I made a little progress since the last post.
Remember that I had to decrease the diameter of my top by 1/4”? Well the problem was using a 1/2” diameter flush trim bit. That was a little too violent and had some chip-out , oh well. What I should have done is go back in time to this point:
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Then take a couple more passes with that small bit going as deep as I could. Then just go ahead and flip the top over and use my 5/8” radius round over bit making the cut little by little.
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Then I ended up with this chip free perfect edge.
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The reason for such a large bit was the make the edge look thinner and giving it the appearance of lightness.
Then I took one of the corners I cut off when I rounded the top and used it to create my edge profile sample. It worked perfect since it was the same thickness.
Here you can see the profile I came up with. Now you can do whatever you like.
For the outside edge I used a 3/8” radius round over bit.
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Then a 1/4” radius round over bit with the bearing ground off.
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Then a Classic Fluted Plunge Bit. I got it here: Rockler bit #91414 http://www.rockler.com/product.cfm?page=5300
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Then you see a 5/8” wide flat area. The top at it’s thinnest will be 5/8”, which will be the entire inside flat surface.
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Now the hard part (at least until I figure it out). How to cut that edge detail with those router bits easily and reliably.
That may take be a while since I don’t want to screw this up at this point.
-- Gary, East TX -- The longest journey begins with a single step.






















21 comments so far
TopamaxSurvivor
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3077 posts in 576 days
posted 210 days ago
If you don’t figure it out, noboby will !! Do yoiu intend to make the whole top with routers and not carve by hand?
-- Debt is nothing more than the 21st Century's form of slavery.
GaryK
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9555 posts in 888 days
posted 210 days ago
I plan on doing as much as I can by router, but that will only take me so far. All those sharp inside corners will have to be cleaned up by hand. I’m not that good at carving.
I may try to do a lot of carving on the base since I won’t have as much time and lumber invested in those pieces, just in case I screw them up.
-- Gary, East TX -- The longest journey begins with a single step.
spanky46
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737 posts in 290 days
posted 210 days ago
Great work Gary! I look forward to seeing the problem resolved and the finished piece.
-- spanky46 -- Never enough clamps...Never enough tools...Never enough time.
a1Jim
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17211 posts in 477 days
posted 210 days ago
Looks great Gary , I guess I’m missing something but it looks like you have the edge detail done. Thanks for the great step by step photos and even were and what bit to buy.
Jim
-- Jim from Heirloom Woodshop, custom furniture ,maker, woodworking school, heirloomwoodshop.com
GaryK
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9555 posts in 888 days
posted 210 days ago
Jim – That’s the bottom of the outside. The next part is the inside edge detail.
That is the profile I show on the sample piece.
-- Gary, East TX -- The longest journey begins with a single step.
Rj
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571 posts in 531 days
posted 210 days ago
Its really coming together nicely ! Thanks for the step by step.(I’m learning alot)
-- Rj's Woodworks,San Jose & Weed Ca,
Betsy
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2386 posts in 796 days
posted 210 days ago
Looks like another masterpiece in the making!
-- You can't get a hug from Facebook.
mrsawdust
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47 posts in 467 days
posted 210 days ago
Gary,
very very nice thus far. and, i’m sure it will only get nicer. just remember – GO SLOW…..
mike
-- mrsawdust, pittsburgh,pa.
RBWoodworker
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215 posts in 252 days
posted 210 days ago
Beautiful!! I have often wondered how in the world this was done..thank you for showing the step by step process.. Keep us posted on how it goes.. I want to make one of these myself and need the advise..lol
-- Randall Child
lew
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4515 posts in 655 days
posted 210 days ago
Interesting predicament! I’ll be watching to see how you solve the routing problem.
Lew
Tony
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814 posts in 930 days
posted 209 days ago
Really nice profile of the “crust”. Thanks for the step-by-step and the warming about the diameter of the flush trim bit.
I am looking forward to the next installment
-- Tony - All things are possible, just some things are more difficult than others! - SKYPE: Heron2005 (http://www.poydatjatuolit.fi)
Karson
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25871 posts in 1300 days
posted 209 days ago
Gary A great set of photos.
Nice job so far. We are all waiting for the TA DA.
Looks great.
-- What happens in the workshop stays in the workshop. No wait that doesn't sound right. Karson Southern Delaware karson_morrison@bigfoot.com †
jockmike2
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7368 posts in 1146 days
posted 209 days ago
Gary, you are making those cuts on a router table right? Mike
-- Mike. mwurm13@yahoo.com
Dick, & Barb Cain
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7050 posts in 1199 days
posted 209 days ago
A great tutorial!
I’ll be patiently waiting for next installment.
-- -** You are never to old to set another goal or to dream a new dream ****************** Dick, & Barb Cain, Hibbing, MN. http://www.woodcarvingillustrated.com/gallery/member.php?uid=3627&protype=1
GaryK
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9555 posts in 888 days
posted 209 days ago
jockmike2 – No Mike, they are all cut using a hand held router. This thing is way too big and heavy for the router table.
BTW figured out how I’m going to do the inside. At least I hope.
-- Gary, East TX -- The longest journey begins with a single step.
Gary Fixler
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649 posts in 281 days
posted 209 days ago
I think you should just have a custom shaper bit made that matches the profile created by all 3 of those router bits ;)
Seriously, though, it’s beautiful and inspiring. I’m eagerly anticipating each next step, and still a little confused as to exactly how you’re following the profile with each new bit. I’m sure it’ll click at some point, but right now I might be a bit too amateur to get it.
-- Gary, Los Angeles, video game animator
DocK16
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714 posts in 987 days
posted 209 days ago
I’m trying to figure out how you are going to do this routing on the “inside” edge and what you are going to use as a guide. I have thought about doing this on the Legacy using the circle cutting jig and the template attachment. I think it could be done this way but I’m waiting to see your technique.
-- DocK, WV
RBWoodworker
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215 posts in 252 days
posted 209 days ago
I’m prolly going to feel a little dumb for asking this Dock.. but what’s the Legacy?? and what’s the circle cutting jig?? LOL
-- Randall Child
Blake
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2763 posts in 774 days
posted 208 days ago
Wow, what a neat and complex process. I can’t wait to see this finished.
-- Check out my new website! http://www.blakeweberwoodworking.com
pommy
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977 posts in 591 days
posted 208 days ago
your putting in a lot of man hours into this project gary love the pics and great detail thank you
Andy
-- cut it saw it scrap it
Woodhacker
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1145 posts in 623 days
posted 208 days ago
Very cool Gary. I admire your ingenuity.
-- Martin, Kansas