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ADVANCED ROUTING

T H E ART OF WOODWORKI NG

ADVANCED ROUTING

TIME-LIFE BOOKS ALEXANDRIA, VIRGINIA ST. REMY PRESS MONTREAL

T I M A I t o a ~ M n m d ~

k * imda ISBN 0-809CMI-4

l.aoldcn(-) 2Wbodwalr.

I.Timt~Boolu. II.SakMof1R(13.5A78 1995

6W.08320

9512164

awhdlpamdsubwd THE TIME INC. W O K COMPANY

CIP

TMSIlPB BOOKS
Itaidan

IobnD.t*a

3
6 INTRODUCTION

CONTENTS
86 88 90 92 94 96 97 102 104

JOINERY

12 ROUTERSAND 14 16 18 20

ACCESSORIES Anatomy of a router Router accessories Maintenance and safety Basic cuts ROUTER BITS Choosing router bits A showcase of router bits Sharpening and maintaining bits ROUTERTABLES Commercial router tables and accessories A shop-built router table Building a router table Safety devices Advanced table routing

Commercial jigs Double dado joint Corner half-lap joint Plate joint Lock miter joint Mortise-and-tenon joint Pocket holes Dovetail joints

110 DECORATIVETECHNIQUES 112 Jigs and equipment for 114 119 127 134

decorative work Dowels and wooden threads Routing decorative accents Carving with routers Freehand routing

140 GLOSSARY 142 INDEX

144 ACKNOWLEDGMENTS

PATTERN ROUTING Routing with templates Inlay routing Routing hinge mortises Pin router Vacuum clamping Adjustable routing guide

OF ROUTING
W
hen I rtarted working with wood halfa century ago, the electric mtersaw only lidled w in dshops.The machines were short on power and adiusrments o h proved diflicult to make. irnd the bits! The hiah-sueed st&] bits dulled'so auickly thaiyou learned to sharpenthem or made a doud &&e sawdust indead of dshavin@ One advantage of steel was that you w d d grind your own cutter shapes; but you had to do that anyway because there just weren't that many p m h available. And d e a d of a pilot bearing there was a s t d post on theend of thebiithat rode on the work, leaving a nice bumihed surfacejust below the cut that had to be sanded out When I used a muter then it w a s generally to mund ova or chamfer an edge because it gave such a nice crisp r e s u l t . F i decades later, my old 7 1 ~ - h dver-colored o ~ , muter is still around and makes an occasional cut in my shop, but it's been pined by a trio of big, versatile machines that do the real wrk Technology has c h a d the mutin,: and shamgscene wid^ a vengeance. Bearing failures, once &on, a& rare with &fi-ft-start ektknics Meanwhile, multiple speeds let me u x Lugediameter b i t s ,and p1"1ge routers have &mated the hazards of "tipping inntothe work Theocome the cutters which, after all, are the reason the machines exist With few exceptions they all have carbide cutting edges that last forever, and there are literally hundredsof shapes available, many with pilot +that kt me faihhlly follow a master pattern. On the shelf ova my working mutm are racks with enough standard and qmiahd pmfiles to let me take on any job.

Today,kthehhasmovedthe~andmadrhKsto~todennngofhddmgthe work and the muter A cotrageindustry of ingeniousdampsjigs and "uI!imaten muter tabks has sprung u p and I can now make one or many parts with repeatable accuracybetter than the smallest diviiomon my ruler. But, as good as h e muter world s e e mI can still wish for better thugs M a s t important. I'd Wre muters to be quieter and deanet The noise stems partly from the machine and pady h m the bit, so both need

work, but wouldn't it be nice to run a muter without ear omtection? ~ n don't d forget thme ~ n e r sThere . are ahmys &es to be made but I t h i i therealchangeslieinleducedtermutandimp~cut@ty.W'realready~idear I i k spiral ~ edges that shear cut and limited-feed shapes that reah workso theremay be a whde workl of new immovements out there-& manvthat i exuect to bok back in another 10 years and say;"that's the way things were befdre mutekgot really

mi

Howard Wing L $ an engineering cmePr w be a serf-taughtfurniture maker spekzking in "foirly complicated geometric and organic shapes with a contemporqfiir."He lives in Hartland Vennont.

Martin Godfiey invents

THE WOODRAT
R
5
'Y
La.

~ d w i s d o m h a s i t h t n ~ t p . i s t h e m o t h e rinvention,butmybest of

i ~ s e a n t o a r n e ~ a n i d l e ~ a n d u e ~ ~ t o ~ I k w little about. The WaodRat, mounted on the shop wall behind me in the photo at ~camefromjustsuchanidlethoughtAhh~Imsd~tatsmoalI~ not cut a dovetail since then, and I wanted to 6nd a better way of routing them. Yet workingwith the m u t e r is to a l a r g eextent a business o fmakingjigs,andjigmaking often takes ova fmm the work at hand and becomesan end in itself. I envisioned a single j i g to hold both the wood and the router, replacing the need for multiple jig. I called it the W&t
~anideathatnomeelrpinthewholewideworidhvhadka~~ rience-lhewhole wide ~0116, on the other hand, is often mmghgquite well without it. Why are they not beating a pathway to my door to buy me out? I feel a bit like a mad inventor. vn Myoriginalpmt~madc~yearsagohmscnpplastt:andwire,~~rks ellenoUg.The~tofrmldngthatfirstmugbborhas~the~ ever since.Then the dhaPray pmm begins and 1bea Lkdopmmt Engkm, learning too mu& tobe mad anymore. By holding stockverticallyin thejig, I fouud tht1drmbpncticay.anylargtbofthnber.h~aBowdenable~ stacktobepverfedsmootbly withthedire&nofbiimtation,leducing~ andpmlollgingbit~.Andoncethe~ueaUsorted~~Idisawercd~the Rathacw~~makioganyotherjomtinthebodLSu~onecur& h e furniture without a seven-year apprenticeship. GatlaeringfolMntmomentum,Iswit&edhatswitheachnewstrge..productiw manager, photographer,copywriter, businesrman(mmpletewitb suit), and tcchniulwriter.IamnotquakfidfwanyofthisbutnooneelseQoesa~jobforno pay.WasthiswhatIintdedwhenitalIbegan? But there ue mikones, like the first kllow that pays with a wad of notes, the dd~Whthpdntes,~outnmperbshothkmdd@o t h y fit? Y e s ! ) , thethousandth sale. It5 a heady momentwhen theUS. patenturivcS

and1pintheraoksdpatientsden~kempddIfbtheoolgWd
diplomatharis&tbereisnoxhoallor~Aiaderrops~hrr,pleoe lbaemustcomeapoint~rhe~@km~~moot-

L~mnr~do~tthnIhove.~outdkadkdthcDmy0wishnhrgfunWithmymrhineeaceptme.ldd~phdt~~~

wheretherearesmnepmjedsthatI2~justbeen~ramidlcdoogbt,rbout

Clive Joslinon

TIMBER FRAMING WITH THE ROUTER

M
y first encounter with timber framing was 13 years ago, when a friend enlisted me on raising dav to help him erect the frame that he had spent the better part of the summerY&hng.It &a 2,500-square-foot saltbox w i & a one-story shed on one of the gable ends At the end of the day I stood in awe at the mag&cent structure before us. Timber frames are their most spectacular at this point. Standing alone, the visual appearance of the fame exudes strength and durab'ity. As we dosed in the house over the next few months, I had numerous occasions to admire the joinery and contemplate simpler methods of mortising. Where the tenon workdemands no more than a drcular s a w and the occasionalhand s a wwhen the depth ofcut&eeds the power tool's limit, mortising the traditional way requires hours of mallet and chisel work. I knew that with routers I could accomplish the task quicker and probably more accurately. Timbers for a frame are normally mugh sawn,so mortises can vary considerably for similarlydimensioned timber, creating the need for a jig design with a h$~degree of flexib'ity. With a very simple jig made from 11s-inch-thickaluminum angle, I can quickly set up to mut an infinite variety of mortise sizes The basic requirement is to extend the bearing surface beyond the edge of the timber to allow guide fences to be clamped, and to pmvide support for the muter base. I do the bulk of my mortising with %-inch stmght bits, leaving a '14-inch radius on the corners. Rather than square all these cornen with a chisel I've found it easier to grind the radius on the tenons and comers of the beams to be housed. On deeper mortises-up to 3'12 inches-two different-length bits must be used. The degree of accuracy and precision achiwed with the muters allows cleaner mortises that are truly perpendicular to the surface. This pays off when fining knee braces and tightening the frame prior to pegging. The accuracy d t h e knee braces in particular is critical to the alignment and structural integrity of the frame. Being able to mortise simply and quickly, even through large knots,makes it easy to fuUy house all tenons, increasing the overall strength of the frame and giving a cleaner look to the joinery. In a typical frame there canbe 200 to 300 mortises. With muters I can cut my mortisiig time in halfor better. That adds up to a substanria) saving in the production of a frame, and the joints' greater precision makes a much more pleasant raisiig day.

ROUTERS AND ACCESSORIES

T
most vemuile and arlentpmertoolmthemodern vmodshop. A standard fbd-heroeatwidra~

hcroutaisarpblyth

clloose; fixed-baJc mdc;w

aphmgcmadel--orbot&
selertingrhebesttdtod p u r jwticular needs is of p~rmouat bportance. The relative strength and weakne~~esofthetwatvmaredis-

bitcanpbwr&be&~ PnB~insccDndsWed withan+-foradtlgbit,tbc tool mmundaver atabletop orshPpcapimofchbomti mddina Couoled with a iie.

~~k~ an thcright bidaJfieundlsteckamJssamuta pow&. Also, spend the few d-tcno~ with inblewhik hping the opcrmds haads char ofthe b i t extra d o h for a tool with Pndprdi~~~th Theshop-made~rmihr~pwdaabaningnrr~~ a d j w t & ~ fifi the and^@ Ifir bit. eter cutterswork beat at slow an~**d inrhesbop q d s , w a i l e ~ ~ M u q r o f k kdrsaar q u i d homrr ofhborjoushand bits operate better at Mgb speeds. ~ k A h h o u g b s w ~ ~ b a m r c m t h f r t t h a t t t l eW h i l e r m t a s d o w t R & n ~ r e q u i n d ~

muter0 en the market and a survey of some hdpfu-corn-

&at a x e h r l d in detail in hter cb9plcnc.

: 3 I
I
'

Fined with a piloted three-wing doning c u m ,a router plows a rn in tht edfe ofu board. l7w mndipilot be;rring*alon; tie& to -re thm the cutting depth remains unifmm

ANATOMY OF A ROUTER

EI lthough the Gxed-base router has been available for most ofthis cene: tury, the plunge muter is a more recent invention, dating back only 30 years.But its popukrityhas grown exponentiallyin the past decade. Each type of router has its strengths. For hand-held routing, a fixed-base tool, like the one shown at left, is a good choice. F i - b a s e models are lighter, a d p t more Simply, and are generally less expensive than plunge routers of mmparable sizeand power. Because oftheir simplicity, Gxed-base routers work well with a muter table; in most cases, q a rating the motor barrel from the bsse platecan beaccomplishedbylommq a screw and twisting. For plowing gnwves and mortises, on the other haod, a plunge muter, like the model illustrated opposite is a good option. This type of router allows you toplunge the bit into the stock to a predetemhed depth with the sub-base flat on the &With a fixed-base router, the tool must be held with the bit dear ofthe stock,turned on, and then pivoted into the surface. Either type of muter performs well in edge-forming operations. When selecting a router, consider the following~11~and~-IhetoolshouM have variable speed; bits should be easy to change; the subbase should be perfectly flat; the onloff switch should be easy to operate with both hands on the tool; and the router should be substaotial and durable. I f you are choosing a plunge model, check for a smooth plunk a&n and a plunge lock that is c o * to engage while operating the tool WeU-desiened models shoul2 allow you to Gake minute adjustments to t h eplunge depth with little fuss

ROUTER ACCESSORIES

ROUTERS AND ACCESSORIES

MAINTENANCE AND SAFETY

pinning at speeds of up to 25,000 'IherearetwomainhazvdEarsociatrevolutions per minute, a router can cause a significant amount ofdamageb o t b t o i k ~ a n d t h e ~ if it is poorly maintained. Fortunately, keepinga router in top working order is simple and takes relativelylittle time. by~thetdtopwshopdust Start by keeping your router bits and

E:

jj]

msrorieEdean,andby-cuttine edees as reauired. Periodidv a router h l l e t for runout,

shownbelow,wilaDowputodPtamine whether your bits are spinningtrue.

cdlemonsystem,asshowninthephoto at left. Other muting safety tips a n presented on page 19. Keep in mind that sharp bitswiU generateh e r and der chips than dull cutters.

E < 6 ; E!:

CHECKING FOR WUET RUHOUT

~adblUkarandmqdcbm
Install a centering pin in the muter as you would a b i t and set the tool upside d m on a metal surface, such as a table saw. Connect a dial indicator to a magnetic b a s and place tha base wxl to the muter. Turn on the m a w and posit1011 the muter so the centering pin contacts the plunger indicator. Calibrate the d i a l of t k d~al indicator to zero following the manufacturer's insbuctii. Then tum the shaft of the mute by hand to rotate the centering pin f&W. The dial indicator will register collet runout-the amount of wobble that the mllet is giving the bit. If the runout exceeds 0.005 inches, replace the mllOt.

BASIC CUTS

m ~ a r e - h * o f a tabletop with a decorative

bitormuthgaw&sinthcmiddleaf aworkpkcebrapimofi~,dcuts with a muter iue guided by the saw basicplinciples.For~thespeed

atdk-htbebitmtates~cmthe xiuofthecntla.Ashinthedmt

belor*,thclqptbtbit,theslowetthe bit mtation should be Always adjust the speed d i d an your muter to suit
thebiidiame&beforestart&amot-

Peeddireuimissmther~ c o 0 1 1 in muter work. Proper tecbiqw wiU bdp you maintain control of the tool. h a P e .the route^

Ma

Setting the cuttingdepth on a w -

bmemuteriikethemtcshonwalnm? bivlehvs&?tdngtfretwlrcp*dmvn on a w k surfbos, plming the work*rnthe&ba(&lom~Ihe damp saw, and turning the Bepth ~knolrrariIthctipufthe bitalignrwiththedcpthtine.

RWTER FED DIRECTION

~ ~ d L a c l l r Fw most operatimi, guide the muter into a -piece a n s t ' the direction of bit mtation. Thii will pull the bit into the m o d and help pevent the muter hrm "climbing" the worlfpkce and pullingaway fmrn pu On an auk&e&ge, mova the mta in a counterelwkwi38 directtan; an an inside edge, feed the tod
clockwise (rigM). %Start with cuts that we againsl the grain so yar can eliminate any tsarout with the cuts abng the @ain that follow. Position yourself to pull the router toward you, rather than plshir(g the tad.

ROUTERS AND ACCESSORIES

BASIC ROUTING

Clamp dmvn the workpiece with the edge to be shaped entending off the work wrface by a few inches. Gripping the router firmly with both hands. s e t its sub-base on the wwkpiece with the bit clear of the sock. Turn on the t d and guide the bit into the workpiece until the pilot bearlng contacts the stock,keeping the w b base flat on the surface and the bearing flush against the edge lab^?).

S w l s r ~ n i l h a r i ~ ~

Ro*lqagmdIanacplr#LI Install a cmmrcial edge guide on the muter, inserting the guide rods into the pedrilled holes in the t o o k base plate. A l i the bit with t h e w wtline. t h butt the guide fence against the edga of the stock. Rsssing the fence flush ~insttheedee,sWthecut~meond of the &piece and feed the rokW along the surface faboua).

r
3 ' 1 1

ROUTER BITS
bondbetweenthecuttingadgeand router is only as good as the the shank. A bit with an uneven bititturnsl'hequalityofthe cuts you make will depend largely bondmaytlyapartundatbestresr of a cut. Other features are worth on the quality of the bits you use. considering. For example, a bit Recentd d q m m t s in b i t - d g boasting a nonstick coating l i t-hawinaeasedthelikelihoodtbatyourbitswiUbeginsharp TefionN will take longer t o become gummed up with pitch. As shown and stay sharp. And they haw on page 25, you can also choose expanded the choices available to w o o d w o h although hose extra 1 between piloted and non-piloted bits, cutters that feature anti-kidoptionsan sometimes seem more back characteristics, and bits with confusing than helpfuL Thefirstdecisioninv&esb spinlcuner~ Bits with different shank sizes ingtheappqriatemateriaiforthe p e r f o r m d i h t jobs To shape an Lubricating a router bit with a s i h e - b a d bit. Most cutters are made from edge with a hand-held muter, for lubricant b e f m andafer using it will help either high-speed steel (HSS) or example, a 114-inch bit is usually prevent the cutterfrom overheating. high-speed steel w i t h carbide cutappropriate. If you are using a bit ting edges. HSS bits are adequate in a table for workingwith solhod, but they will not stand up well to with a lh-inch-diameter shank, mounting the wte~ long-term use in dense harhvood While carbide-tipped bits wiU yield the best mults. Large bits can be dif6cult to control in a hand-held router. lnsteadof usingone hrgebiihoware more expensive and prone to chipping, they stay sharp ever,you can make consecutivepages with two d e r bii. longer and cut more easily duougb harder wood. This chapter iUustrates 4ofthe more popular bit proMany orperts argue that machined bits are better made thocast muterbii and double-fluted bitscut more smooth- files and shows the shape each type cuts in wood. Edgely than single-fluted cutters, Quality is, of a , , important. forming bits are presented beguming on page 26, grooving Before buying a bit, make sure the shank is perfectly straight. bitsare shownon plge 28, and muter& bits tollow on page 30. Useful tips on sharpening and maintaining bits are proA bit that does not spin true wiU shudder, producinga rough, imp~cut.On~tippedbits,alsoinspeathebrazing videdstartingonpage32.

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The stairrase kmuhailrhm at lefr mcs shaped by d n g hvo cuts with d i f o m t piloted bits mounted in a tabk-mounted router. A handrail bit shaped the bottom portion afthe p~ere and a table-and-handmil cutter roundedom the top.

CHOOSING ROUTER BITS

here are several characteristics to look for when buying muter bit^; each of them is shown below and on page25.Asitcutsthrollghwood.abit shouldd y contact the workpkewith its cutting edger; the bodysboald nem

bkThet;rJtisthehdangle,umkhis the angle formed by the intmection betweenthccuttingdgeandthespioning axis of the bit. l%esecond is bit
~,s~onjmge25.Onbita

withshear,thccuttingedgeistiltedm-

1 3

tourhthewaodAsshowninthephOt0 t i c l n y ~ ~ t o t f i e ~ B i t s w i l h +left,pucanchedtforthisferhue~ sbmandahaolrangleofaboutu~witi meamingthecuttingckkddKbiC pmduceasmoathatwithlitdeteamnt thehbaweenthecuaing* a n d p e l a s ~ t o o u s e ~ and the wing diameter. In a properly Bits with anti-kickkk, or chip made bit, the cutting cirde diameter biting,designsare becoming hawsaoeedsthebodydiunaer;tbe*inglyannmon.Thea~armkbits ~isknownassldedesrance fmmtheMtMybyonlpw A bit should PLo JliCp though woad smud.lasonastandadbitByt& withtheedgcofthemtterratherthnn ing a shallower b i i the bits place lcac thefm.hferhnesmaPetJ6spmi- strain on the router motor. In addition, the bodies of these bits BIP v h a l t y s o l id, with only a small ga betwm d A J e t o f ~ m r m r r m d t c ~ c l e a r - cntting edge and the fa Z body. This ~ o f a r o u t m b i t , o r d c e d ~ i n tedurestheriskofkldmPck diameter beaween the bit's cutting Some shPight bii are nnoufictud swy(rhandthcbabody.habitd withaspiral~.Upcntspiralbits
adequate-thebitbodyniU not contact thewprkpke a s tlrc cut~ ~ ~ b w ; l e r e t h e y e x p e l

tins*-thewacre

wmddlipSupwmtDDwn~~~ peEbwa,,buttheypmideaba.

ROUTER BITS

BIT CHARACTERISTICS

A SHOWCASE OF ROUTER BITS

and bits. A tgpes abngwiththeprofileeachonem ~Hwdisill~atrightandonthe Mowing p a p . Edge-brming bits are golerang used for decorativepqmes, such asthe bowklgeforming bit, whih isconumlllyusedtorwndovakitchen countertops to prevent spills from drip ping off the surface. Gmoving bits, such
as&iisingorstrai&&&~

oodworkers use two types of W muter bits: edge-fonning gmovinB sampling of both

to phme into a workpiece. Certainbits f r o m both categoriesare too large to be used ddy m a hand-held muter. These cutters are best w e d for router-table work, and are shown -onpagem.

ROUTER E r n

ROUTER BITS

ROUTER BITS

ROUTER BITS

SHARPENING AND MAINTATNING BITS

will perform poorly a d an even be durgem~ls; it will teu at wood rather

outer bits require p r o p cue. A

cllaawithd0Im.u~~

t~arttingit-l~~~pln
theroutaoutofyoorbands.Adirtyor

d u L + d b i t a n ~ ~ ~ t h e bit t of A m e Get in the habit of inspecting por bits p h k a l l y for damage, wear, and hilt-updirtandpit&~am&jkg
glpg,ifneasuy.Ah*~bit

shouldbediscvdedAsshowninthe
A bit is beingdnnadd m m d

~ & w i t h c u ~ d e C U ~ ~ use adiamond harpen& 6le. For t i &

should send out pur bits to a profaaendaruur. ~ s t u h p i r c h w d sional sharpening sprvice, prdculrgun, t f w b i t m b 1 0 l l M i n ~ c l e n n - lyifthecuttershavechippededgesor have lost their temper as a mult of erinaskaamvpmardsmrbbrdwith
arwthbmA
&eating.

-~uetimes,h~,&yw

srrllnllraaan-piblad~bil
Use a benchstone to hone the inside faces of the cutttng edges o f a high-speed steel bit, like the one shown a h . Holdtng the ins~de face of one cuttlng edge flat against the akasive swtace.rub it back and forth. Repeat with the &we&. Hone both faces equally to maintainthe balance of the bit.

sL.)mhlaplloW~ R e m the pilot bearing i~ 261, then sharpen the bias you would a nan-p~loted h t (page 32). F a a dide-tipped cutter like the one shown above, u s e a dialnond sharpening file. Reinstall the bearing If 1 does n d mtate smoothly. sfmy a little beartmg lubricant on it. If the Imariw is w n out a d a m , replace k

aib ?&xk thiikness. Cut the nbM

S W I be ~ abaa htUrds

ROUTER TABLES
E P

:T

berorrtertabledoesforthe
mduwbatasawtahk-

forthecirclP1PrsawMdaIt

EZmsa-dintoa

slahalydintbe(~~e0f
them~enablaittoperform

quality hardwood p l y w d , but w~lrougeinin+~-Y waifice in stability Pnd emmenicmc You IIIIISI Jehct a p d d y almwarpedpPnelM+h

anmaoalgawaabkhr

6W-mrmaly~rmarged + ~ a n ~ s h P p e r .
~ ~ d o w n P n d 6 x e d

~beprparrdtogluem ~4rceto6cetoaeateatopd adequate thickam As sbcmnr on

prgc41.thctopcanbehgedto the leg auaclie,arsbling it to be

in podtion, the table-mounted

muter Pllorsa the operator to use

b o t h k d s t o ~ a ~ i n t o thbit,poaudng&,-amsictent results. Andbecausrtodr alsocanbPguidcdahgaIma,ar ~ralparrrEldrothctrrMcloplfic hamiter-atemplak,ora &mmmrulmrrtarnMehaBDHnm jig,tPMcacanbedwith

liftedforeasyaccesstotbermda
whenitcomatimctochangcbhr

~djusramiagdepth. Oneofthemostusdnl~ damutertabktheh~ be bnih horn plymod md saap moreplgisiolLAmthrbake6tof ~~tkirjigarmpasr59. hunba@crgr~).Forfradiqgnzodc therouter~kthtlargercatgoacanlaeeitbuamitaw(hrt t a s , & t h o a h ~ o n p n g e ~ ~ p l b e d s U m b i t rrideJinsslotinthetop(pllgc&)moaethtLguided~ would be dangmm and virtually imposi'Me to amtmlin a theedges ofthetable ( 4 8 ) . A shopmadenmte~ t$deqn also incorporate all of the essential safety krturrs aomdly ~ t o o L Althougbtherearesevcnlmakesandmodelpofmuter roundonarmmadPl~indodingilanatrddswitcb hoods, and bit guards. Instmdions for tables on the m & t 4 a range of ;;uxcssoria to spruce

"'5

36~chptawinshowgouhcmtobuad

eochd~clcmmtrt0tbebsrktPMc~arr~

oaempnr .IbctabIeiOustrPrrdonpagcUIis~sturdy on -49. vasion, and it is s h n p kand In addition to buic +-forming, a +made admsatileas i ~ Y e t . Z ~ ~ n r Y * m a * raih-madcfor~compleK+ TbebartdtheroutertrMeisbtotopAgnodclniais%- ations.lrioncThecbPptcrha~ofuJefol

table is

a l i n c h - ~ m e d i u m ~ 6 b a b o a d ( M D F ) D m m d d v d fFomstoppedgrm~s(pge53)aodaahcdsad*dplld~ 57) . atuReotwo sheersofplasticlambate. You caa aka usegood- 54) to a cope-and-stickpint @mge

nleaaual~ofrkeorcfvdpomldrmcnrar~ir~bndrd
onataMc-~mnterpnedwinhaMthd~miaigbir. Ahro-pauj%~lDrlv~hmmidariaJaavccutiYlra

h * * w * * & * -

hokiiiglkcplndcrgdnrtIke+iharh~maW* mqpplypmrrrchi&upantficilratpiacc,rninbnizing~g.

35

COMMERCIAL ROUTER TABLES & ACCESSORIES

T tionofthernoreusehrlonesisilhmatd
here is no shortage of after-market devices for router tables. A selec-

below and on page 37. Some items, like the speed control or remote switch, must be purchased. Others, such as fences or table inserts, can easily be fashioned in the shop for a fraction of the cost of their commercial counterparts. One advantage of most commer-

cial router table fences is their castaluminum construction, which makes them strong, but lighter than the average wooden shop-made version. Better commercial fences also feature a wooden face that can be trued on the jointer (page45). A l ~ , m o sof t these fences come with a built-m vacuum pick up, you can add this feature to a shop-built fence, as shown on page 50.

~&mast.

mrtsr (pads nb:cr- &mutmta#a&hr

Fcatum slrn for attaching rolrtar to in&; designed to sit in reas6 in tebfetm. Uscfvl if different

ROUTER TABLES

The muter table

shown at right can be bolted to a smvdk,asin the illurmrtion; i t is a h with for a

frratrmdiins
sehrp. is made of&-

m e

iron, making it ar

sturdy andflat arthesmvtak

A SHOP-BUILT ROUTER TMLE

ROUTER TABLES

BUILDING A ROUTER TABLE

A S S E W THE FRLlME AWD ADDING M E TOP

start project by builtling Iqwhl-rail assembly, refdng to the anstarpr Mustrabbmon pages fa d i i ad Jdnay. Then, cul the topto~adMetmthe(heilssernbly.M~Jheetsof%hchpbsticlaminateah incharlagerthanthatop.Waklngoutdms,ainawsll.uentiWarsalrwbaqspply mntac(cenwnttoaneskled~topandanedtheplasticshkh Lettheaddryfollowingthehe~S~inceitwlllbe~~toreposiabnthe plastic mce it cmk@ the top, usethe method aa b m to bmd the larninrde in pkm. Place seveal Ylnch d a w e k at equal internalsacross the tap, then set the plas tionthedwcclr,cmtmingitonthe contacting it. Pull out the middle a n a p a p a n m ~ . ~ i n m w i m E , the dowels and pressingthe laminate doun, until the entire sheet contacts the SINface. Flatten the g&i'rrifh a hand roller, then trim the exms flush with the top (phdo, M).RRepeat the pocesson the top's dher side. Gluedid-waod edging to the ends and fnmt edge of the top.

1Pwlrbpbrllc-m~tq the the 38and 39 tuegested

wrlliarmm-m*IIhw 2 &assmbly uung S t a t

Fastenthebackedgeofthetoptothetable's a piano hinge. ty p o s h

back rail sotha hirlgecylindefjust -averthe rall and &the W o r n of the sclew hdes Then drlll piM hdes at the makr, repositii the h i m andcLSuethehasrrs.Tofas$nthedherkaftothe top,purrlll~tohddthelopdthe~dk tance han the back rail with its underside k l ~hthe~Opedeeofrail.Clamptktoptothe legassembly, qmtltqj the twD pieces, with a ghim the same t h i i as the hinga cylinder d i a t e ter-4ypiilly 36 in&. Cut t w b o d s the same kngthasthekgsandusethentosuppartthefa edgeofthetop.Thenvvilhtheheehiilaaffbt

ROUTER TABLES

Use a spring-loaded catch to secure the Wont edge of the top to the front rail of the Leg assembly when the router table is in use. For the banjo catch shown In the Illustration at left, set the table upside down on a worlc surface and position the catch on the unde&k of the top so the bdt 1 s about Ulnch fran Its8 mil W it Is retmted. Mark the snanr holes, then angpc,the strike plate with the bolt. Extend the W. hold the strike plate flush m i m ithe rail, and mark b scmw hdas and bolt openimgon the nil. Usa a ehbJ to cut the b a l openlng recess in the mil and ndoclflc drill to bore pilot holes at the screw MIa I I W S Th(u, f* ten the strike plate to Wa rail and thl WIch to thl W. To lift the top, simply ntrPct UN bolt; whur you bw er the top onto the nib, ihr M wlll lutanrtMly ehga8e the slrike plate.

---

ROUTER TABLES

PIIPMWNSTHE TOP FOR M E ROUTER

O l Y L l ~ r ~ i ~ r I * t ~ The table insert can be wsitiormd an* on the top. but L d cudmnq to center il bstwreenthe edges and offset A abwt 4 inches c W to me end than the Fi: 1 other. Holdingthe imert in placa. use a 6;; : pencil to cutline the m i =fpr it on the

Fl

wide rabbeb awnd the apeniq measur~ %i(l~hinfcrmthecutline,aduseapm ciland~tomarkaseeondsat of lines parallel to the fW [/eft). Ee SUE to mund the awners of the cutting wt linetolnatchthecontwsofthei~.

crm~ort~opnlr(rlhei~ Drill a hale t k q h thc top at each -of the w t l i for the openlng, M s i l g a blt that is larger than the saber saw blade you will use to cut the open@ To emure that each cut is pwtectly sbalght, a l i i the blade with a cutting line, butt an edge guide blade against the saw's base plateanddampthewidetothetap. Insmtthebledeincmeofthehdesdndsat

~~PlatewnSttheedsewldotheo
hmmthesmadcuttothehokatthe olher end of the guide; keep the saw fltlVl ~ m t ~ ~ g u i d e ~ ( r E g M ) . Ropestthepmcesstosawtheamarsides of the openin& Snmoth the edges and crmen of the openingwith a rasp.

ROUTER TABLES

of the opening unbl the plkt besrInstall a %inch piloted rabbeting bit in ywr router a d set and ease the bit into a sf@ to the thickness d the table insat WOK?, ing contacts the stcck. Then gudethe rWter mund the openiq Iha cutting m ? , stopping the cUt whea you rehnn to yaw sWiq / & If the insert is thicker lhan YI Inch, adjurt the bit height to M paint. Sand tha la@ smooth, then test-fit the table hsert in the onehalf tha insert t h i i and mut the kQge in two pass. T o m a k e t h a c u t , h o l d t h e m u t e r ~ p ~ a t e ~ a t t h ~ing.Itshauldbepafeet~flushrciththe~ifitpmtrudes, a~~ the bit insida the qmning but clear d the stDdL Tun on thetool increase the muter's cutting depth slightly and repeat the cut.

---

m,

~*IWIin4eJt.~till)

Bacausethetop i s h i m , it isagmd idea to anchor the t a t ! & insert in place to pevantitfrantopplingontothe~Rm --alongwith yarr routerthe top b I~fted. Positian the table in& in b o p m ing-4th the muta base plata ettached --then cut two Yeinch plyrrPodcbrb 3 incheswid8 and a fa* inches &pa lhrn the wklth d tha table opaniw W h thedeagsotheyorer*plbadrdlb ~ingbyabaa1imhmdWa1~

tothe~dlbtup~ThmTh*,cLII w o r o m n a e r s n k ~ t h e ~
-QWintDd-blw8~ intDmchholaM&*n~wm limbvslwltharl~brlowthotopur-

ROUTER TABLES

MAKIW A FENCE

Cut fence- base and uprigMfmrn Wnch plynrmd, making on one ede$ centeed cn the bit clearance hole in the bable M thepiacesaslrmgasthetap.ThencutkxRtriangularw~ Clrtthea:myourbandw,rnaldgaserlesof~ruts frwn 1-inch-thiik s o l i d stodr Each suppat should have one 90' thrareh the wste fran the edge to the cutting line. Then saw wgle to fit in the amer between the hsse and upight;trim itre abng the c l r t f i line fakW, feedlngthq t m eaaoss the saw oUlerhueaFglessotheywillmteatend~theedgasdihe tablewrthbdh~~epaemuprlghtthellanaw,butcut base and upright w h m the fence IS assemW. To pepare the a square openin# on the bottom edge justnida and high em& ~ p a s i t i o n i t o n t h e t s b l e a n d a R l i n e a 2 W ~ a n :t o a c a r m r o d ; b e t h e l ~ b B y o u p b & l s e o n t h e ~

1-*Pi@= the

2 t

IlrrrYhgkhW Attach the fence base and upfight e witti glue and =reus, using a try

sqwetokeepthepkesatrIghta& Next, attach the suppmts in place t h q will belp ensure that thc base and upright remain perpendicular to each other. Position the supports adpining the fence openingt e aemmmadilte any dust d m t i a n hood plan to install onthefenca @age501.

f w ,

To help yaw stock slide mae &b aknp the fence, due a piece of plsstic laminate to the d d e face of the upieJd Secure the base in a bench vi8e adcutapiecedbmiMte~brga thantheupr@t.Thsnfolthepbsticto the fence with contact cement (ab~~e), following the same pmcedure wad b bardthelaniMtetothetopfpiae4J. Press the plartic dorm with a hand mlkr, then cut the exeesflush with the edges and enad the uprightdga laminate bimmer.

ROUTER . . TABLES

Pasitlon your miter gauge on the router table with ~ t bar s parallel to the tabk's edges and a gap of at least 41 inch between the bar and table inseft. Mark the edgw ofthebaronthetop,thenextendtheeabngthe table's knglh, usinga carpenWs squae and a sk@tedge to ensure that the lines m a w parallel to the table's eQges. Next. Install a dm&t bit in your router the sane d i i as the width of the miter bar. Mewrs the distance between the bit and the edge d the router base pMw, then use the measurement to posit~on the stralghtedga tha will guide ywc muter as it plaws the mi* slot WnwJ.Make sum the eclge guide is parallel to the s l d outline.

2 Cut the the

miter slol In two passes F a ct h e m one,adjust muter's cutting depth to omhalf the t h i i o f the ba--a cmnmercial table saw miter ba b W l y % lneh thick With the bi clear of the table at one end, butt the muter's base plate agatnst the edge guide and eonfirm that the bit iscentered between the laplt lines. Then tun on the tool and wide the bit mto the top. Crmplete the slot, w i n g the muter flush agalnd the edge guide t?&W. I the cuttlng depth to sllghtly more than the full thickness d the miter bar m d make anotb psss.

ROUTER TABLES

T u r n t h e ~ o v l r n d ~ t t m

cut fabolle).

ROUTER TABLES

@
; t 4

SAFETY DEVICES

from beininidred by a s p h q bit,

ahngslseaMtguPrdthatdthe cutter. T m types-a b m o u n t ed guard and a are shown on

using dm acrylic plastic or pdycubonatewindowpu tovkwthecutting adion

The +mgaof wood dust and chips areIerr~thanthosc~ad with bits, but prolonged expoam canamkibukto~tory~ udirritptetheskinandegesRefcrto pa@Mfortwomcthodsfor~ uppmnmtertabktoadust~ system~purshop Two of the simplest--but most ilqnmmt-*euc sbawnintbephotoatlok~ pou~makiuga~cutoa the router table, use f c a h h d s to

ROUTER TABLES

.;*, . . . .'"..

..

. ..

:. , : ...

. . . .i - : . . ,:..

..

.......
..........

. . . .

........

'm. *m
wb
. .

thehJ&&f,&@&,shM,& j flush with thala~f$bdfamdthc::: .......* ,

the.#-@-:

'.&,
......

;; .-..

. . . . . .: . .. ... . ... ....... ,*

ROUTER TABLES

BIT GUARDS
bnwammbitpud To pmtect your fingers during M i ad cuts on the table, use a fencerrmnted Ssw a blodc about 4 inches long and 3 incheswide fmm 'X-inch-thiik stodc. Therl cut a wnkircle d clear acrylii tothesanesizeandsctwittothebdtan edge ol the block. Clamp the jig to the fence. centering it over the b i t at the h i r e d heigM (MI.

-A.lilr

-.

-wglPrd Use a freestding bit guad like the ane shown at left when you are p8rfwmiw freehand shap~ngoperati~ns Cut a p h of clear acrylic 10 inches longand 3% inches wide, with a S m i C i i a t om and. Sswawppwtboardfatheguafdfmm 1%-inch-thick stock, making it Ute same width, but 3 indics shakr. Scmw fi# acrytlc to the bosrd so the ends d tho pieces ae flush at a m end. Mad, cut a

~etospanfrcmUteWtolh@Inh*l

endofthetaMcnd~ittoUm(nnt

enddthaJuppartbo*drrlthma(lr iron, lbning cn 1 jl#, T o m tha guard,ebrnptheuppatbo*dmdkncr

toUmtebkrnttNWb~co*
sAdbyth0~.

ADVANCED TABLE ROVING

ma~mttmindn.AsDhown kkw.you an shape a handd using tmdahrrntbits.Whapanel-ding bh (pgs54)andaaetofqeaud-stick cutters (page 571, you an make an archeddoorpnnelontheroutatable,
dtheapmduce~joiuerytc, hold thedoor f r a o tqcthm. ~ Thew are oome limitations on the
~~cmdoaaamrrlatabk,mod

eovasedbgtheMtsizcSawcatters

aretoooohrge6orsmPlhr~tohpi-

can~beusedinaf~ll~
apoblcof~tingolh3hmc
p o l n a ~ h ~ ~ l u g b i t * p u

Stat by irptalliq a Mnch nund-oue bit In ya* rolhv and mrdingtke bml in the t a b . b e three feahba& to suppat the handrail Mank. clamping two t o the fm~--~~megehs~deofthebit-aM thsthhdtothetabla, ahad mashim. (In the illustratiarsat right, the featherboard m the outfeed slde d the fence has bea, rer*ruedfnrctaity.) FWhthefancefa a shdlau fipst pa55-aboUt Ye inch. Then ( e e d t h e ~ t o p ~ i n t o t h e bit, keepingthe s t ~ flat ~ kan the tabla and flush against the fence f@#. finish the pa~gwithapshsbck.F@eatthEcutmth the other edge aga~nst the fence, then make the SB~OIIII series of passes. t h i s tmewllhthefencealiiwiththe~ ol the bit's p~lot b e a i mT o c m p M the aperaticn.repbcethehermncCaverbitwith tka handrail cutter. Feedingthe stock bat-

-@#dl

tankcedom,mdcetwopassesmsach atge (Ima)). !$tad with a shallovr cut, hawsingto the f u H depth with the sec-

ond-

CI

-ROUTER TABLES

b
L L
Ra(mN6 A STllPWO BROWE

Mount in t h table ~ with a thm-wlng dottirgcutta in the W. Align thefence&ththeWsplbtbewingand adjust the cutting hdght d the cutta lo centerthegmvaakngtkedgeofthe ~iMaktheMvdalldofthe ~mthetopfacedtheatodc.Tohelp pu determinethe kcsbiand the bit when it IS h~ddan by the lvakpkec d u i q t h i ~ cut, also mark the points on the fence

lrladmrnar 1~ r cpr muter

wherethecutkerstartsandstppa~ To stact the cut, turn on the router with the workpiece clear of the bit Hold the board f a c e d m on the table and allgn

the front cutting line on the wakpieee with the bii cuttlng matt on the outfeed side of the fence. Holdingthe board f Y anthetablewlth bath hmds,sbwfypivot itintothecutterf~.Gripthe~ firmly to awid kickback.

When the workpiece is flush against the fence, feed R fornard while pressing dam,tcmad the table and pushing winst the fence. Continue the cut untll the back cutting line on the workp~ece al~ms wih the bit cutting mark on the infeed side of the fence. Phrot the Wlir\gend dthe stnck away fmm the cutter one hand fmt). Jteadying the board agalmt the table and feme with yw ather hand. Avaid l i n g the stock until it is clear of the bit. If nec-

esafy,?quaietheendsofthegrocvewlth
a chlsd.

ROUTER TABLES
II

I U I S ~ AW ARCHED PANEL WITH A v E m w PANEL-RAISW BIT

the panel to sue on p r band saw, then mwnt ya. muterfitledwithavarticalpaneliaisirlgMmthetsMe. %t i i the fence tor a shallow cut sopu can reach yow final depth in hro pmes To raise the ached port)on of the pand, pwam a feeding jig. Usmgthe panel as a guide, outline &desired euve on me face of a 1-Inch-thick boad. Then
cutthearveandsawthe~inb&themid@ntdthe ach. SandthecutendsMoothandswwthetwopkcesto the fenw on each s & d the bit to fonn a cradle in rvh~ch yw wtll be able to -1 the arched p o w of the panel To suppat thn panel dining the cut. clamp a feathe h w d tu the table. ptupplng it on a t h ~ shim k so the h t b d o d pesserthe wdpmx flush winst the fence

1W

-hIr*d

(w.

2 -*a

W i n g the oubide faceof the panel flush wins4 thefenw,~lQuathetq?endontotheartter.filtthe bottan d the panel tarad the outfeed end of the table sotherual(plgecontactstheMdthestartofthemhal portbn. W a your right hand nipping the b o t h amer oftlcapsnelandpur kfteftpwssmgthefacaagainst the f e w , begin rotatingthe -piece in a cloclruise direction, swiwliw the bottom end torvad yw Wow).

ROUTERTABLES

RnWUtlnd Continue rotating the panel tcmrd you (abas)until the arched seelion has been s h a d horn one end to the ather. ~hensl&liithepaneltneeafthecutL R w i t i m n the hmtothe final cuttin# depth and repeat the cut

ROUTER TABLES

W W G A CURVED PAWEL WITH A HORWNTAL PANEL-RAISING BIT

~ U = d - h h . ~ Bandsaw the panel to size,then instdl a horizontal panel-raising bit in pur muter and mount the twl in the table. Adjust the bit f a a shallow cut so you can reach the final depth in two or more passes. To raise the arched portion of the panel, clamp a freestanding bit guard with a o the table (pa& 511. Holding the fence t panel flat on the table with the curved end flush against the fence, pivot the stock into the bit until the caner contacts the pilot bearing (right).

lrirLI~Mwi~dlbepantl F'ressing the stak against the bit's

pilot bearing. fead the curved end of the panel into the bit (below). Raise the cutter by no m e than % inch and rwke anather pan, cmtinuim as necessay to reach you final depth.

ROUTER TABLES

3 llrWr*r#IY-dkplal Rwnan

thr Wstanding bit guard Imlclmprrtrndrdfancatothetable,

al~ihabbbawilhthebit'spikt bmring. k w Ute bit to sat a shallow cutMW d@h. TO th pnel dwi ~ t h e c u t . ~ a ~ t o t h e fenc=3!jlntto~infaxltiidodtha~. Withe~nattmthetrbk. feeditMthywr@tlthandpmmit flatqainstthefaneeMthpuk(tfIsdV. Cutthebcrttomofthepanelfnt,Umnthe sides. Make as many pesm as neceswry, raising the bi m m e than U inch at a time.

mklonpsinbmil Make a mpe-anc!-stiik joint by first clming toneues in the dofthersikthendthegmovesfathepanelalongthe inside ed@s of the rails and sbks. The gooves in the slilss will rcawnmodatetherailt~esFuthetongues,installapiM-

top of the uppennait eutta is rli@lUy lbovr thr

dcopilbitarail*4nywrrouterand&theW in the table. Set the cutbngdepth by buttingthe end of a rail winsIths bit and adjusting the muter'sdepth setting so the

F d thestak~ngaj&lihthaaw~m#r48,cd~a notch in L to scanmdda thr #t md p(btbrln(l. Aho butt astopbkdc~ihrrddihdlmdclwnpthaMockto thejiiR@dngthaa#khC#dthrctpckMtmthet;lbL hold the rail flush a p h t thr jb nd StOD MOcU thmuElmut eacwcut &bmsA

w.

ROUTER TABLES

Replace the coping b i t w l a piloted sticking bit--also known as a l i l e cutter. To set the cutting depth, butt the end of a completed rail against the bit and raise w lower the bit so that the grwve-cutting teeth are level wlth the rail tongue NgMI. Align the fence with the edge of the pilot bearing.

2M=w-l*rrklllw

3 -hw-

Use three featherboards to secure the workpiece during each cut. Clamp one to the table opposite the bit and the &her two to the fence on either side of the cutter. (In the illmtdon M o w ,the featherboerd on the ~ltfeed side of the fence has been remowd for clarity). Make each cut holdingthe stock's outside face dwn, pressiw the vorkpiece against the fence. Use a push stick to cunplete the pass

ROUTER TABLES

PATTERN ROUTING
P
and &cient method of creating multiple copies of a single contoured shape. T h e w n q t is easy to under&and and the technique simple to

anan routing is a precise

h*mm63,pDttan

mulingc~abcdauprt~~~ ilyonamutgt&k!as~itba
hnd-beklmuter. Another potentidy awpkteslcthatissimplificdby pattern muting is cutting
~cessafOr*~67)snd

ercende:Onceatempkofthe
~pattanissbapaiand

tastenedtotheworkpiece,the
r o u t e r i s g u i d e d b y l h e m t n n shapetoleplicalethe~on

-~doorhinges~Pw 71).Usin atemphtebasedon thesip theidayathehge

ensuresthattheraiesrwillbe

thewodqriece. The two main ways ofpat-

"

precbelVthe~ightJizc. tanloutingme~sta~tIfpmedoingalotdputern muting yon should conhg0nFi?ge6LIfyo~~USiOg non-piloted bits, y o u need to .siderbuyingapinm~'Ihe ~ a t e m p h t e g u i d e t o p u m l ~ ~ j i g g u i & a r o u t e r a s ~ p b w s a n invatedpinmutgsbcmnon ~ router'sbasephteandmake gmovejwdemmiiwinhy~gmaraMctopThejig ~72htumapinJarpmdPu template &&* k P muuudinawr*sofsuawMydceperpazcato edewthe&~abon than the W e d size. This rout& taMr'sartlinc.~ertoplgciH~inmuc- the bit. The stock is canparFatafortherionsonmaking~edy~jig. abngthe~pin,mabt tuol in dhmekm between the bit idealiadDingtrmphtelroa andthetemplategui&Ifyouusepibtcdbik,ontheotha AhbollgbwoodwniruJhpw~uatd~to band,atemphtegnideisnotdandthetemplateaabe a a r h t e n p ~ t o ~ r ~ i n p t t e r 'n

e
t o

ora*tytheramesizeasgow~*

~routioghrscoundaspncticalandderorativeappli- uumdamping~Mlpnlphrpntpgr(llludYItmdhOdL cationsfor~g.iududingtheuseofcomplemen- A s s b o v m o n ~ 7 8 , t h i ~ d ~ ~ ~ g r h m i s ~ ~ ~ Q ~temphteslhismahodallows~utomaketempLte~ ble-sidedtapeandeasiertodbqpgc,drmlilPn3rud withdedgesthtuewmplamntaryimagesofeach ~crrwsthereiswrislrofmarringthewdpicaq~a o t h a , a n d ~ ~ c e t h e p a t t e m s o n t w o w o r k p metplhstenerwiththebit ~

Wfhitrguidc~napeRdedabovethenwktrrble,apinmuter rlurpatkmntmmofahmdmirm ntestockisanochcdbeha templateoftkdrrindpumnwib,a~~um~ngsystn The n. ~h~~aguidcpmmerfhetnMe,wfrilcthcbi&whichis mountaidi~bclnvthepin,rcpliartrrthcpanernontheworLpLrr

ROUTING WITH TEMPLATES

'heP=d=pll*hpman . mutingdepmdscmthetypeofbit uaaeusiag.Wdhamn-pibedbit, umustatkha~
piloted bit @w bi)r a W t e guik i s ~ , r i w c t h e p i l o t ~
fplbvrshplaw

The tempkc should be made f h plymodorh..-mmprdandcuttothe uterkphkhmetal uuds the bit shank, the guide rides desindprttsnwithabandsawocsda saw.Touuuretherearen~impafccwktbcofh-r b i t t o r h a p e t h e ~ w b k h k tions tbat the bit will t m d u to the unped below the template. W W h t i r ~ c a ~ d t h e a d g e s u f t h c ~kohmmcmprgc62,you~11 alsoure'kincbdarlcrplicphstitas a tempktc. Whichmr material p u ~tmn ~ m a k r i t p o s s i m g t u e chaaae,ptlrpmnnwillbe&to pmdacc i f p ur using piloted bib rapadLTf"nbmnlrwithMvcd Earmu~Simthecottermdpht that mate f o g r d m w . As rnthemmc-youmatyl,aUpuMarlnamasm malv tqdatethespne~asthc mpfateuiih rhedesirednnvc,apibtfinished picas p u wish t o pmducc. lamight bit mmth ~-~ banWithatemphequidc,youmusta*ngs, andapihdpvdr--bit. k b i a m r u s a d t o m a h r t h ~ ~p e m t e f b r t h e ~ b a m c n t h c ctoterdPmarrandthedhxtaofthc @-*h--ffodtapc cwor9iam(pagc60. t m r p h c * -

~ss's2

Usimga-glid.inrIY*YIm ~emnetheba4e~framthe&,iimen~lathreaded~at a l the ternplate gulde thmugh the apenirlg In the middle of the w (atawe. left), and screw m the locking ring to hdd ihelwobgethei. Chooseatempbdeghjewhmedwnrterisas dose bthat d the bn as posibla withaut W h i n g ibcutting edges. Reimtall the base plate onto the muter, then pepare a Imqhte that is s l i smaller than the finished piece to amplnsae fa the d i m betaearl the bit diameter and the

diameter of the template guide. Fasten the templab atop the narkpece--tn the example shown, doublesided tape was me%then clamp the asmhiy to a wPrk sutfam. Holdingthe mutawithbothhands,reditmthe~atmeendwith thebitcitElearthestackandturnmtheW.Easethe bitinte thervakpiece,thenfeedtherartertDwvdtheotherenddthe cut (abwe, rigM), keeping the bsse Rat m the ternpbte and the templab guide flush against its edge.

uc*rrrimm
Fasten the template atop the w k p ~ e c e and clamp the assembly to a work surface. With wood lips on each side of its curvad ewner, the template shown doubles as a corn-munding jig. Make sure
thetop-ofthelipsaefllshwiththe top surface of the base and the lips are butted against the edges of your wokpiece. Starting at one lip, cut the curve as you would with a templateguided bit (page 621, feeding the cutter into the stock until the bit's pilot bearingcontacts the template. Complete the cut to the other lip, makingsure that the bearing is passed against the edge of the pattern thmclghautthe opwation

(m).

R a n ~ a a m * r ~ Tomakeiteasierandsafeftofaedatmplate and vPrkpii -a muter* t attachabogdasaphbbcka~tha back edge of the template-in thb e m . the pattern I s made from clear urylk plastic.FaftenthestaLtolhm~ with d o u b W tap and rarr 8 palr of stop blocks to thalrrmp(ata & rtitha end of the workpiace to hPld tho stock securety. Neat, cut a bR hOlll a scapboud, W y r mlchhom~w, ~todmnalipthatvlllo#Uthacutt e r . ~ t h a ~ t o t h ~ T m O n ~ l w t r a n e J m ~ j i g ~ t l w t*torhrphhrf(MU.~ ingtha~prrd~natlhabit% pibtk*lw--OPwah.

PAlTERN ROUTING

Rqrrilan-m In the m o i npesented on this and the Ml~ming page, pu can shape two c u d ed&!es that a e matching irnqges of each other. Stat by l a r e a mrrster tampiate fmn which you will make the templates fw the t w pieces. C h p the master to a wrork surface and mark the desired cwve on it. Then, to compensate fa the diameter of the pilot bearing you must use to guide the bit that cuts the right and left templates n w k a semnd line oti the master template. T h i s cutt~ng line should be dhct fmm the fist ane by onehalf the d i i between the bit diameter and the bearing diameter. In this c a p e , t h e d l k e t k C i n c h t o ~ a % - i n cbitanda h
Y-inchbssrirlg.ToenswetfrattheEuttingllnebpardkltothe crigind line, use a pencil h a shopmade &it@ guide, Far the guide,drlllahde~adMock~eaconeendtof%a pencil snyly, then cut a notch on each edge % inch frm thecenterdthehola A s y o u n r a r k t h s ~ l i n e , alithe mtch s h o u l h with the M n a l line and slide th8 guide fnnn pna end d the template to the other (W. Cut the template along the second line on your bsnd saw, then sand the cut
e 9 g d .

#Jll-fm-mw 2 INa v l l s e t h e m a s t e r t e m p k t e c n a k e han

the right and I &tempbtes a single plnd withonecutofthem&r.Setthe panel ar backup W . ma nak &ax, then cbnrp the nrastps template on top, aligning the ends and edges of the ternplate and panel. Next, install a Xinch upspiral straight bit in your router and attach a Xinchdlsne$r pibt t o its shaft. F*.a sbDp rdlar on each side dthe beaimto seane it in place (inseP. MjustthecuningdspthsotheMwilldice thetempktepanel intwoasywridethe bearingagainst the edge of the naster template (rishth Keep the muter flat on

themaaertecndatethrmBhoutthecut.

b
D D D D

D B I

8
I I I
Rough-sizingUte mdfpisnrr Fasten each wkpiece to its template, ensuring that the straight edges of the boards are aligned. Before trimming the pleces with the router, cut away the bulk of the waste on your band saw.W~th the edge of the template parallel to the blade, feed the left-hand workpiece into the cut, savvlng to within about Y inch of the template (above). The remaining waste will be removed by the flush-trimming bit in step 4. Repeat the process to roughsize the right-hand workpiece, leaving about M inch of waste for the router to remove. The extra amount of waste will compensate for the larger bearing u ? x x l in step 5

I
0

m
1 1

the 4 Mmnimg m

I&-hand

piece final size

a
I

Install a tappiloted flushcutting bit In the router and mount the tool in a router table. Clamp a shopmade guard over the 3 ) ,then slide the left-hand bit (page 6 template across the table to shape the left-hand workpiece (rrght), keeping the template pressed against the bit's pilot bearing throughout the operation.

I I

P A m ROUTING

m*r-ralpba Remwe the muter from the table. reim$ll the Yinch upspiral bit, and replace the Yiwh pill bearingwith a lYinch one. The mlting offs& (win, ane half the difference b&ween the bit d i e r and the bearing diameter% inch) will compensate for the kerf remwed by the cutter when it fumed the left and right templates in step 2. Th~s will ensure that the two workpieces match Wectly. Tnm the workpiece the same w yw shaped the left-hadone, keeping the template pessed against the W n g at all times Ir@tl. Separate the workp i e m fmm their templates, then glue them *ha edge to edee, forming a panel like the one shawn in the photo m pace 62.

shim

INLAY ROUTING
ined w i t h a straight bit, a tanplate andasnap-onbushingand a shop-made template, a plunge muta can plow a recess for an inlayqui&yandamnatdy.Thesame m p can be usedto trim the dayto l i t the recess perfectly. A wide range of i n l a y 3 i s ~ h ~ ~ o f amticwwdtoetabadc~pat-

tcms,asshowninthephotoatright
Rolltingthe-totheF4opel+ isoneofthechalkngeJofthir,operation. For m a r q u e t r y inlay, the recess shouldbe only slightly deeper than the

* % * I f &

gloinBtheinlayinplace,itSmbebwthe
smrouodingh,youcansandthe

woodadpiningtheinlayuntilthetwo slrrCacesue&sh.Tominimizetearout
asyouroutthe~ortrimtheimly, use a downcut spiralb i t .

. ,.form * of dl 1 tabjcbop. 'flur- into in a v e n e c r . ' h n which the inlay is set was c u t with a templare-guidcd routor.

6LU11(6 MARWETRY INLAY IN PUCE

The key to trimming an inlay and muting a perfectty inat&

and template wide. Rill a hok 10 1# r d l rm #ub Uwa@

~ l m M e i n l ~ m a p ~ d ~ , ~ d a w a d ~ a~ u i t t- t o ~ ~ . . l l c l l ~ t o t t ~ ~ ~ d Iim Y inch lamar than the first to a l h fa Me width of the b i t d W i t i & d 9nd up bme rmrksd lka.

PATERN ROUTING

the b a c k i & ~ m sidr d the i n C .

~ositkntt#~ontap,p,ng
itsapeninganlt#hJy,hclmpthe assembly to the taMs. R t b bushingfmt'tlthe~b&,Wt~~~plate guide in place, and Mm the inlq tha~wsyyauwt~~krphrO t h e c i d e p e s s e d ~ b ~ w 4 ~ of the template thrarghan M A

m i n b y i a p b w
4~lhmthe*.rrsidedbpandbacWngpaper Iran the inlay, then test-fn it in the if the inlay is still slightly oversized, place it a microwave wen set to high heat for 10 to 30 seconds to shrink it. Once you are satisfied with the 11,rpread a thin mating qf glue in the reces and set the

inhin~.-thein~fiaprCrdw~thm
top it with a d block d i i W k r (hntlm inky. C)np a caul x m e s the black to scum it Wlun the $ua has c u d , r a n o Um ~ block m d Md tlm iinqa tho m n d i w wood tb make the rurhar flush.

~~

PATTERN ROUTING

Withthesameternpbteusedtorout an inlay recess and trim the inlay fm 671, you can p l m a ~ n a w ~ c c awnd a the inlay f a a strip of banding. Once the adhesive securing the inlay has cured. clamp the template to the wokpike SO its opening is centered w the inlay. Set the router's cutter depth X inch deeper than the thickness af the template, then mut the recessthe same way you trimmed the inlay fpqje 691, W i n g sue the tam plate guide is pressed against the tern

1~ I b H r m m a

Makethetendingfmmswmlspecies panel and the inlay. Cut the strip about 2 inches longer than the perimeter d the recess, beveling one end; since you will be instdllngthe bandingmedge,makeit#iwiderthanthe recess depth and its thiiknass equal to the recesswidth. If the bandingir s t i f f ad difficult to bend amund the recass, soak it first in hot water far 30 minutes. Spread some glue in the recess, insert the beveled end, and paek the banding around the recess fright), bending the strip and tapping it in place with a wdWen mdlet as you go. M ~ I R a cutti* lineacms the band~ng at the point where the ends meet. Then. with a backup board to tect the wwkpiece, cut a matching bevel at the straight end and finish ~nserting the banding in the recess. Sand the banding flushwith the wmwnding a.

2 that contastswith the

PIN ROUTER

I d s * # & : .

m,T1,

An OVERARM PIN ROUTIN6 AllACHMENl

MMM6 A fW0 MIRROR ON A PIN ROUTER

PATTERN ROUTING

E mFmMmWlTH THE PIW ROUTER

Insiall an adgehlng bit in the pin w t e r 4 thhaxamph, a butt nose bit k sham--snd g u s t lta height to shape the edI0aofyw-adtb~mughly to size on the band saw,than fix it with doutape to a iinch-thick rrylicplasticfecdingjithaR bsllghtly~than the blank; place a shim b e the bbnk and the jig so the bit will mt cut into the acrylic. The jig will protect ycur hands fmn the bit and, being clear plastic, will alkw you to view the cutting action. Nert, fir your pattem to the opposite side of the j i i makingsure to align it exactly o m the blank, and adjust the guide pin to rida along the pattern as yw make the cut. Cbmp a suppat t)oard to the table in line with the cutter and turn on the router. Holdiw the jig and pattern flat on the table, butt the back corner of the jig w i n s t the suppot boad (MU,then piuot the jig and bbnk into the bit until the guide pin ccntxb the pattern and the cutter bitesinto the a p i e c e .

,.. **,".

2 WlLI-IlP

Keeping a firm hold o f the jig and pattern, feed the workpiece along the table w i n s t the direction af bit mtatii ( & M ! A Make attain to press the pattern against the template until you return to your sWing point. Once you wmpleP thecut, pytkwakpiecefmmthe ji

75

PATERN ROUTING

STRAIGHT ROUTING ON A PIN ROUTER

mratkl
Astheill~mthiips~eshaw~you can use an invected pin router for edgeshaping as you would a router table. Start byramaringtheguidepinfmmitshdder and raising the haldert o b h i i s&t@ For pattern routingwith a piloted bit, fasten the mnkpiece to your template and adjust the Ws cutting height so the pikt bearingwill ride against the template with the blank flat cn the table. Clamp a sup pat board to the table in linewlh the bit and turq on the muter. Holdingthe tem late and blank with both hands. m e s s bne edge of the assembly flush .&inst the suppat baertl. men pivot the workpiece into the cutter and slowly feed it against the d i m Or btt rotatiion (left. Keep the temolate msed against the pilot bearing throughout the c k

the help of a shap-built fence, you can mold the edges o fm i g h t stock on a pin miter. W e a fence as you wwld fa a muter table i m44, then damp itto the pin muter table, aliiing b fmnt face with the W s pild baing. T O support the stock, use three faatherboards, damping one to the table and trvo to the fence, one on each side of the cutter. (Mate: In the illustrat~on, the featherbcad on the outfeed side of the fence has been remoued fatlarity.) Feed the wakpiie across the table, peEsingthe edge flush against the fence and the face flat on t h e e (rig& Finish the pirnwith a push stick.

VACUUM CLAMPING
m ~ g k a outlbtofdamagetothPstodc.a~ ~ d Vli4L1.1tokenlqhd mph~altisdrdtmali~~g&be w d p i e m kgdkr.'Ibespans&om tht md smooth. i n this section of the chapter offer as There arc two common vacunmmucbholdlngpowerasmecbvlid clamps and greater convenience withdampingsgstrms.lbeventwisystem (bdmv) is relatidy iwrpmsive to set

apbutyduwiilneedrconqmmrwith % h o m q ~ ~ r q t * . f ~ ( O
ta8OFSLlbc~~00~82 relies on a vacuum nnmn rated at 1 rc u b k ~ p e ~ ~ o r ~ i n c i r h a case, m l u n tape ir fsstcned to bh sides of a a d h avahbk beach plntc,~icapabkofchmpingo~
~ ~ ~~

1
ESSENTW PAMS O F A VACUUMCUMPIN6 SYSTEM

two*~pIateitthnsanctwicbed between dw wo&pii and template ~~6oPatbevenhmarpompis attached to the 0 0 t h on the bemh pkte-omforthewodpbxside~d om for the tanplate side. nK venmri mpumptheaEarbairh~on botbsides
Thcwtypshmmctt~nfiePmthme -urn tubato hold a drawer side

ag#bmawm&wjig.% arhcmb=~r-toaL~ ~ I h e Y P T t i C I J s d c tiarhdathcworkpICerinpositimc andthebPu~theemiieac~~Mytatftrbcnrh. Thcwmummbc d t o k M j j g s b r d d n g barrrd)6rcrcnrthe&to&~~~~

P A m ROUTING

2m o r n - k h d

Cut the workpiece roughly to size. then set it on a work wrtace. Position the u n bench plate on the stack, making t the tape strips am flat on the w a k p h . Turn an the vacuum sauce to the rvorkpieceside of the b m h plate and pms the plate on the w k p k e to seal the

m. W, podtbn thr tunpMa on

thebanchplrbfMI,alisnil\sVM~hlht ~d.the~p*(rrmdthewakpieea Turn on the vacuum to t h templabside of the bench plah end p m a down to attachthrpltbmtothopbta.

w w m . Air

will hold tho lw

PATTERN ROUTING

inarwterand mountthetoolinatat&. Adjust the b i s pibt bearing I& with the template and set the cutting h e i i so the bfi mll shape the entire edge of the wwkpiece (inset).Clamp a notched board to the table as a bit guard. Race the bemh-plate assembly tsmpl*e-side down on the table, turn on the muter. and ease the stock into the b t unt~l the terndate contacts the ~ i l obearinn t ( & , r i g t ~ t l .Complete'the cut, w i n g against the direction of bit mtation and keepingthe template flat on the router table and the edge of the template pressed flush winst the beering.

A SrmPMADE BEWCH PLATE

Rsriaramwefor-r#hl
Far p a t t m you mut frequently, you can convert a plywocd template into a shopmade banch plate, rather than using a conirnercial ane. Bae an outlet hole through the middle of the template fw a vacuum pump's threaded hose cannechr and

apply vacuum tape along the perimeter of its underside; make wre there are no mbatween adjacent pieces af tape. Then use a wrench to attach the hose mnector to the top of the plate in the outlet hole MtoveI.

B U K DfTYOURSELF

ADJUSTABLEROUTING GUIDE
The shcm at left is ideal fa muting re~taflgular gmaras; it can also be f i e d with templates for cuwed cuts. Rather than following the paitem with a piloted bit or a non-piloted bit and a template guide, you feed the router haw plate along the jig's inside edges. Saw the guides from 1-by-2 stock and rout a gmwe ?4inch deep and wide along the inside edge of each one. Cut a shouldered tenon at one end of each guide to fit in the poms and bore a pilot hole into the middle of each tenon for a %-inchdiameter hangar bolt. Screw the bolts in place, leavingthe machine thread protrudingto feed Umgh the adjacent edge guide and lack with a washer and wing nut. Finally, mut %-inchwide mwtises through the guides; start about 3%inches from the end with the t m and make the m a t i i 4 inches lcq. separating them with about ! 4 inch of wccd. Asemble the jig by slipping the tenons and bolts thmugh the g m w s and m a r t i of the adjacent guide and installing the washers and nuts. For curves, make ternplates like thme shown in the illustration.

r c * r l l 1ulw )lg

.. ,

.~.

Outline the pattern m your stack and lay it on a work wdaa heen the wing nuts of the j i i and psjtim it m tha stacksothe~guidarRanethwtlina PbcethemutafYmthe~cnd a l i the b i t with one d tha d i n e . Buttoneoftheedipgqkbsfiurhrginst thsmuterbaseplate.&dmthdhm edges until all cnd lmpk&sm in po*tion. [Use doubbMd tape to secuotfatcm~to~uolkglece.) r i t h a m n u b n d c l m ~ t b j i g a n d ~ t o t ) WAftarpluqf~ .

-q-Ooovr

~thebltInti,um~rtodlthaaJtin ackckrrbrdW,knplr\sthebara p*bsfiurhpllnrtth~guldeartnrr pktratJIthnr.Fampatcuts,*mply ~ ~ t b ~ t o t h ~ c # w d louttbprtbn,(MU.

PATI'ERN ROUTING

. ..*.~. -

:&kllbe@&has

the guide to

< % , , % i t !m-slidesam . .

:&awbua,

.' . Mdrshk-hWRa~i~~8.01. 1 5 - i h mM M plywcrad, To

. -

cut tho cham& in the bass, install a

dWWIMtinarouta,nramtthetOdl .hetrbk; &&'the wlting h&@t to K inch. A+ the rnlddle d.ane

to thaliaw

w>:W$.*,i *;&;-dm W s f o e k ,
two
, ,

.,. . ... .. ... .. .. , . ..., . ,,., ., ; . . .%.>

. ..

auwtk,wh!*,;&;rSeh

andfisedirrllLLw,- .., 'ipuelrkk, fm. siatr the'w:&IIw in

the ' j l m m q i ; ~ . * : . ~ *

'
..
,

2-inch-%1M&Mdlp f ! q n the W, ,M d & & lq.8 Wih .Wl , ,. i*.**~ 4th final,:. cut : . # . ' dewelsand a

m;huei,*
,

thuni&-&&dim .. T o . ~ . t hkW&uttillggui* s d,,,hw& . . . .... , , &,$#$&~*,&qpacihg a &&~i'~te*als'~~ qtiq~ie~tbat ttp it

: *,-w

'.

ti&&i:kM+hbsrad*

.,~ ......,. . , . to:.~$$$,e,uh&mii M the t);ei:

ma j,.-&:&plDg$pdd shim +*P1",BR&,:&

..

r--

JOINERY
T
a1common joints is a muter table. he router is by far the most With a three-wing dotting cutter adaptable joint-making tool in the workshop. Numbersof comandanadiaryhoceonywrtable, for example, you can produce doumercial jigs and router bits have been developed over the years that ble dado joints (page90)b r enable the tool to produce many blingdrawasAnottaerimedorking joint that is simple to cut on the common joints, such as dovetails, muter table is the lock miter joint box j o i n t s ,and m&-and-tenons, (page %). A table will also enable and perform o h ,not so common, you to convert your muter into a operations. The jig shown in the platepmw the simple setup shown photo at right, for example, relies on page 94 simplifies cutting slots on router-like cutting action to cut pocket holes. Although the jig can . . for the biscuits, which swell when acwmpU little else,it does thejob glue is applied, creating a sturdy, invisible joint. And although of assembling face frames quickly With its router-like c u m , the wmmercial jig shown above cuts precisepocket h o b quickJy through dovetah are traditionally and precisely. Other commercial craftedbyhandormtedwiththe muter jigs are iUustratedstarhg on Wah aface-frame rail clamped in thejig, aid of a commercial jig, the techpage 88. Some of these devices are the bit i s pivoted into theface of the board to cut the pocket hole. The rail will be screwed niquekgbhgon page 104shows e e , and if you plan only to to a stile. Refer to page 102fm instructions how to create this strong,amactiw make the occasionaljoint, you may on building a shop-made version of the jig. joint on the muter table aided only be better off doing the work with by a miter gauge. hand tools. But if your upcoming You can enhance your muter's pintatting capacity with pmjects indude a lot of repetitive work-a chest of d r a m a variety of shop-built jigs. The simple T-shaped jigshown on with plenty of dovetailed joints or a series of doors with mor2 ,f o re m m p B a lm p e l,is ideal for muting half-lap pints ihe b i i tise and tenons, for exampl+these jigs can quickly prove to page 9 cuit-slot jig (page 9 5 )transforms a hand-held muter into a be a worthwhile investment. work plate p i . And thejig shown on page 97-baUya Although the router is seldom used freehand to cut joints, very few muter joinery techniques absolutelyrequirean expen- surface with a slot cut through it-will serve ar well as a comsive commercial jig. The only accessory needed to rout sever- mercial device for muting mortises

--

L
1 Y
The laminate nimmershown at b$t routs out the waste between thepins of a half-blind dovetailjoint. With its o w base, the trimmer a h a U M tof m all downward prernrrp on the work surf&, which helps pre~ e nthe t toolfmm wobbling. The base rides along an edgeguide, ensuring that the depth ofthesuckets remains unifan ~ mthe sboard 87

.,

L
b

COMMERCIAL JIGS

ting a wide range ofjoints including t?umghand hal~-eb'nd dmrcdk hp

~ ~ - r c n o n s r o n g u e 4 -

g~lm.sandmbbm~mumnhdd &tma&+anthcjigand oneornms~anchmlpaion

askhgbarbdautheplatrlkmutcr
anbGgridodabngtkplateintoasta-

tionarywdpka orthedod;mnbe@ inmthebitbyturningahm&k&ac shnvninthepbomat~Thcsmrp rintcb~butrhcjig+some

~ ~ ~ S k r a e d i r s i a J r m n

k~wirhthcdirmiOn4~mrarint
( ~ a n ~ ~ ) d u m J ingnacm~nmolhwirhvirtrranynoaamnrtALamwkMdin~ IZF-kand&anpallmatkay@~ wrkMdinthcti&t-handwaif
youpdjUrt~~&mtthemfLrfor

a t i m m d f aramp*,thepin&etwmtis-iwm jig is& Wfbrprod&rygcqpaa&w&~&uptoachmrdpiaLcamkcutatthesameikmina matterofaJkvfiinmrrer

tonplru*tke*ltbsinr-

plLsaMcdtoa-4Wand ~+tothclaMcThsjig~
-with macmqarjkrrraool inch. lkiiummnbcuxdtocutaither

~ o r b m r ~ ~ J I m r n a t ~

JOINERY

with a higher price tag and usually involves more setup time than a fixed-templatetype of jig. Moat commercial jigs are designed to cut dovetails, since this joint is a cornerstone of cabinetmaking and one that seems tailor-made for the router to produce. There are also jig for cutting mortise-and-tenons, like the MorTen shown on page 101, while some dovetail jigs, like the Leigh, can be adapted to cut both dovetails and mortise-and-tenons. Before buying a jig consider whether you need all the features that

it provides. There is no point buying a device that requires an hour or two setup time if you only plan to cut a few joints. On the other hand'onc big project may make the purchase of a . iig pay -. for itself. A traditional six-board blanket chest, for example, requires more than 50 dovetails. Unless you are very experienced, those joints will take you hoursif not days-to cut by hand. A simple jig like the Keller, on the other hand, would enable you to do the job easily in a siigle morning.

KrUcrlig
7'he K e k is a n'mpkftred-template dovetailjig, of

which there a n numerous varieties on the market. This particular device consists oftwo templat-e for cuta i l s .The bmplates ting the pins and one for cutting the t are mounted to backup boards and then damped to the worbiece. A dovetail bit is used to cut the tails. as shown r in the photo below, while a straight bit routs thepim. Each bit has a bearing that guides the router in and out of thejigifingem to &t thehint. A stop-block (clamped to the right of the workpiece in the photo) makes it errcy to cut any number ofjoints with the same setup. Thejig is awilable in lbinrh and 24ilrch models.

nleLcigh'sdbb'naivcfaahmicitsfinger~whids asshmvnabmrr,aanbearljustedwitha~toalaer thespacingandwidthofthephgivinga hmulnaftod boktothedow&kith+scut.Oncethepbuatead~

thefretar2cset~.nK~asmnbly*si~

Pippcdomto cut thematingprt. nKfkrger-p& aaanMy ran bc adjmtedprrirdy t o w t u n e the righhlm qfdrcjoint. Ihcp#mn be used to cut a varktyofdovctaiLS indud& dmugh, w b l i d&ding. and arllincd An cfiodnnmtalroenables it to rart mmtk-and-tenon joims ~ j i g ~ a v a r ? a b l e i n 1 2 - ~ a n d 2 4 i n c h m a d c l r

DOUBLE DADO JOINT

I
ROUTIS

The double dadojoint amnects two dadoes oneledado on theinddcfhceqfoneboardand theotlier&with one toque shortened-on the end of the mating* The joint is stronger than a srafidanl thmugh dado banuu it provides more gluing s u r J i i It is an ideal choice for joiningboar& ofdifferent thicknesses, such ar attaching a d r a m f t a r t w thesides, attdprovidcsgwdrsistanrr to tenion and racking. The Khlp shmvn in the steps below and on thej6hwingpage willjoin a 314-inch-&& drawerfront to a '/pinch-thickdrawer side 'Thethree cuts can all be made with the same bit-4 tinu-wing sloning~.hIntlrisan/+inchbitisucerf;theJhim attachcntothemrxi~f;mccis&o~/rind,thidc1Ey
wyiqthesizsof~nmcrandshim,youannrtthe samejoint in h r d s ofdiff*Ynr thickness

A DOUBLEOAW loin

Moiqtkca&.rlnmtr**hrat If you ae using double dadoes to asmble a drawer, cut the dadoes with the shortened tongue on the ends of the drawer fmnt. Stat by installinga three wing slotting cutter in a rwter and mountingthe t d in a table. Cut a notch f a the b i t thmugh an 8-inch-hii arailiay fence and attach the fence in place; the high fence is essential f a feeding stock axms the tabk on end (steps 2 and 3). Position
the~inl'iwiththeacteredgeofthe b i t pilot baaringand parallel to the miter slot, then set the cutting height by butting the mxkpiece against the bit and centering the cutter on the end of the hard. Keeping the face of the bard flat on the table and the end pressed against the fence, feed it into the cutter using tQe miter g a y (right).

JOINERY

mb*h*rrsidB Cut a notch in a wood shim for the cutter and rrew it to the auxiliaty fence. The shim shauld be as long as the fence and equal in thiduwss to the difference in t h i i behween the drawer fmt and sides. To rout the dado in the drawer slde, hold its end flat on the table and i n s t the shim as its inside face flush w yw feed it across the table (MU. Ee sure to keep your hands clear ol the cutter.

Trim~Um idhIpllrar mllwb.rratnn) To complete the joint, yw nmd to shorten the lmi& tongue of each dado you routed in step 1 . Lower the cutting h e i i of the b i t so the b o t t medge of the cutter is just above the tabletop. Then feed the drawer front aemsr the table as in step 2, holding the inside face against the shim (Mow).

CORNER HALF-LAP JOINT

Ilw comer hay-lap joint b

used to

asxmbkfmma and doors. Adding dowels a screws & thejointproviduan m a ntcasutc ofstrength. Thejoint can be cut on a tabksawwithadaQoblade,butamuur
windothefobjwtarweU.Lhnottryw make the cut)khand. Thisjoint dcpends uponpcrf~sqwn~eu Use t za T-square iike the one shown below w guide the nwtrr. q ~ y m rare making many repeat ~tson~thaterethcsamesize,rokc rhc time & b d d tkrjigshmvn on page 93.

UILIITap.k

TQmut hult-kpwith&uldaE thet are strawt and s q m0 Me:dges.of tfte ~laoa~-sqU&8j&lil1~~d~eshawh atf@l.rUpkethvijigflpnWtl~ sathetdplireisabPc$4inchesiridq; the w*,d,*> oneitks*,of

the eBge wide by Abqut the dm ofma muter base pl*. RPPembh tha jia by

attgMngt)\e~~$Wguide*.rn~ ~ ~ u e i ~ a b y q w e t o . ~

mbin thelnwpieeesivaplapsndiwktb eah etha. M&the,~holllllQd th8Mlf7

laocmvolr~adsetnle~on'
a ;rark-swfaw. install a sbaight bn h the roc*a, dlgr,the alter wilh the lRoulder

lltleafthe W-bp, anddmpihs'))Bstpp hm*kp[eceobWe~8uideisbuflod m l l s t * h e r a a g m p l e 8 , + t h s * dthelEencepnd*in?flu~hoga~nst edo~la.rn~uttherwsf~p-withaaies. d~asses#rptlull~thsmddthe

~,asshambythea~avinhllus
~,StartatthseRdgSfhe~ and continue Umll yw rnWL the lapl
*ttsrnderMi~dmplhaerlge~.

JOINERY

PLATE JOINT
Fitted with a thwwingrdonitlgartter
andmountcdinacommendbiscuit jabtefattachb~t.a muterats semi&nrkudotsforwwd~ Winto two matingslots, the biwtrikfom a strong and drrmMcplatejoint-witbout theexpenseofaphtejoiner.Yarmako nrr thesamepint on a mu& table with

arimpkshopmadesctup,asshmvn W a n d on thefbaolvingw In j u t ,
a &-mound can ort all the samejajantsasa Wtjohcr,W n g +-to4ge u i g t o r n and end-tofbrrjoin~.OneercepMlisanaige-~ )bajointin themi&kofapnrJnrdr

asllrouldtypidybeMadedtoinstmll
Jhdshelwsina~

~thrrmlg*cr~#eba To rwt biscuit Jots for an end-to-face plate joint, as shown here and on 95, by slotting the end @in. Set up fa the cut as yw would fa a double dado 901, installinga threedng slottinganter in the mt~? and an auxiliary fence on the muter table. Also screw a board to the miter gauge as an extension. Since the wood biscuits are longer than the bit diameter, yw will need to feed the wakpiece along the fence after plunging the bit intothe stock. Oraw a line across the fence centered above the cutter and mark the slot location on the &piece centered behneen the edges. Measure the difference between the biscuit length and cutter diameter, and mark lines m each side of the centerline on the fence, offse+Arg each me by onehdf the measured difference. To stact the Jot, butt the edge of the workpiace against the miter gauge extension with the end clear of the ' t and align the slot location mark with the offset line on the infeed side of the fence (&HI). Them slide the board along the extension, plunging the end grain into the cutter.

1 start

Once the board end is flush against the fence, slowly slide the miter gauge forward, holding the wwkpiece against both the extension and the fence (above). P i i the stock away from the fmewithout lifting it off the tabl-ce the slot location mark aligns with the offset line on the cutfeed side of the fence.

JOINERY

the s l o t 3 smwtlr~dkr#llanl you the

Ma& locatkn on the I&& face of the workpiece (near the kap end so u n see mark when the board is flush against the fence). Hold the rrakpiaee against the fence with the locadim msk s l w with the ofket llne on the lnfeed side of the fence, them butt the mltw gauge against the edge of the board and clamp it in p*cs With the workpiece clear of the cutter, turn m ths IWW. Pmwng the edge of the board w i n s 4 the miter gw@, pivot the Inside face toward the fence (I&), plut@ngthe bit into the stock. Once the bwrd is flusti against the fence, slowly slide it forward, keeping it pressed against the fence. Stop feeding the -piece once the slot location mark dignt wRh the oSM l~ne orl the outfeed side of the fence. Then twn df the muter

andphttheboadawyfranthefenca.

..

.. .

tha*b.*

of thp bcrse,; ane.wrmb(sc(lR . $Z&onanaedge, &.,k;ip,dch-h jl(lfEh fOT rro.

, ,

W i * . ,

dtm&er.:Cut the

20w
& , * I

a ~+-i$#&q,nrtdlfq',@. tam c u l l a ~ amtZh : lor ~

~ ~
ylpopriate notch 'nrith thestor . &, C ~ [ ~b W y w H l d i mak on the workpiee, . . . ~ ~ ~ ~ b o t t a n d '-'.stwe the edge guider on the. ..: :< , pim u u n ol the base are !hid;: ;; @+ & e n s t me st&. ::;.:&&~steb,,~~~tt# base p @ & f l * ~ t < ,. knasianbatoopbVrt*nitcan-

centw. ~&k&mUre ~ a r s p u r c ly on a -;.:cut four 1-inch. wide e & e ; & $ &e onein eEh ~ r m e r E & w & l u a per.-. TO rout a & & -. * & *... , + a n a,
gllM.a&iM;*

No.~Qltall~~nqtchssl~ lneh&.'*w olle &

ii!::&&jj

-*

ik&..
;

t q , , #@,ine~*f*:;#:&&.~..:.

........ . ... . . . . . . .: . . . . . . . . . .of . . . . ... .. . . . . . _ , l, ,i . , . 1.: . ~ . , .. ., , ,

'.%>

.:w w;fh

*,

LOCK MITER JOINT

ROUCIWB A LOCK MITER

Install a lock miter bit in your mrter and rmunt the tool in a table Attach a notched auxiliary fence @ageW)and screv an e&nsion board to the m h gauge. Set the W hem so the uppermost cutter IS mtmd on the board end with the wakp k e flat on the tabk. W i o n the fence so the bit will dado Ula stack without shatenlng it. Holding the nwkpke against

a m -

the fence and the miter gauge extension, feed the stock into the bit iabaue, IeW. To cut the matlng piece, clamp a guide block to it to ride along the top of the fence. Then feed the board a end into the cutter, keeping it flush the fence with one hand rvhlle pushir~g 1 and the gulde blodc fmnrad with t h other ~ hand labaue, r i m

MORTISE-AND-TENON JOINT

Assernbledfmn +inch plyulmd, the J@ s h m at r i g h tw i l l help pu mut n*rbherMaIIethetopadupisMabout10 inches bne and 6 inches wide. Cut an

awldotiniherniddledthebp,oRng itsliilylongerthimthenortisecutline andvrideena@toEmtdntheautlim and the tempb$ wide p u will uss wilh the bit. Snew the pieces in a T shape, countersinkingyour fastenen,
makethegaptmlweentheslotandthe upright rnessure at least omhalf the

~dthsthid&stackpuplnto matii. This will e n a k you to center t k mMtise outline under the s l o t with the beard face flush againat the u m you un center thinnar stock by p k Ing shims between the wwkpiece and the W s M

JOINERY

* o m

aanpthepgtothe~withthe

mortise outline centered under the slot; place shims betwRen the w o r k p i and u@gM, i f ~ . S e c u e t h e ~ i n abenchvise,sattingasuppDrtbor*dunder thenakplecetohdditsnugapainskthe top. Install a %inch madking Mt in a plungamutfr.attaehatempW~kleto the-adaliusttheurttingdepth nryoucanmutthemartkeintvaaUree successively deeper passes f&t). H H d d the router Rat on the ja top with the bit Een$redarsrmetYldofthesbt.Twnal the todl and plunge the blt into the s k u % Thenfeedthetooltotheotharendofthe slat to finish the CI&, passinBthe temp& guide ~ m mthe t ins id^ edge of the slot thtlJ@mtthepaedwe.

~ ~ t m m m a ~ t & h 9 Mountthemuterinatabk-anextemiDntlaardb th0miter~~andmarlcthetemnsharldersmthe~piece, using the finfished nratise as a guide. A d * the cuttim wdth op the gap between the fence and the bit@ the d k tance beheen the shaulder line and the end at (he board. Set the cuttiq he@ to obtain a tertocr s l i i t h i c k e r than the nKut& you cut m Sbzp 2. Buttinjjthe rail rgalnst the tenee

andthehelniter~,feedtherrokpiecefacedm intothecutter.Tumthebaadoverandrepsattocutthedher temn cheek &ad. Td-fit t h e t h i b of the tenon in the rmtke and make a d d i i l passes untll the M is snug. Then lnrk the top and Wtan of the tenon on the dmk, adjust the bn height to cut to the line and feed the stack on eQpe, d i g a pas on each 6 d @ to cunpkb the tenm.

JOINERY

mmrkOne way to ensure that a squareedged tenon t i snugly in a muterntis+with its mundedamers-kto mundwertheedgesofthetemn,using eithervowtablesawaasho~knii F a the table saw methad, cut a.v-shaped wedge out of a wwd block, ueating a jig that will hold the workpiece at an a m to the saw blade. Position the j& an the table alongside the blade, slide the miter gauge up against the j i i and clamp the gauge in place. S c m the jig to the miter gauge. Adjust the cutting height s u the Made will lust trim the unner of the tenon. The rip fence should be pasitioned so the saw bWn will not cut into the tenon shoulder. Then turn on the saw and, hddiithr face of the workpiece flush against om slde of the V, slide the stock alap the jig(asshownbytheanowintheillt6b tion) until it touches the fence, trirnnring the comer of the team. R e p i t h the wkpiece in the j i g to lrim the m i , ingtmcomws(~leN.Fathe shop knife metho$ simply round o w thetenmbytrimming(hrearwrrhmn the end ol the bord to Um shwW
( -

m a

JOINERY

Uai*Uro@rrourWrYiubsmUldo Uwnt you mvter in a tabla with a mortising bk in the tad.

'Ihehit'sdismatarshauldtFacgualtothsmatke~ cslly, about omthii the stock U n c k m .Mak the beginnire andenddthematisemdlfwsiderdbwakpieoqlhen centeranendaftheboadonthe bitandlluttanaudliifence ~nstthestack CbmpafestherbaardtotheWbracingk wilh a support boad clamped at a 90" angle to its edgeX twnd ~nriklPpawrdthefefherboardslishtlytofkilitatekmrmgthervakpieeeartothebit To h e l p p u d e $ r m i n e t h ~ ~ tlpnd~c~vvhenitishiddenty~~duinglhii cut,rnark the points on the tenea whem the b i t stats and s 4 w i cutring Nexlalignthemortisestatlinemtha~wnth thebit, Mastopbbck~imtthabottanendofthe* and clamp I to the infeed side d the fence. Then align the mottise end line with the bit, butt a drip bbck agsimt the top end d the , and clamp it in place. Turn on the muter and lcmer the wwkpiem onto the bit. Leeping it flush agaimt the fence ad the stop Mock fabael. FeadthewdpieceauossthetaMe,psssinBthesloch~nst the fence and tlat on the table ir@tI. Onre the warkpiece wntacts the stop black aa the outfeed side of the fence, tun Mtherwta.

Ilplsradaal(lrolld,If the desired depth of a matise erceedp yow muter's maximum depth of cut, use an electric drill to help cut the cavity. The illustration above shorn the three steps neeassay to cut a mortise thmugh thick stock. Start by installing a martising bit in the muter and making as many passes as you can until you can go no deeper (A). Then use the drill with a bit that is lacger than ywr route^ bit t o bore a hole through the remainingwaste (8).Install a piloted flush-trimming K the I wdqke bit in the muter ~ turn over. Insertingthe bit through the hok made by the drill, mut ad the m a s ht W , keep the pilot bearing paaed against thewallsofthemoitktomplotethc cut.Umachikeltoqquaethemcrtise awne~, if dgked.

POCKET HQLES

Cut the j i body and feme fmm hankmod, then taper the the body bthe fence, makitq sure the tsstaner does not in$rt o p f a c e o f t h e b o d y i n a ~ a n c a v e c u r v e , s ~ B e c u t rect wiM the guide hole. Finally, drive trro keds into the 5 inchestmm one end. Now rout a pinch-wirle, 3QjncMang irside edge of the fence, leauingtheir haado pmudii then s l d thmgh the body, canted m the tapwed fea, as sham snip ofi the heads with p l i i the pointed ends d the tifads aoVe.ailltwopeephdes~thebodynearthetapmd willhelp you porWonthewdqke~mtthefUmee.Topre end;the holes will help y ~ d , i i thewrakpieoe the ji pare the laminate trimmer for the j i i cut a nsmrv shim fmm Notch the top of the fence to accommodate the body, then !Uwh hadbrrardas long as the tool basa k wide. &illa hole glue the pieces together so the end of the body is flush with thm& R fa the M and temp& gu& & p 21pu will usa. the outside e9ge of the fence. Onm the adhesive has cured. and fix it to the base ot the trtmmer with doubhidd tape. bae the jl-inchdiameta guide hole thmvgh the fence; d i (The sh~m will allow the muter to ride smoothly alang Ute the bit with the slot m the body as yau drill the hole. Saew slicdwrfaceofthetaper.)

2n - p c r a
t l K 4 imi&

lmtsll a cutler and tsmdate g u l h in

bimur; the Gulter dim* Shpuldba~~thantheheads

dthenraw~puwillbeusisingtopinthe
workpieces.Thensetetthestodcad swface,mthem*ii%MtoP and, with the brads securingthe workpiece tksh m l m t the fenoe, elamp the m r n b l y in place. Holding the trimmer

abovsthejigwlththeMcentPredmerane end d the W ,tun m the tool and plunge the bit into the rtcdc untll the hadbod
a i m lsflatontheiiglmdy.Thenfeed the tool along the J@ to the other end 04 the slot to finish the cut, pressing tha template guide against the inside edges of the slot tlmwgh the cut . # i f (

Wll-CYlr*

ToimnpleteMapockahob.yw need to drill Ma pilat h d f01 ~ the r r e w used to secure the joint. Fi the bi into the guide hale in the Jigfence and bore the hole (/oft). The bit should emsrge from the top of the &piece, centered in the pock& pu muted in step 2.

DOVETAIL JOINTS

-\

ucinga handwwmd~~~bramanyI waodwrakasnmvmnkcitwirlramytn. herearea mft ofjigs on the mrket rkat, parparred wifh a w t e r , &you io mt atw&yqfdmctailjoin& (page 88).

CUTTIN6 THROUGH D O E T A U OH A ROUTER TMLE

hM-phsateachend(a&eaTorout*kelointstatbyurilwa

1 A dovetall pint mnWs d a tail bard and a pin LDlrd rrith

an a lOrk suface,pawtionthe template on top, and start by

maki~waste~equalto~lthaMtheWchwidIhat each be sure to align the temphWs notched end W the board end and hold its eQges perallel to thm d the *crkpkcaOutlithe~iwlsteseetionsfabaehrnaking then, with an x as you g a 7hae are no rigidguiddines for Um n~~rnber of tails required, but evenly qmad tails that are at lpaJt(wkethesizeoftherrartesrrctionsbetweenth8mpo dumanattractiveandsturdypint

cuttingpagad~tothsJtoeLthickneJstowfbeashoulder line semss and of the tail board, To mark the tails, caeashopmade$mpbte;adapieceofdearaaylic~ about 3 inches wide and 8 inches kng. than rmt a notch into madwilhthesamedovelail bitprwiUllsetocuttheplnt. lhedzeandshahapeof the notch willawrespoldtothewaste se&m betrveen the tails-thal rs, the pins Set the tdl bawd

Mount your muter in a table with the b i t used to notch the dovetail template and screw an extension board to the miter gauge. Securing the tall board on end. adjust the clming height so the bit will cut to the shoulder line. Then allgn one of the waste sections at the edge of the b d with the bit and damp the w k piece to the eatemion. Butt a stop bbck
againstaned@aftheboadandwumit

totheextensbnsopuanmutthewa!3te sactiom at each mner of the board using the same setup. To cut the first waste section, sfide the miter gauge forward. Then t u n Me boad m n d , butt it against
thez$pMadsredampthe-to the extension and repeat the cut. Cut the waste &iom at the other end of the boadMesarnew(rn

~ Y Once the wastfa at all fcu mnen of the tail board has beon ciaared. mnxm the stop blmk, then align one of the remaining waste sections with the bit, securethewolkpiitothemiter~ extemim, and m b m p the shp bbck againsttheecbpdthstalr. Routthe wastesdm, than flip the boad end-forcndtocutthe~llgsctianat theaUmrend.Rapsdthepocasstocut
amTgthemmainl~Matancbom(WU

Secure the pin board end-up in a bench vise and hold the cumpletedtail board inpositiarmxathed. Making suretheedeesofthetwoh&are aligned and the end of the tail boad is flush with the outside face of the pin board, t u n a Pencil a&p each edge of the tails to outline the pins m the end of the pin board fieftl. Extend all the pin marks down both faces of the board, using a combination square to ensure that the lines are papsndila to the end of tha bpard.Makeachwastescthwitt~anX

5Simhpinsm~Wmthe*fkedtheM,pu need to m&!Ia the miter earn m your rcuta table when yo(r cut them (steps 6 and 7).To delerm~ne the cmect angk, use a Slidig betel. Holdingthe handle of the device flush against the end d the tail board, adjust the Made to align with the e @ e of

mr*c-*@mm

aneofthatails~-,mThl-theadj-an the muter taMe miter @ I @ , butt the handle d thq s l i i i bevel against the gauge extension, and srvkpd the head d the paqge until the bhde d the slldirpl b d is parallel to the mila Wf h , T i hadjuJtment h a n k

m.

JOINERY

0 ~nsbiiasbaiihitinthe~ad
adju$tthecuttingd@htuslim thaBthe~dthetailW.AI~ the @$It-hand edged the fint marked wastesedlonriththebi buttastop bbck againd the edge of the stodr and clamp it b the miter gauge exkmion. Holding the extemim with both ha&, teedtherrorkpiaeintothebitThentun the st& end-forend, clamp it b the externan with itsedge Rush against the stapMockand~thecut1theotherenddthebogd. MavatlpsbDpbkdc mmyfmnthebitbyanamruntqualto the cutta dimeW and nraLc andhm CIB at each end d the baprd. antinuinguntil pu have d d t laapt ane-half the waa&,dadowt~muchrmchthan

. . ..

. .. .

hdltb~apu~cutliintothe
~lpi=Rcpsatthepazafa each wmte snctkm b b ~ ~ s lh) i, i the s t o p = .

h&&!tlrmld.lymsb immlbmpimbor( Once you have cut away half the waste franthepinbcard,remcmthe~e' and stop block, and use the sliding bevel to angle the miter gauge in the oppmite direction. Then follow the same pmcedure used in the previous step to clear the remaining stock fmm each waste section idght).

Start by cutting the tails on your router table, as descrilpd on page 104; with hawblind dovetdk, adjust the cutting height so the length of the @ik equals twothirds the thickness of the pin board. Before outlining the pins, set a cutting gaclg~tothetailkngthanduseittomak a line across the end of the pin buard, closer to the outside than the inside face. Adjust the cutting gat& to the thickness of the tail boad and scribe a shoulder line on the inside face of the pin board. Then use the tail boad as a guide to outline the pins on the end of the pin board (pzge 1061, but insiead of lining up the ends of the tails with the outside face of the pin board, align them with the tailend line. To complete the marking use a by squm and a pencil to extend the lines on the board end to the shoulder line (left). k k the waste sections with an x asyou go.

1~

Secure the pin board end-up in a use a laminate trimmer fitted with a straii bit and qoffset base h remare the waste fmn the &iece. Tht offset base a l l m you to focus the d m ward pressure on the bench, which will help keep the tool from wobbling as you mut the waste. Sum a s u m board to a plywaod shim and clamp the assembly in a vke with the walrpiece. A d j u s t the stock up or down until the tip of the bit aligns with the shoulder line when the trimmer sits flat on the shim. Next, to keep irom cutting beyond the tailend line on the i t with end of the pin board, align the b the line, butt an edge guide against the trimmer base, and secure the guide in place. Then, starting at one edge of the mkpiece. rout out the wade between the pins frightl. keeping the trimmer flat on 'the shim throughout the operation. To avcid gouging the pins cut only to &in ?&iinch of their marked edges.

magammlrupII,mpim 2 bench vke and

-mu the d 3 tiw w

Remova remaininnwaste horn pin with paing& ~lrerr chis. Working m one wasb section at a time, pess the flat side d the chisel against the

r
r

I I L
D

D E C O r n TECHNIQUES
lthough many woodwodPlsdtbeirroutas high among the shop workcarving tooh in practised hands. Coupledwitha simple shop-made jig and a pair of clamps, the muter can taper

'A

horsesthetorllrvecdpaMeof muchmore than simply shap-

B
I

~ng edges, pFwiag grooves, in the photo at left, you can andmutingarcks~with rout flutes intolathe-mounted the appmpriate&whether quarter columns using the c o d or s h o p - m a 6 simple jig shown beginning the muter can accomplish a on page 120. Other carvinghost of decorative t a s k s .This like tasks include reeding chapterwinshowyouhowto 1 - f~agr 123),+put jigs to work to expand ing legs (page 125), cawing ywrmutdscapabilitiesfrom The mnmaeninl d i n g machine shown ahwe decorative fans ( j q e 127) and the workaday to the more m tn s mthc router mto a carving tool.Much like turned objects such as bowls ornamental a lathe, the machine secures up to three wdpieces (page 130). Fitted with a 6V V-bit and between centen. Fixed to a metal p/ate. a muter am Although most muter w d mounted ma table, fw examthen befed along the bed ofthe machine by had is guided by j i g s ,keehand ple, a muter can cut precise or with a motor drive. The router can a h be left muting has its place. You can wood threads (page 117), enstationary whik the crank is tumedat theother end cut ~desigwonwwdpanablingyoutomakitemslike ofthe machine,rotating the workpiou into the bit. els (page 136) and etch knahandscrews or vises in the ing (page 138). Even if you shop. As shown on page 114,the sameresult can be zchievcd have the carving skills to aaomplih some d these tasks by with a muter and a commercial wood threader. And with a hand, one advantage of using the muter is dut the work will shopmadej i g you can use a table-mounted muter to make go more quickly. Wth speed, however, comes dust and mhe.

legs (plgcjj9).Aoda~shown

domelshbardwoodstodr(pageII8). The moter an also be used to shape and adorn furniture parts with the precision and artfulness usually restricted to

BesureywrshophugocdwntitatiOnaddustcolkctiar,and weu a dust mask,hearing protection, and safety pgks for all muting operations.

IPcbmaltoabm-kjigthatridesahntgthebed
ofalathcthemutershnmatleftpbmaj7utem

a quarter c o h m For inrmrtinrr on bdding and usingthisjig. wfk topage I M

JIGS & EQUIPMENT FOR DECORATIVE WORK

I
m

DOWELS AND WOODEN THREADS

aldngpmamr dowels M for a great more G in your &king projects dun if
d e a d

in presses for o h oil and for wine.. For the modem woodworler, wood threadshave-pcdegrinnrms-

you rely solely on annmemal dowel ins~msandbdtstoembenirhfmnistodL The principal advantage of au- hucminshapmadcdampsandviu* tom-made dowels is that you can use (Seethe front endo~uer for iartmcany speck-one that matchesthe sur- iionson+wdodenhsndscrora) mundin wood or one that cantnutg The traditional mahod for AllathaLkthalwEPlldeetbe d t h m d s i n v o M b d c u t t i n g dowels precisely to suit your needs. thanudngatrisngohr61e.Nandys, The simple shopbuilt jig sbown on a 5 s h o w l l o n t h c ~ ~ p a e e s , ~ gage 118describnhowtousearauter c a o d o t h e j o b m w h m c n r ~ d totraasfom~clo~resmdtintodnveb, easilybyattiqdmadsondmdsmck Woodworkers have been cutting w i t h ~ ~ & s u r e t o a r e a f r r s h wood threads for more than 2,000 sharpad bit; a d d ratter win saip ~TheRomvrsdvnmdennmns as it ~MJDS them.

~~

krews and bolts fit into an opening-a hde, plastic anchor a, as sham at r@tt. a nut Whan cutting thraads into rmnd stack, certain d i m sims are critiil. llte high points of the thraads,kna~lastheaests,andthebw point% a vallqfi must complement the shape of the nut, attho@ the creB in a woodenscrewaeRatterthantheymuld be in a metal sum. In a d d i i . the distance betmen adjoining crests called ihepitchoftheth~,rrmstbeapefed match between thefasbw and the nut Wooden serews are often cate@rind accadim to the d i i around their aedb (majar s c m diameter) and awnd ihehvalleys (minar s a w diiamder).

1Phl*klhj* am sized t o piM a

DECORATIVE TECHNIQUES

2 need

T ~ a k w l W To rout threadsinto mund stock, MI to pepare a threadingj i g . As shorm onpage117,the jiiwillguidethedorvel stock into the muter bit, albrving the cuttem to carve the threads. Start with a wood tap the sane d i i as the threads you want; a Kinch tap is shan in the illustrationat left. Seure ywr ji bbnka 2-by-3 board will do finefamup in a vise and use the tap to cut threads all the way through the stock (MU.To feed the dowel stock into the ji you need to enbrgt the feed hole fa about ane-half its len&lh. Install a bit in your drill press that is slightly larger than the feed hole, then position the hole under the bit, damp the, jig to the machine table, and adjud the drilling depth to one-half the stock thick ness. Bae the hole ibebw).

DECoRAnVE TECHNIQUES

muMbgI*itgmbn*u~ 41rl.Ia60Ylinthe~rand~thetooIina tabte. Clamp the thraaded half of the jig bottakedge down fa the tabla so the tip of the bit is just in fmnt of the thread fabod. Adjust the muter's cutting k i t so the tip of the

KtkMlnhthecdoftb*Minthejig.Buttthe unthFeadad half of the jig against the half already in place. align the holes, and clamp it in place. Make sure the marlred faces of both pieces face out.

DECORNIVE TECHNIQUES

n 5- r on

Turn the router and slip the dtwel into the unthrealed end of the f e e d We. Push the dovrel fmvard and once the cutter b i i into the stock begin rotating the dowel in a cloclnvise dinretion, as i n d i i by the a r m in the illustrah above. Cantinue until Me dowel has been threaded to the desired length.

DECORATIVE TECHNIQUES

, ,..,.\ > ; p -. ;. . muter ti^ with a ?$244tfcIr,s$aieht bit, it.~iie.shauvn at

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ROUTING DECORATIVE ACCENTS

arved accents and ornamentation have been a feature of flne futnihlre for centuries. Traditionally, these details were etched with painstaking skill by master carvers wielding a battery of gouges, chisels and files. While a router cannot duplicate the finely detailed work of a skilled carver, it can still produce impressive results with far less effort and training. With the right setup and techniques you can use your

muter to perform a variety of decorative cuts, from tapering legs and cutting flutes in quarter columns to she1carving.The6utesshavninthequartercolumn in the photo at left, for example, were cut in a cylinder while it was still mounted on a lathe; the router was 6xed to a simple jig that rides along the lathe bed Instructions for setting up the operation are shown b e g i ~ i n g on page 120.

m*lllr
start,~enoughspace~thaUneand~top~ndtortho~mathod ycu W i l use to attach the kg In the nib. Them outlirw,tha finished dm d the tiOer anthehotfomend, usiq)wrfingasssalpli6todnnralinpnllalbesehm

DECORATIVE TECHNIQUES

.-I

DECORATIVE TECHNIQUES

To taper a leg with a router, use the shown at r&t, wnsistingof two tapering guides--one fixed and one ad)ustBble-a p l y w d base, and two wedges. For the jig, cut a %-inchwide, Isinchdeep tabbet h o n e e&a of each guide, then screw one of the guides to the base so the rawst is facing up. Hddingthe leg flush against the fixed guide, slip the wedges under the workpiece at each end sothetaperstwt llneon thefaceand the uppermost outllne on the end are both level with the rabbet shoulder on the guide. Then butt the rabbeted face of the adjustable guide against the leg and clamp it in place so the ends of the guides are aligned.

srr*rsMaocririk 2 jk

DECORATIVE TFKHNIQUES

You can use your router alongwith the ~nlsdjiishavnon~120to cut reeds in a twned leg. F a t h i soperatian, install a datMepkted bead b ~in t

---

the muter and, to ensure that the kr(Bth of the reecb is unifmn, c h p a stop bbck at each end of the lathe bsd fkftl. Make index miwkq for the reeds on the lathe
faceplate, spacing the lines equally, d mount the leg on the lalheso the cut will stat at the leg's thicker end as the muter 1 s fed against the direction af bit mtatii. Once the setup is complete, mut the reeds as you wuld f l u h (page121J. g*dlnglhe j~ and muter aga~nst the d i i o n of bit rotaionfmonestopbkrektotheother to cut the reeds one after another ~ ~

DECORATIVE TFCEMQUES

----

flat and theiLends straight. Finish canring the reeds by hand. To round over the top surface of the reeds, make a series of cuts on each side of the gmom between them, rolling a flat carver's chisel slightly fmm side to side. Follow the leg's contours, making the reeds wider at the top than atthebottom.Atthebottomofthereeds, use the chisel to extend the grooves right to the next decorative element-in this case, a bead fabow)-paring away the waste in thin layers. Round o f f the tops of the reeds by making a plunge cut with the appmpriate-size carving gwge (WU.

SPIRALING A LE6

U)qLlb.Wrpbll Fbcthewalcplecedrartarontheji&adjustingthe&@h knobss,therou$r platfanndeasthe stock. Set the Ruter's cutting depth so the Mt will p m M e the stock the desired amount when the knobs contact the wide ail. Neat. use the jlg indexi~ head and pin to evanly space the numbs d spirals. To emre dl the -Is will bethe same length, t o t a t e t h e m k to move the platform to the headstock end of the jig, butI the stop on the guide rail ilgainst the platfgrm, and lock it in place f m tqaL Repeat with the stop at theother end. With the platform tilted up and butted against the s$p at the tailstock end, turn o n the muter and ltmec the platfwm-pl&ng the bit into the stcrlwntll the depth kmbs contact the ~ l d mil. e Then tun the crank, M i r ( gthe w m i q k e and rnoving the plalfwm, until Um mutw

rsaehestheheadstackwdlrn~.

DECORATIVE TECHNIQUES

1
-im--rphl Before yw can rout the ned $mi. readjust Ul e iwbxhg head and pin to s z t the desired spacing between the cub. Make the remainilrg cuts in the sama m , then use a h a wrench to detach the cable clamp lTom the helowereabk labwPIand hmk it to the upper d e . Thii will change the directii d m W i d the wakpieee as yw turn the m k .

'1

&j

-3
F:

l*rrrp*llrChrh 3~ to the adjusting the

Cut4ssond~dspiralsperpendicula first set, spang between the cuts aftereach p a s Af$r four passes, the leg shown at left has a pineapple pattern.

CARVING WITH ROUTERS

m m g has traditionally been the

ewiusivedormainofartisawwield-

moPion,ratherthanpusIungitahmg,so
s e t up pur opentiom amrdingly. l k e are few hard and fast rules in carving, so it is a good idea to practice p u r cutson scrap material, particubr-

you can produce carvings similar to

hand-wroclgbtwrks. lywhenyouaremutingfreehaod Ahhough most plunge bits can be usedinmuta~somecuaershne specific applications With their capach d in the bowl-carvingj i g shown ayfbrranovingtaFgeeofbowlbits,forenmple,areidealforr$ief at right,a muter cuts k & f i t e s carving. A V-bit can be used for proa agoblet. Thejigsits on the bcdofa dudngsaifsinlenering,whiieveining lathe, d i n g the carving to be dmte and lettering bitsexcel at creating the without removing a tunvdpiece@m linestypi&lofindsedletters.~tiseasithe machine For details on making est to feed the router with a pulling and using thejig, refer to page 130.
ROUTING A FAN CARVING

~w~bmp#s T o cave afan with a laminate trimmer. you need a tuv-piece ji consistingof a m a t e and a muting mnp (inset). Fw the template, use a compass to draw a semicircle of the desired d i i on a piece of Yeinch plymad a hardboard. Draw a second micirclefmm the sane center about 1inch hgm than the t ' i . Mark lines for the rays of the fan along the lags arc, spacing the maks equally. Also mak an area a n d the arc center;

this will provide a solid bearing for the amp point. h i l la hole for a scmll saw blade thmugh the waste section of the template and set the stock on the s m table, then slip the blade through the M e and cut away the waste fakrve). Drill a hde thmugh the template at the pwt hole mark and each ray mark. using a bit of the same diameter as the dowels you will use in the ramp.

DECORATIVE TJ3XNIQW.S

YltllWrolllirmp Cut a 1-ty-3 wmd b k k a few inches 1 0 than the fan rays yw pian to cawe. Rout a slot through it; the width of the dot ShOuld accommodate the template wide pu will use on the laminate trimmer and the length should eqwl that of the fan rays. Starting a few inches f m one end, bevel both faces of the b k k on ywr band saw so that it tapars to a thin wed@?. SmooZhthecUtsutfacesonadii sander (right). To finish preparing the ramp, mark a point on each side of the o w e k the distance between the dot for d Points should equal the gap betwaefi the Pivot hole and the ray holes on the tern plate. Drill the holes and glue a short k g t h of dowel into each one. Trim the dowels flush with the ramp top.

Seei~uy11*jigad*1l~~ Install a s b a ' i l omre ban bit as well a s a template guide in a laninate trimmer ( h ) . hen lay the wakpiece on your b e n c h and c h p the tempbte on top. Set the muting ramp in mitb, fitting the dowel at its t h i i end in the plvot hole and the other d o v ~in l the first ray hole.

DECORATIVE TECHNIQUES

Start by holdingthe laminate trimmer on the l h i i end of the ramp, tilting the base plate u ,the bi 1 sdesr of the stock. Then turn on the tool and pimt the cutter '?to the r r a k p i , butting the templab uide at the end of the slot. Once the rrlmmer base ptate is flat on the ramp, fead it down the ramp. Turn off the tml and tilt the base plateoff the ramp mce the template guide cant& the end of me slot (!eft).

b.Ynl*-f-w

-w--*m 5 the

P i the thin end of the ramp into nerd ray hde. Then mut the ray the sameuayyoucutthefirstart.CMltinue until all the rays ae dme WwJ.

DECORATIVE TECHNIQUES

9UlLD IT YOURSELF
#

W o t e h acry(i, the jig shtm at right will enable yau to use Yqwreutert0E;arZdecorativefeatwcs infofwxphte tufningiuhikUtey ae still mounted on your M e . The j+ holds the rwter ova the &piece I k k w I , ddbwing t h e wto pivDt * m t h e c u t
w&&&.*-dtthet-, tamem~*:*ao~~':
~

:*+ G'Imii*the

width o l w

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. 6 & m : t a hddthe ~ . * :thk @r@m.*rhenW j g is set on

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1 1 trilha'tJy2,mmw y,the ~@~..waI'~hdesIbr h;gw,c & , & : d t &

I;oards~ l-i&h int-,.cljfb' baees and support zjmias shoivn, drill holes t h r o e the a q near tha
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DECORATIVE TfKHNIQUES

DECORATIVE TECHNIQUP

CAWING IW M E RWND WITH THE ROUTER

P a i d with a canmerc~al pant-ph like the one shorn at ri#ht, a router fitted with a Xinch velning bit can be used fa carving in the round. M 3-D w i n g . Set up the router and jig follow i q the manufacturn's ~nstructiom The jishormiscrewaddormtoawksurface, while the rrorkplece and the pattern are secured with doublwded tape. The muter is fastened to the jiis metal plate and the j ~ g stylus is positioned abwe the pattern. As pu guide the stylus the surface of the paUern, the p m t m p h moves the muter in the same direction by the same rmclunt. enabling the bit to repoduce the pattern on the workpiece. With mast jigs of t h i s sart. you have to adjust the setup and the muter's cutting deQth (below) to emwe the bit will cut both the high and low points of the canring vrithwt g o u g w ton deep or mksing any areas.

1 -w--=dR

b-

DIPIICII](I*PII*I Turn on the router and grasp the handlsadj'oiningthe stylus firmly with both hands. Stacting at one of the pattern. begin running the stylus slowly along the surfaee; the router bii will make a auresponding cut in the wwkpiaeaf~iFwkstmu4movefrPm the high pointsof the paltwn towad the lcw ones; To copy the paitern exactly. the stylus must uwer all the pattern's surface; you can llft the jig and muter off the workpiece~lodikally ( M t lto

FREEHAND ROUTING
reehand cuttingwith muter, guidF ingt~etoo~ontvwim-eyesand ha& issimikr to dpture,'re&iring

pnctice and patieace. Although e x p i euce win hdp you settle on the wood species,methods and types of bii that work best for you, even a novice can achieve satisfactory results-provided
themudngisdonewithcuc Freehand routing will allow you to do &cutting, whii involves c m h g amy tbe waste s m & g the pattern yo~want,leavingthemisedformonthe furface, as shown in the photo at right You can also do incised cutting (page 138), in whicb thcwasteseaiom are the final d u c t uitil you becomec o m f o with ~

the~oflkhandm~nactice on Scrap wmd-md hoed &-gesIionsdtipspresen~onplgel%. r ~ ~ w ~ m u - ~ n y r ~ ~ s u c l - b a c l a d a % - d - m d t m n m g ~ a r o w p r I b e ~ p q p ~ d t h i s s e s i i o n s h o w i s u x d ~ t o a u w l e t t e r i n g i n m a p i t r e o f WThesub-&is how freehand mudng can cut relidand tnmspamrt n,tke user can view the cutting auion, cuad ii is wider h n indsedlettering, a rtandardsub-& to hdp ksep the muter steady on the workpie.

FREEHAND ROUTER BITS

DECORATIVE TECHNIQUES

PRllYClPLES OF FREEHAND ROUTING

~acCa*inh&mUdim The large armws in sllhwette fmn in the i l l ~ ~ abqve o nr e p resent sewwal wmmanly used freehand muter strokes, ranging fmrn straight and d i i n a l cuts to gentle arcs and Ian& sinuous umras T@ mi red indicate the direction ~nuhiih the muter willtendtomoveasyoumakethesecutS.Toobtain~cMpu want, you will haw to counterbalancethii tendency with feed pressure. W i t h , applyingtherightanountdpeswm

in the propec direction will become second Ratwe. For best results,alwayspulltheroutertowsrdyw,~thzulpushlng the tool into a cut. For deep cuts, it is bed t o make severd W mediate passes To rnirrlmize splintering, cut fmm waste seet i taxard uncut wood ~rritead of the ather way around. And a d d back strain by selting up your wwk at a comfortaMe he@ -which for most people is at the level of the base Or the spipine.

kickback design i m2 9

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e * d d w ~ ~ n

-~saauetspeslretomunhr . ~.ramPrSpllrirlltsndency. .. ., . :

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. . r;s;g,w*mkerp ..~.CnZMnir,apsnkdwnm .*m m,mns.

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aundertheinfluenceofakoho. adiertb.

. a i ~ , ~ ~ $ .,i.'"'-..'.... W . x X *$ ~t p ~u m u . in*& :. nckWlllnlbilr ~'

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DECORATIVE TF,cHNIQUES

RELIEF Cam"N6 WITH THE ROUTER

on a Piece O f paper and affix it to the

workpiece ( a h ) . If you use a spray adhesive, yw will be able to peel the pattern off the surface when the caw ing is completed.

Sketch of photowpy your pattern

subbase router Repbce the with a clea a c r y l i c one: this all1=Me you to view the cutting action as you mut the pattern. Cut the suthbare from Y a ?&inch th~ck ~ l i plasttc, c mdclr(gthe pieceus lsge as m x 6 s w to keap the muter steady on the nrakpiece; as a rule of thumb, the sub-base should be Wee as rvide as the mlwkee. Use your standard subbase as a leanpbtefaMlllng the bit cleeance and hdgthmrgh the anylic, then fasten the subbase to the muter (right).

2a n w I k ~ s & b m m pw
W W - k

DECORATIVE TECHNIQUES

3
a
3

lmtall a smalWimeter bit in your m W , the cutter in the illustrat~om m this p s ~ is e a X-i nch veining bit. Startig at one end of the pattern, cut a k q its edges to remove the waste Justoutside the marked Imes. Work on the outside edges af the pattern, then move on to the waste areas on the ins~de edges. Keep the sub-base flat on the w a k p i thmughwt the operation fahe), guiding the router against the dtnction of bit M i o n whenaver passible.

mau#-*L-,---

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md.m,~pYaPrsfp~(hs

,qm5#ltr~Wumsihe

mlimau61rfi*d,~.b

.wrslOkcrWtLIbrrehbd,911se& 4.Lnnran*lrPIhorntlOM*

13'1

DECORATIVE TECHNIQUES

W h i m g l h . l l l i b x p m a m Clamp yow stock to a *nrk surface and mark two paallel lines along the sutface, spaced to equal the desired h e i i d 'your letters. Then use a pencil to outline the letters on the surface. You can e l t b sketch the letters freehaml lahm?>or trace them fmm a pattern; for an elegant, tradiiioml look. p u

can reproduce the old English letters shmm below. Try to match the ddth of the letten' stmkes to the drameter of the blt y w will be using. To pmduee a traceable pattern at the appmpriate size, me a phdocop~er with an enlargement feature; then, secure the finished pattan to the wartipiece

DECORAnVE TECHNIQUES

2 ma.

A..."

'.....A

Install a 6W V- bit in a laminatetrlm set a shallow cutting depth, and stat by mutingthe letten' straight elements; leave the saifs, or taiclike stmkes on the top and bottom ends of the lettem for later (step 3). Use a T-wuae j i g to guide each cut, align the bit with the outline and butt the arm of the jig sgainst the edga of the workpiece with the fence a i the top surface and flush against the trimniefs base plate. Hddingthe ji in place, turn m the tool, plunge the blt into the stack i the baginningo f the stmiit portion, and cut akmg it, pullingthe trimmer toward yw.Hold the bsse plate flat on the;norkpiece and flush against the edge guide thmugtImJt frlghtl.

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3 BefopeaddingtheseritstotheM$rs
padlcemahingthearvedcuBinapicEe ofscrap*loodf~.Cutthc~byQrtiw at them deeper, rvlda ends. Runeethe bitintothestock, routthe paltun, and slarlywithdrawthsbitfrcmthewaod while ladingthe tod akq the surface thisadionwill podua,the~nw,tailof the d. Once pu ae salbfied with pur scrif-mdcingabilities. add t h i s detail to

GLOSSARY
A-EGD
ArudllnyfmccA wood fence attached to the standard fence of a muter table; usually high enough to suppofi awmkpiece beingfed acrossthe table on end.

End g m h The arrangment and ~ondthewoodfibemviewed h m the end of a b o a r d

I b d d m m k A piece of wood with thin fingers or"f&thersnatone end; used in canjuoction with damps to hold a workpiece against the fence o r top of a muter d i e .

EEEH-1-1

IOdrb.rlcThc te&nc)r of a workpKcct~beMmwnbackinthe direction of the o p t o r of a t d

BLnL:A length or block of wood used for turnings.

pattem muting,a small metalringthat snajs on and otfa template guide to change its diameter.
i n I& A router bit on
a campound o f hmgstenand carbon; auchnntioged~arestmngerand staysharperloneah d high-speed bitk
rnAbdphadatwepndunp6

knee An adjustable guide on a muter table to keep the edge, e n d , from the bit.

L a t h e The distvKe betweea centemon a lathe; l i m i t s the length ofspindle work that can be mounted on the machine.

Medhnn-fibcrBond

FhdesGmcavechannels,usually
evenly spaced, c a r d dong the lengthofspindlerurninggSeed Also, gmwes m muter bits that a h waste chips to be erpelkd.
FNn4-pa11elanued~A

W P ) : A type of manufachued shea material made from a wood tiber and resin camposite; available in thicknews 6um '14 t o 1 inch.

and the workpiece to distribute pressure.

Mita~AsuJedinrouting, this device slides in a slot to guide a wwIrpiececnwthebft;itcanbeset

t0v;niousangIeS.

<3Kalc ln a mortiw-and-tenon joint, the part of the tenon parallelt o the boardhcesandperped~to
the shouldet.

method of *rceworkconitmaion in which a wood panel h t a in grooves in a frame made ofhoriu)ntalrdJsandvaticelstiles.

hdehgheak An accessory on some lathes that enables the headstock to be rutated manually m mevurrdYawnents.

~Dacorativestripaofwood that can be carved by the muter.

Cbip-UmMngbitAbitthatlimlts the depth of cut of the cutting edge; this reduces the r i s k of kickback,
often caused by the larger gap of standard bits.
C a l k The sleeve on a muter that

cut in &e board fits-&toa &ding

hole, or m o r t i s e , in a n & .

Infee& The part of a router table that supportsthe workpiece before It reaches the bit
* A .

h k t k A rectangular,c i m h or oval hole cut into a piece of wood. O d e d T h e p r t of a muter table that supports the work after it pasm the bit during a cuttingoperation.
Psttan r 0 A technique in which the workpiece is secured fice-to-face to a template, and a piloted router bit or a template

decorative strip of metal, hvdwoodormarquetrytbatiglucd ~ - s t i e t j ~ h ~ A m e t h ~ d into o f a groorea t in a workpiece Fining stilesand railsin frame-andpanel construction. The ' int feaJi&Adeviceforguidingtherouter tures mating tongues an gnmves or holding a prlrpiece during and a decorative molding alongthe an operation. inside edges of the boards

holds the shank of a bit.

d"

Ihdo:A rectangular channel cut into a workpiece.

guideisfodakmgthetempketo repmduceits wntours on the edge oftheworkpiece

PllotbmiagA freespinning metal

collar on a piloted muter bit that follows the e* of a workpiece to d t a i n a u n h r m cutting depth or of a template to reproduce a shape.
Pilot hole A hole dried into a

R.ll:In a table, the boards that join the legs and support the top^ in a chair,oneoffourboardsthatframe the seat. Also thehorizontal member of a kame-and-panel membly.
See&

T-U-V-W-X-Y-Z ~Ahandtaalusedtocutspiral threds in wood or metal.

~Thetendencyofacum

toteacthe6befsofthewooditis
Eutting,leniagraBged Eknyattheendoredge

slightly smaller than the threaded seaionofthescrew.

Raised pmd:In frame-and-panel construction, a cabinet or door panel with bevelededges that creates theillusionthatthecentralportion
is "raised."

F the

Pin A table assem that suspends the muter a h % w v k piece; a femx or pin on the table guides the workpiece under the bit.

Rmplrtc~AmetaIwIhr screwed onto a mutm's base plate

to guide a mu-piloted bit during a muting operath~~ ~ A n ~ ~ , w m r e pattern x embellishment carved along the length of spindle turnings.SeepUte. Tan* A pattan cut from ply-

Plan-

A router whose

motorassemMyismountedabovethe base of @ tool on spring-loaded

wlolumns; downward-* on the handles feeds or plunges the bit into the wood.

RmoukThe amount of wobble that a router mUet imparts to a bit when the tool is operatin&; 0.005 iach or less is acceptable.

wood, hardboardorpartideboard

allowing productlon o f multiple identicaI wpies of a part.

SeriE The curved flourishesat the top and bottom ends of letters
W In a mortiseand-tenon joint,the part ofthe tenon perpendicul;ll.tothechee%.Inadovaail joint, the 'WIeys- bmwea the pins andtails

T c n r m : A protnmh from the end of i t s into a mortise. a workpiece that f

lbree-WhgsiottlngcuUmAmuter bit designedto cut a narrow gmove.

Push block or stldcA device used to feed a w o r w into a tablemounted muter bit to protea the opaator's fingel's
~hokAnangledholebored intothefaceofa%wwkphxand exiting from its end or edge; typicallymedtojoinframeraikandstiles, or fabkrails and tops.
Qaata~Atumadandsometimes &It4 d u m n set in niches in the b u t comerso f highboys and other 18th-Centuryfurniture.

llmugb dovdailphpt A method o f joining wood by means of interIockingpinsandtaikthename deriveshunthedistinctiveshape cut into the ends ofpining bouda
-mAioinery

a-jaino AjmethodinwhimadovaaikdsUde on one piece fits into a matching grooveintheother.

Stile The vertical member of a frame-and-panel d l y . See r d

method featuring a probwion from the edge or end of one boardthat fits into the gmove of another.

Woodmovenm&Theshrinlohg
or swellingof&

RS
R p w a t A step-like cut in the edge or end of a board; usually forms

Stoppedp o w A p v e that stops before reaching the full length or width of a wiw.

in reaction to changes in relative humidity.

partofajoint

INDEX
Page referencesi n i t a h indicate an Safctyp?ecauIians. 135 Te&liqus cPrving in the m d , 132-133 b h n d , 134-139 relief, 136-137 with pantographs, 13&133 See also Deamtivc technigua C i j i i 17 Collnr Checkinga c o b for slippage (Shop Tip), 19 Runout, Id- 1 9

Dow$f 114118
DOwelbBDdlcS(SbopTi), 117 Daud-mPlohgji&s, 11Z 118 SeealsoWoodwoodmveodo
DmWem m 9 1 Lodc miter joints, %

A-B-C
1617,112-113
% & s ;

Tables

Ba8a

Offs& 16 Sub-bercs,16 aa$c 136 Q l m i 7 . d sub-bass for large

-(Shop
Bench p
k

hptcolleaionhoods,49,50 Edges 21 Curved sZ G 6 6

Pinroll-75
Fsemioncords

Tip), 68

ConmIhg templates into, 81

Vacuum muting with, 79-80

customiziag o bench plate
Biscultjoints soeplatcpints

%J), 80

Comer U - b p joints, 92 ligp 93 Coma-roundingjigs, 17,63

Cluvdcate

Column-fluting* 1131m121, IW Plutodquarter, 114 119, l M l 2 l ~alldstidtpints, 57-58

M i u m wire gwge for.

fan carvins,127-129 Parthehad%@ Feeddiredon.20
-iig*.18

fronr-

Bit gusrds,51 Bits, 23-31 B i t shear, 24,B chip-hithgd&l, 24,B cutting cirdc dbmkr, 24

Cuvinginthemund. 132-133 Edpiea6263.6475

J&h&

134, IS139

Feekrgmgs, 19 Fenas.M37 44-45 Splca,16

Mating*
Cuts'

62 6466

32

l&uidn& 23 3 i 32 Rotatianspeed20
Stongs racks, 33

T * (* Ti). 45 -cuts, itam Foot switches,17 Frechnnd loutin& 134-139

PaddiccEtiaazO
Cuttm 30-31 Handrail crmm52
R d c u t t u s , n

T y p e s ,2531
anti-b i i 2% 25 sdgc-forming% 26-27 sroovirrg bits 26,1829 pilOrcdbiu,u,at routatable bits, Wr3l spiral bits, 24.25 Bowl camin& 130-131 Jig& 12% I , 130-131 Build It Yoorsdf: Biscuit slot jim 95 bd-awhgji&s, UO-131 C d u m n - e j i i 1m121 Cornw l a p pim j i i 93 DOWd-dg* 118

GH-1-J-K , UPtln. 8-9 Gmoves. 21

Bit%%zg29

*cutters58

Tabkandhuldrailamers, 22 Three-wiag slotting cutter%94

cuttiagr&Qth,20 Inbyroutin&67 P b w Ionterr (Shop Tip),21

Hand mirrors, 73-75. Handdcuttas.52 Horhvue

liiberdnsrc,hd.Hinge moniw%71 H o r i m d panel-rakingbits, M57 Incicedcuts,138 lahyroulin 67 70
d S U b b f o r M rrasses (Shoplip). MI REcesses. 68 q ~ ~ TwplaceS 67

stowed 53

83

D-E-F
Ihdoea, 9091
Deanatktecbiqus, 111 Bowlf 130 Pan c;ming,1 - 129 Flute cuts, NO,127 ~ u t 110,119,~ lax121 Reed Nts*123 Relid136137

Dustcdlmtonhwds90
Feedtag&%

OVd-cUttingjisf, 84-85 Pattan-routingh 66 Shop~pinr~nag77 StOragendrPhr&33 Vacu~tables,~

Imnncd~inrolltas.7276

&h-

Vi-mounted router tables, 59

M
Ropctp

bowls,130-131
fan& 127-129 s e r i f h 138-139

Spinla l%lm Taperingatableb 1 1 5 % 1 2 2 T&mdj&i 112-113 soeato-g Dial iudicators. 18 DovcailjOiat6 104-109 Dealing with a defective dovdi (shop~ip). im
JbB

Jisr

Adju6tabk routiugguides, 83 Biscuit-slot jisr,95 ~ ~ f l g1 1 s % 1,, 130-131

Cirdejigs, 17

cohmul-*jig, l l f 120.121, Comer half-lap joint j i g $ , 93

hr-muadhrgji(p. 17.63 Dowel-*jigs, 112 118

knsprvio8j@ 113,127,
Peedingji@,46

Hiage mrtires jigs, 71 Incnji&%ss K$ladovetailjisf,89 Lcg-tapeliqjisf, 113,122

MobaLUl-taunpints, 97-101 Mortises, 97,lW H@cmmS,71 Mortidng- 71,97

woo dm
w~-mmdpopLr ShapT~ eench phtcg 80 con*alippPse, 19 Cumingdcptb21

0-P-Q-R

L&hawetailjig%s9 Mddingj@ 16
Mortlsiagjigs. 71.97 Oval-Cuniagjigs, 61,8485 Pattern-rouhgjii 66 Podret-holeiie* 87,102 -groovidgjisf,83 Round-tenonjigs (Shop T i ) , 99 ~prouterjig%77 Tapjugjigs, 121) l k d k g i i g r . 115 Tumiagj i i 112,125 Twc&pkj i i 34 Vaeumnclampingiigr 78 WoodRatiigr 9.88 W-hsndlas,13

OesePmaksn
d & = *
Panels Arched, 54-55
-30

DovdPajolats lo7
Dowelhandks, 117 Rolmd-tmrm*99 Rout6 ePb*s, 37,4547.49

OvpluuUingjisS, 61.84-85

Ovenrmphmutingattacbment,73

Sub-kfor~lrcesscs,as

cuned 5657

PPntopphs, 112,132-133
Paltall~60-70 -*62

Jigs 66 Router tables, 63 Templam, 61.62 Template guides,61,62 Pilotedbii

edgesbaping,21,25 Pattemrouting,63 Pin muterq 6V, 61.72-?7 J % P 75 Imuted pia 72-76 Making a band mirror, 7%75 pin routingaltdmmt, 7 3 ~ r n ~ 7 6

Spnmfwa. 16 Speed controls, 17 Spirrl c"t% 125-126 rack for bits, 33 17.37 Remote on/olT(ShapT i ) , 49 Tables, 35 36-37 4043 Bits, M31

rig-,b.citahfeqJU

Joinery

-jigs.& lnaais (Shop T Q ) . 37 M i slots 4647

aluminum miter dot mdcs ~ ~ 47 ~
) ,

Canoepints52 cope-and-stickr'its, 57-58 Comer M-lap joints, 9293

DDQjOintaPo lheIailpnts, 84 104-109 hawerloclrpme, %

owarm

Half-blind douctailpinb, 84 1#109 L e g t o r a i l p * 39 Lodt*joia4% Mortiscand-tcnonm 97-101

ptotepints,94-95,s

PLtejIJiIltaP4 Bisnstpiwatamments,Jr Bkmit-dot jigs, 95 Phrng muterr 1415.21

Inlayroutiog,67-70
athe-aepth (W Ti), 21 PO&-hole& 87, I&?-10.3 PuShstidm.49 RMpondr,X
ReEesres, lm

lodin,clive, 1011

LM-N
LpmirUte~eni.4LlS6,la 112

tegs

Reeds, 123-124

Sphal$I25126 Tapering, 119-122 -134,136-139 Maintemmce, 18-19 MarqW, 67-69

me

Tmwd~12FW

Reliefnmiag
136-137

Bordcr*g.m

Cuniry depths. 67

Round-tewn jig f o r the routs table (*P~P). 99

Ro\aapa& 17

v a c u u m m u vaawns:

vma+

78 ma

Sae&Inlay routing
Mitabga.4647 Mitas;

Rwtera, I4
secakuPi.~PhqerOuIerS

Atdunen& 17.18

Rolda table imertr f bTie). 37

Verticll penel-raising bits, 54

Vi-mounted router t a b l e s ,3559 WiHowPd,6-7 Woodthrradas 112,114 Wood heads, 114-117
ScrhDmds

Tabkssz

M k slot mck (Shop Tip). 47

Shapinga handrail, 52 M o l d i n. g . b 16

---~-.
--~

Workpiecehpndlen,13

woalcnamdsaewswt-

ACKNOWLEDGMENTS
The afitmwizh to thank thcfidkng

" 7

i Ont; CMTT o & Oldaau,FL: Delb I n m n a l MachhqEorterCable, Guelph, Ont;D e W a I t l n d u d a lTool Co, (Canada) RichmondHiO, Ont; Linemastet Switch Corp., W o o d a t o c L , m, Makita Cmadn In~,Whilby, Ont; MilwdvkceEIacuic Tool Corp..,Brmldield WI;N e m ~ Took n lot,Montral, Que; Oakpa& Eate@e% U d , Maa,RokrtBogbP~~T001P.1n~(caMda)~~Ont;~,RaebuckdCo,ChkagJ.II; T Trend L t d . , Concord,Om;Vermont AmecbnCorp., LkoInton, NC and L m i d k KY; Pobidr Wamn. Esmndido,w;woodophSu~Coip,~~WV;mwoodworbdsGtorr.RograMN
Ad$&&

Chmp Co, Chicago, I k Birchan &Aaaociata. M

RolJrEUsANDA-RIES

ROUTER B r n Adjustable Clamp Co.. Chicago,I L i M r a n Tool Liocdn, NE; CMT Tools, OIdsmu, FL: Dclm Iotaoational Machiney/PortcKaMe,Guclph, Onl; Diamond Machinq T e c W Inc, Marlborough, MA;F m d Westmore Tods L t d ,mugs.Ont; ~obert%h power ~ o d a k , , ( ~ ~ s d% a) i 0nt
Acfjlubbk Chmp Co., Ulicaga R; BLadi& DcdvrlElu Power To& Tavroa MD;CMT Took Oldgnu, FL; Delta lntemnimd MschinayIPortn-C&k, Gdph Oat.; D e W a h I d u s h i d Tod Ca, (Cands) Richmond Hi& Ont.; Freud Westmore Todr,L t d , Mhissauga, Oot; Grim Industries. Inr. b r a Am, CA; NuTools. CLwaon.MI; Porta-Nab I x , WilmiogUm NC;Robm Beach Power Took Lrw, /(3atudslMisoissanm Dot.; Scvx Roebuck and od Chicam ILTod T d Ltb. Concord. OnL:
ROIiTRR --- - - -. TARI.PS -- -

&.

Gdph, & & I; b;c, watedord MI; Dsvid ~ e l l r r , - ~ u &dA;Makita Canada Inc,Wh~t O ~ Ken L PicotlDesilpl, Austio. T X ; S M Im,Davton, OH, and M o n k d Quea Spiehds W o o d Worlrr, F iCrat,W I ;T d T;ad ~llt,~oocind Om. Wainbee Ltd., Pointe Claire QueJDE-STACO. Tmy, MI; F'aI W a r n e r ,b n d i d o , CA

Ih&g-%ys~lr .

-.

Adjnstable Ckmp Co.,ChiIL;CMT Took Ohmar, F k D e bn I Machimtymater-Gble, God& Dot; DeWalt JnhLetrial Tool Ca, (Culad.1Rkhmond Hill, Ont; Msrtin Gadfrey, Web, %merxt, UK;Great Nedc Saw Mfrs. lac (BockBmaDRirion), Millbory,'IW D a d Kelb. P*ahrms.CA:LGehIndurtries I m . .Part Coauitlam. B.C.1 Ta r ~ e s i b ~ronp, ball& 7 % Sea, ~oebud; and ~ o . , IL;' ' ~ S&'r W o o d Works, F i Creek,WI; Tool Trend Ltd,Concord Om.
Ad+bk Clamp C o . , Chiago, Ik Amerian Tool Coa, Lincoln. NE; & I ITod Co., Newark OH; Delta International MachincrylPorter-Csble,Cudph, Dot.; DcWalt lndlrarhl Tool Co, (Gnada) Richmond Hill Ont; G m t Neck Saw Mfra. lnc (BuckBma Division), M i . MA;Phantom Engineaing RovoRovo UT: S/J Fine Woodworks, W Orchards, WA; Scsrs, Roebuck and G I . Chicsgo, , IL;S 'elman's W o o d works F A ~ m ~td.. d conc~d, ont; W ~ W S~ u p ~ llo=., y, WY WI;
- - -- . . . . .- - --. . .. - -

JimmY

&,

& ' o n ofthis h k 7 k f d b w i n g p e m q aLo a d t d m h e Lorraine D o & . A h Regs, ~hiHp ~ore.%kvi&ve Monettc

1% 11 M ~ o m o n g l o / ~ k m h 37 Couutag NuCrnft Tools

11 1,125 Courtes). Phantom Engineering

ISBN 0-8094-9541-4