressed to develop as wide-ranging a guide to router techniques as we did And while we weren't testing the tools, just using them pretty much the way you would, we can honestly say that we didn't find a dog among them. As a general rule, router manufacturers sell through...

Hand Routed Slots

Where the work is too unwieldy to maneuver on the router table, you must rest the jig on the work and cut the slots with a hand-held router. This is unlikely to be as quick and easy as doing the job on the router table. frame-splining jig helps you reinforce picture frames If you rest the frame-spliningjig over the tabletop.you need to use a slot cutter, as shown. Use the fence to control the depth of the slot you cut. With the frame-spliningjig riding the router table fence, you can use a...

Self Positioning Dado Guide

A logical extension of the fence and locatingjig co-operative is this all-in-one jig. The locating jig is glued to the underside of the fence, and the router rides on it. In the version shown in the photo on page 228, you mark two tick-marks per dado are all you need one edge of the dado to be cut, align the edge of the guide with the marks, then clamp it. Although I've never done it, it would be easy to incorporate a crossbar, so you could align and square the guide on a single mark. The guide...

Interchangeable Cutter Systems

An economical way to expand your bit collection is to buy from a manufacturer offering interchangeable cutters. The bits are assembled, meaning that the cutter is a separate piece from the arbor. You can buy a complete bit. but you can also buy just the cutters and use them interchangeably on a single arbor. You save roughly 7 per profile by buying the cutter but not the arbor. Doesn't seem like a lot of money, but think of it this way Buy three and get the fourth free Jeez, I could be a...

Making panels

The panel used in framc-and-panel construction ordinarily is a wood that matches the frame, but it can be a contrasting wood. The most simple panel would be a hardwood plywood matching the frame. Most familiar, however, maybe the so-called raised panel, a natural wood panel with a beveled or shouldered band around its edge. Whatever panel you choose can be set flush with either the front or back surface of the frame, or elevated so that it projects beyond the frame. Of course, to fit flush with...

Routers

The basic router is extremely simple. In general terms, it's a motor and several crucial controls. The motor can range up to about 3Vi horsepower and can turn anywhere from 10,000 rpm up to around 30,000. A rotary cutter is fitted into the collet on the lower end of the router motor. It is direct drive in the purest form. But just to complicate things a bit. a huge variety of cutters is available. See the chapter Bits. Being the business end of the machine, the cutters largely determine what...

Sliding Dovetail Joint

Rits a hybrid of the dado and the dovetail. In the sliding dovetail joint, one of the mating pieces has a groove plowed in it, the other has a tongue formed on it the tongue fits in the groove. Because both the groove walls and the tongue sides are angled like dovetail slots or tails, the joint has to be assembled by sliding the tongue into the groove. The advantage of the joint is its mechanical strength. Ever, without glue, the mating pieces will stay linked together. Only if the wocd breaks...

Jointing with a router

There's a cenain chicken-or-egg quality to this operation. Maybe you picked up on it. Why, you ask. would anyone joint with a router Wefl. you tell yourself, because he or she doesn't have a jointer. He or she has to joint boards for edge-gluing,, and the router can make a square, clean cut along the edge of a board An essential, of course, is a straight, true fence to guide cither the router or the work. And how do you get Ahhh The sigh of recognition Well, recognize, first of all, that your...

Forming Convex and Concave Surfaces

If this is all a logical progression, then the next step is to machine rises and depressions, using the same basi c technique. If the tracks arc cut to a concave or convex curve, the router carriage will rise and fall or fall and rise, as the case may be as it is advanced along them. The bit will penetrate deeper at one point than at another. If you like cabinets or other furniture pieces with curved surfaces, this is a great way to produce those surfaces. The surfacing platform can be adapted...

Keller Templates

Keller Dovetail Compound

A big step up the sophistication ladder you'll find fixed-template jigs like the Keller. The Keller dovetail templates produce through dovetails with an absolute minimum of setup fiddling. Compared to those cut by most other jigs, the dovetails produced by Keller's midsized model are relatively large, which makes this jig a good choice for carcase joiner gt r. The unit cuts Vs-inch-wide pins spaced IV- inches on center. While it's easiest to cut evenly spaced pins and tails, you can vary both...

Working on the Router Table

To joint on a router table, you need a jointing fence. But it's a different sort of fence than the one used with a hand-held router. Like the jointer's infeed and outfeed tables, the router table's jointing fence needs infeed and outfeed sections, adjusted to support the work both before the bit trims away stock and after. The most simple jointing fence is a strip of V -inch plywood withi bit notch and a strip of plastic annate glued to it. left of the bit, shown in Jointing Fence. You ca bond...

Box Joint

Finger Joint Jig Plans

The box joint is used in the same situations as the dovetail assembling boxes, assembling drawers, and casework. I used it on my bit case see the chapter Bits. It has pretty fair mechanical strength, but what it does is generate long-grain-to-long-grain glue area the son of glue area that yields the strongest bonding . The box joint is a machine-cut one as opposed to something like a dovetail, which, although it is easily machinc-cut. is nonetheless regarded generally as a hand-cut joint . A...

JL Breadboard Ends

Horizontal Router Table

The sliding dovetail is ideal for joining a breadboard end to a glued-up panel, like a tabletop or chest lid. The breadboard end, which is simply a narrow strip of wood, is a traditional method for preventing wide, glued-up panels from cupping. It is attached across the panel's end, concealing the end grain. The breadboard end prevents the cupping, but because its grain direction is perpendicular to that of the panel, it introduces a new problem It has to be attached in a way that allows the...

Edge Joining Along A Curved Line With The Router

Inlay Bit Adjustable Bushing Guide

Inlay work docsn t have to be done using die internal or female template. You can make an external or male template for the job. All you have to do is reverse the bushings used for the two cuts. To cut the recess, apply the template to the stock with double-sided carpet tape. Install the snwila of the two guide bushings on the router, and make the perimeter cut. Keep the bushing tight against the template as you work. Pry off the template, and rout out the rest of the waste. Then stick the...

Overarm Pin Router Plans

Overarm Pin Router Plans

The pin is another guide device used in router woodworking. It is positioned in the same axis as the bit, either above the bit in the case of a table-mounted router or beneath it in the case of an expensive over arm router. As the work or more often a template attached to the work rubs against the pin. it controls where the bit cuts. Tips on using the pin router arm can be found in the chapters Template-Guided Work and Rabbeting. This accessory holds a pin directly A pin routing artn is...

The Half Dovetail Rabbet

As an alternative to more familiar case comer joints such as rabbets and lock miters, Pat Warner, a router wizard from California, developed this router-cut comer joint. Simple to make with a router, the joint comes together neatly and squarely. It is more resistant to racking than a conventional rabbet joint. Warner prefers to work with hand-held routers, and his technique for cutting the joint reflects his preference. 1 think it's easier to do the cuts on the router table or the horizontal...

Shiplap Joints

The shiplap is formed by overlapping rabbets cut into opposite faces of adjoining boards. I'd call it a car-penny kind of thing, used in siding and natural-wood paneling. For example, in our shop here at Rodale. Fred cladded several walls with ship-lapped cedar. The cedar is photogenic, and it's easy to hang things on just drive a nail anywhere. Rather than just butt the 1 by 12 boards edge to edge, he rabbeted the edges so each board could overlap its neighbor. Once in the warm, dry shop for a...

Hand Routed Tenons

Cam Dowel Modular Kitchen

There you'll sec several lap-cutting approaches that apply equally well to cutting tenons with a handheld router. You can clamp several rails together and run the cutter across all at the same time, for example. One useful tenoning jig is designed to help you keep the shoulders square. The fixture is a T-square fastened to a base. It has a stop fence that corresponds to the T-square's crossbar, against which you butt the work. A second fence a router guide...

Pin Routing

The pin Ls a guide device used in router table woodworking. It is positioned in the same axis as the bit. either above or below it. The key is that the guide pin is located on the opposite side of the work from the router. It rubs against a template attached to the work occasionally, the pin rubs against the work itself , controlling where the bit cuts. Pin routing can be done with the router above or below the work. That means that you're going to need a sturdy overarm to hold either the...

Dovetail Splice

The dovetail-splice jig looks a lot like the box-jointing jig, and you make cuts in the same fashion. But the cuts only allow you to joint work-pieces end to end, as the samples show. Dovetails joining two boards end to end arc pretty glitz ', but it turns out they're also pretty easy to make. A version of the box-jointing jig is the router aid that produces these dovetail splices. The dovetail-splice jig is built just like the box-jointingjig, except that you use a dovetail bit to rout the...

Special Joinery Bits

Round Mortise And Tenon Oval

Woodworkers are constantly seeking the perfect edge joint. As we've seen in this chapter so far, there are plain edgc-to-edge butt joints, which are only as strong as your glue on a narrow surface can be. The tough part is getting the adjacent boards flush along their entire lengths during glue-up. So woodworkers have come up with joints that provide some mechanical interlock and an expansion of the glue surface splined edge joints, biscuit joints, tongue-and-groovc joints. Bit manufacturers...

Rabbeting Curved Work

The most obvious examples ofcurved workpieces that need to be rabbeted arc frames. In many cases, the technique of choice is to use a piloted rabbeting bit. The pilot bears on the edge of the work, regardless of the contour. A rabbet that deviates from the dimensions that piloted bits cut. however, calls for a different technique. This is a situation in which to use the router table's pin routing accessory. Construction details for diis device arc found in Pin Router Arm on page 91. Fixed...

Grooving with an edge guide

Routing Techniques Wood

The edge guide is a basic router accessory that's particularly useful for cut-ting grooves. Some manufacturers include an edge guide with the router, others charge extra for it. Some routers have good edge guides, others have lousy ones. In i he typical configuration, the edge guide is a metal and or plastic-outrigger. This shoe, suspended out from the router on one or two metal rods, bears on the cclgc of the work- t'm' xc.v oak m- wa amp yt qa.k v ' v ' 6 v 0 k imstall slices with two 2 xw...

Making The

The jig is in effect a V-block that helps you to cut easily and consis-tendy through a comer of a box. The jigs supports embrace the box's sides, and the base provides a firm work surface that perfectly bisects the planes of the comer. For smallish work, you use the jig on a router table. The box to be worked rests in the jig. For casework or any other box that's too big to maneuver back and forth on the router table, you clamp the jig to the comer of the work. In cither situation, the bit...

Tablerouted Mortises

Router Sled

The horizontal router table is my choice for mortising all but the biggest work. I've made two mortising sleds that securely hold the work, control the mortise's end-to-end size, and let me plunge the work onto the bit in stages. You can son of freehand mortises on the machine, marking bit tangents on a snatch of tape and cyeballing the cut from mark to mark. That's a good way to get the first mortise, which you use to set up the sled. But the sled allows you to plunge-cut the ends of each...

Profile Bits

Beaded Round Over Edge Profiles

In routing decorative treatments, the tricks are less in the doing, and more in the planning and bit selection. There arc a great many decorative profile bits available, and in many cases, even most cases, you can make a single pass with a bit to create the embellishment your project requires. Once in a while, though, you need to make passes with two or more cutters to get the contour you want. You need to choosc these cutters carefully. plan the order of cuts, and determine how you're going to...

Reverse Ogee And Astragal Draw

When routing any molding, work with a broad piece of stock if at all possible. The extra width gives you something to hold on to, something for hold-downs to bear on. And because the cut is backed up by the excess stock, the wide stock is less likely to break up as you rout it. After completing the profile, rip it from the stock. Don't riskdam-aging your profile by trapping it between the saw blade and the rip fence. Instead, orient the good edge so it will be to the left of the blade, as shown...

Overarm Pivot

Overarm Router Plunge Router

One kind of pivot point that doesn't harm the table's surface is the overarm. Instead of being under the work, the pivot is on top of it. A job-specific overarm pivot can be made using a strip of 14-inch plywood and a scrap of the working stock. Drive the pivot point through the plywood, then tack or screw the plywood to the scrap. The distance from the pivot to the scrap has to be long enough to accommodate the workpiece, of course. The big advantage to this system is that it also provides a...

Templateguided Work

A template is a quick and easy way to duplicate shapes like circlcs, squares, or even ktters. That's one of its primary uses, but there are others. Many others. The typical template is a durable wood or plastic or metal pattern. When the router, fitted either with a guide bushing or a pattern bit, is run along the edge of the template, the bitmakes a cut in the exact contour of the template. So when remarkable consistency from pan to part is required, a template is used to guide the cuts that...

Router Mini Table

Miniature Router Table Clamp

Here's how simple a router table can be. Three pieces of plywood, a foot-square piece of acrylic, and less than a dozen screws. It isn't big, but it's perfect for small work. And it supports a full-sized router, colleted for Winch-shank bits. The back has an extension that you trap in a vise to secure the table, while the sides rest on the workbench. This puts the work surface ahout 15 inches above workbench height, a good placement for small or close work. ROUTER MINI-TABLE AS SIMPLE AS IT...

Half Blind Dovetail Jigs

Adjustable Dovetail Template Jig

The least expensive to buy and the easiest to set up are the many half-blind dovetail jigs. No matter how wide or thick the wood is, you clamp it into the jig, run the router through both pieces at once, and get equal-width pins and tails that are rounded to fit into each other at the back. This is the very institutional-looking joint that is often used to assemble drawers for kitchen or other production cabinets. The trickiest part of this one is to get the two parts offset just half a pin in...

Not in My Router Table

Not every router is well suited for use in a router table. Some examples A trigger switch poses a challenge How do you keep the blamed thing running without holding the trigger Some routers older Bosch models, for example have gravity-dependent depth-adjustment mechanisms loosen the set clamp and you can pop the motor right out of its base. With the machine hung upside down, this is trouble. Loosen the clamp to alter the depth of cut and the motor falls right out. Surprise A lot of Sears...

Stopped Rabbets

Router Techniques Woodworking

A stopped rabbet, of course, is one that does not extend the full length of an edge. It can be stopped at one Of both ends. Here's a list of techniques for beginning and ending stopped rabbets using a hand-held router Mark the beginning and ending points on the work. Make the cut between the two marks, visually aligning the bit with the starting mark to begin, and stopping the cut when the ending mark is reached. The accuracy of this approach depends upon the clarity of your vision and the...

Edge Miters

Edge miters lend themselves to a greater range of applications than do flat miters. You might find them in casework as well as framework. The scale of casework the size of the individual pans makes it worthwhile to find some practical ways of cutting spline slots with a hand-held router. Muscling a cabinet side along an angled router table fence may not be is easy as sliding a lightweight router and jig along the cabinet side. So, here are several options, beginning with the router table. To...

Tongueand Groove Joints

Router Tables Horizontal

The tongue-and-groove joint is the older brother of the splined edge joint. Instead of a separate spline, you have a solid spline that's an integral part of the board. Like the splined edge joint, the tonguc-and-groove joint is used where surface loading might be considerable in tabletops and the like. It's also a traditional joint used in breadboard constructions. The most familiar uses these days may be in the carpentry realm tongue-and-groove siding, paneling, and flooring. Here the joint...

Horizontal Router Table

Roo Stove Knob

Brought to life as a mortising machine, this router table does a whole lot more than mortising. The router is mounted horizontally, so the bit's axis is parallel to the table surface. It's perfect for any operation that, performed on an ordinary route r table, would require you to balance the workpiece on edge, including Cutting dovetail pins for sliding dovetails Grooving the edges of straight, flat boards Raising panels with a vertical bit Routing architectural molding with tall face-molding...

Feed Direction

When doing any template-guided wuik. you waul the bit to pull the tojter toward the template. When you are routing around the outside edge of the workpicce. this fcnof that blemishes an otherwise excellent board can be excised and replaced with a carefully matched patch using inlay techniques. Guided by a template, rout an irregular recess that removes the defect. Using the same template, rout an insert with grain that matches the board as closely as possible. Can you sec the already-completed...

Flush Trimmer Router

Edge banding can be trimmed with a straight bit if you use this jig. The model shown in the following nvo photos attaches to a laminate trimmer, but you should be able to adapt the design and size to fit any lightweight router. Just remember that because of the router's position, the balance of the jig can be really hurt by a heavy machine. That's why a lam trimmer is nice. As you can see, the jig consists of a baseplate attached to a shoe. The side of the shoe is rabbeted and has a hole into...

Dadoing And Grooving

Dadoes and grooves are fundamental joinery cuts, and they can be decorative as well. Making these cuts is one of the operations ever ' woodworker tackles quite early in the learning process. You tire of butt joints after a couple of beginning projects, and the dado joint and its variants dado-and-rabbet. tongue-and-groove, sliding dovetail, and so forth arc among the first improvements you try. A router makes them easy to cut. As router-produced joinery cuts, both dadoes and grooves are...

Routed Tails Hand Cut Pins

Dovetail Router Bit

In the Rodale shop, Fred and Phil Gehret often start dovetails with the router, then finish them by hand. Most of the projects they do are one-of, special, even oddball ones that don't lend themselves well to mass-production-type jigs. They'll start by cutting either the pins or the The basic dovetail bit, the one that's in the sets of basic bits, the one that's used with the basic dovetail jigs, is the 14-degree, ' 2-inch-diameter, ' i-inch-cutting-length variety. Now, the traditional...

Lap Joints

The strength of this simple joint will Used for small or simple frames, like picture frames, face frames, cabinet door frames, and simple chairs, the lap joint is usually considered to be of intermediate strength that is, stronger than a butt, weaker than a mortise-and-tenon. The truth is, a well fitted and glued lap joint will be stronger than a comparable monise-and-tenon. The reason is that in a lap joint, each member retains more of its original girth. Usually, the joint doesn't fail, the...

Adjustable Finger

Dovetail Box

At the upper end of the flexibility-complexity group you'll find the Leigh jig. which has loose fingers that you can adjust. The fingers slide across the jig and back on two steel rods. The fingers can be arranged in an almost infinite number of patterns and spacings. This actually is a template system, though glorified somewhat by the fact that each set of fingers has a side for guiding the cutting of pins and one for guiding the cutting of tails. You can set the jig to produce wide tails,...

Splined Edge Joinery

One of the best edge-joint reinforcement techniques is perfectly suited to the router. It's the spline. You cut grooves or call them slots, if you prefer in the adjoining edges, extending them nearly the length of the boards. Fit a strip of plywood or hardboard into rhe joint as you glue it up. The spline strengthens the joint by expanding the glue area and by providing a mechanical lock. It also makes the boards a little easier to align and clamp during glue-up. If done properly, the spline...

TSquare

Router Edge Guide Jig

Probably the first step past the scrap-board fence every router woodworker makes is to the T-square. He or she glues and screws two straight-and-truc scraps together in a T-shapc. One piece, called the crossbar or the head, butts against the edge of the workpicce the odicr. called the fence or the guide or the blade, extends at a right angle across the workpicce surface. T-squares are easy to make, so make yourself several different sizes. Use a little one for relatively small work, a big one...

Homemade Edge Guide

Antique Homemade Scrollsaw

Tins edge guide is sturdy, flexible, and reliable. You can adjust it from a position tangent to the bit out to one about 10 inches away. Thus, you can use it to make a straight bit cut a rabbet or cut a groove it all depends upon where you lock the guide. A significant part of the guide's utility is the kind of setscrews you use. We used plastic knobs that don't torture your lingers they're higenough to turn easily. With a washer as an interface, the plastic knobs and plastic baseplate get a...

Porter Cables Omnijig

If I were doing woodworking for a living instead of writing about woodworking, the dovetail jig I'd buy is the Poner-Cable Omnijig. I think I'd buy it, anyway. My wry colleague Bob Moran, who did do woodworking for a living, says the Omnijig is a tool that no one working wood for a living can afford to buy. It's certainly designed and built for sustained use. Everything about it is heavy-duty. And it certainly is flexible. The base is a thick aluminum casting. It has broad clamping surfaces on...

Hand guided through cuts

The router perhaps obviously, is an excellent tool for cutting dadoes and grooves. A saw-mounted dado cutter hogs away dadoes and joiner ' grooves more quickly, but the router has a lot of pluses that compensate for its lower cutting speed. One of the pluses is that the dado can be precisely sized the diameter of the cutter determines the width of the dado. Not all saw-mounted dado cutters arc so precise They require trial-and-error adjustments to achieve a specific cutting width. Another plus...

Routing An Edge Joint

Router Techniques And Different Joints

The first step in preparing any edge joint is to joint the edges of the mating boards. Suffice it to say here that this is an operation you can do easily with the router. Details arc found in Jointing with a Router on page 188. But you can joint most boards more quickly and accurately on the jointer, and there's no reason why you shouldn't use the jointer if you can. But a router can help you do a special job of the fundamental woodworking task of edge-joining two or more boards to make a wide...

Edge Joints

Thoughtfully applied, the router edge-jointing technique can give you ey e-catching results. When it's used to prepare boards for gluing up, it can produce nearly invisible seams. But you can do that on the jointer. What you can't do on the jointer is prepare boards for joining along a sinuous scam, as here. Contrasting boards edge-jointed this way can be a smashing element in a small box, a big blanket chest, or a tahletop. Thoughtfully applied, the router edge-jointing technique can give you...