First Box #4: Cut to size

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Blog entry by Bret posted 11-27-2009 08:20 PM 1146 reads 0 times favorited 6 comments Add to Favorites Watch
« Part 3: Starting over.... Part 4 of First Box series Part 5: Fresh start (so far) »

(This is actually part 5 but I messed up the way I added them so they got reversed….)

I ventured back into the shop today to continue prepping my box stock. I planed it down to roughly 1/2” and used my tablesaw to size all the pieces the same.


I then went to my router table and mitered the ends of the end pieces lying flat on the table. So far so good.

But when I went to route the front and back, I had signifigant breakage & tearout. Even slowing down the bit didn’t help, so I’m going to cut off the bad bits (I had actually somewhat anticipated this and chose to route the longer pieces against the fence so that if I had to lose a bit of length, it would be less noticeable along that dimension).

I’m now going to build a fence just for this purpose and make a special-purpose insert for this bit to ensure a closer fit so I don’t get any “dippage” of the piece as it traverses the bit. I think that’s been my major problem. A photo of the table setup as it sits today follows.


The worst case of tear-out:


I’ll re-trim the long sides and reattempt routing either later today or tomorrow. I might replace the long sides and just mill new ones after using these to verify that the new setup works.


-- Woodworking is easy as 3.14159265358979323846264338327950288419716939937510...

6 comments so far

View lew's profile


12019 posts in 3721 days

#1 posted 11-27-2009 08:23 PM

I’m not sure but it might help reduce the tear out by setting the router bit lower- thus taking a smaller bite- and remove the waste using several passes.

-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View a1Jim's profile


117063 posts in 3543 days

#2 posted 11-27-2009 08:28 PM

As a friend of mine says sneak up on it.

-- wood crafting & woodworking classes

View Bret's profile


166 posts in 3460 days

#3 posted 11-27-2009 09:05 PM

I normally do that when routing, but this bit has a captured portion, so you can’t sneak up on it very well. Once the bit height is set, I supposed you could tweak the fence location, but that’s something that also gets set via setup block (I made my own pair once I got the setup right) so that the two parts mate precisely. I’m just not sure how to sneak up on this particular joint….

-- Woodworking is easy as 3.14159265358979323846264338327950288419716939937510...

View jlsmith5963's profile


297 posts in 3314 days

#4 posted 11-27-2009 10:21 PM

I can’t quite tell what the shape of the profile is from the pictures but lets assume you can’t adjust the height and you don’t want to adjust the fence (the setup block in all). What you can do is add spacer(s) to the face of the fence which will have the effect of making a shallower cut. Remove the spacer and run the piece again to get the final profile.

-- criticism: the art of analyzing and evaluating the quality of an artistic work...

View John Bauer's profile

John Bauer

18 posts in 3082 days

#5 posted 11-28-2009 05:29 PM

Try adding a backer board. You can double stick tape it on. I do that anytime that I will not be able to fix tear out.

View Bret's profile


166 posts in 3460 days

#6 posted 11-28-2009 06:28 PM

I did use a backer board. The piece never got that far. :-(

-- Woodworking is easy as 3.14159265358979323846264338327950288419716939937510...

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