I guess I used this step as a lesson to myself on how to remove a lot of material fast. Having never done anything like this before I thought I would try different methods.
The first method was route channels leaving some uncut material to support the router and then use my flush cut saw to remove them. Then I thought of all the dust that would make so I tried to make a bunch of saw cuts and beat them out with a hammer. This worked very well at limiting the amount of chips.
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But when I used the router I was scared to death of slipping near the and ruining the entire thing.
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Then I tried to use a stationary router in moving jig. This is the jig that I used to flatten my work bench.
But once again I was afraid when I got to the ends because I was cutting blind.
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This is the method I ended up using. A stationary jig with moving router. It was very effective and relatively fast.
I made it with hardwood sides the keep it from drooping in the middle and melamine to reduce friction. Another thing I did for safety was to install stops. One on each end to limit the travel of the router and in the lower picture to keep the jig in position.
I just lined it up in the center and made a cut and then rotated the jig around the center point looking through the slot to position it. I also used an old candle to wax the bottom and edges or the router to make it slide very easily.
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The slot was about 2” wide allowing me to make two passes, with the 1 1/2” bottoming bit I used, before re-positioning the jig. One half a rotation of the jig and I was done with the first pass. I took about 1/4” of material off at a time.
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It ended up taking me about 1/2 an hour of cutting to complete it.
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After a little sanding with 40 grit
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And Last but not least 1/2 of the pile of wood removed with router. That’s an 18” scale.
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Next time I will start with the stand. Like I said in the beginning it will be something different.
-- Gary, East TX -- The longest journey begins with a single step.






















24 comments so far
cobra5
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139 posts in 866 days
posted 199 days ago
thanks for the inspirations,
-- tool time tim aka "cobra5"
Rj
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563 posts in 527 days
posted 199 days ago
Wow Gary That looks great! it will be exciting to see it when your finished .
Thanks again for filling us in on the process . (I’m learning alot from your posts)
-- Rj's Woodworks,San Jose & Weed Ca,
Dick, & Barb Cain
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7041 posts in 1196 days
posted 199 days ago
That’s sure going to be a beautiful table.
-- -** 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
a1Jim
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16926 posts in 473 days
posted 199 days ago
Very nice Gary looking forward to more progress
-- Jim from Heirloom Woodshop Southern Oregon
lew
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4493 posts in 652 days
posted 199 days ago
Gary,
Thanks for sharing the trip to what is going to be one beautiful table!!
Lew
tenontim
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1319 posts in 641 days
posted 199 days ago
This has been a very informative series, Gary. I can’t ever see myself making this style of table, but the methods that you used are very interesting. Hopefully they’re filed away in the brain bank and can be retreived at a later date. Thanks for all of the post on this.
-- Tim -- http://tmuli.com
Scott Bryan
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20725 posts in 718 days
posted 199 days ago
Your ingenuity and resourcefulness never ceases to surprise me. Many of us, I know I would fit in that category, would have settled on a removal technique at the start of the process and doggedly stuck with it rather than stopping midstream to evaluate things and try to come up with a more effective process. And building a jig in the middle of things!!! That interruption only slows you down- right?
Nice job, Gary. Thanks for the post.
-- With God's help all things are possible- even woodworking. Woodworking is not just a hobby, it is an (expletive deleted) expensive hobby.
pommy
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961 posts in 587 days
posted 199 days ago
as always gary you look at the bigger picture i was talking to fellow lumberjock on saturday ( philip edwards )at a local wood show
and i told him how wonderfull i think your work is thank you for show us mear mortals how to do things properly
andy
-- cut it saw it scrap it
DocK16
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710 posts in 983 days
posted 199 days ago
I have been waiting for each episode to be posted since you announced the project. Several good ideas to hog out the waste but the final method I think is the best. Can’t wait to see the base I’m sure you won’t disappoint.
-- DocK, WV
Napaman
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3488 posts in 973 days
posted 199 days ago
wow…that is amazing…you said half an hour—-for all methods??? that seems fast…amazing..
-- Matt, Napa, CA...fun is beautiful...just trying to have some fun...
Joe Lyddon
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486 posts in 948 days
posted 199 days ago
Hi Gary,
Very good progress!
I’ve gotta say… when I saw that circular saw cutting slits, my first thought was “Oh No!”... I was happy to see how you modified your method.
Your final solution is very similar to a fixture I made called Router Skiis. For the average project, it works pretty well.
See more about it at… http://www.ncwoodworker.net/pp/showphoto.php?photo=24057
Your Top really turned out GREAT! Thank you for the progress reports!
Now, for the part that holds it up! :)
-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: http://www.WoodworkStuff.net ... My Small Gallery: http://www.ncwoodworker.net/pp/showgallery.php?ppuser=1389&cat=500"
SCOTSMAN
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2244 posts in 481 days
posted 199 days ago
Great Job as usual gary well done laddie Alistair
-- excuse my typing as I have a form of parkinsons disease
Karson
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25803 posts in 1297 days
posted 199 days ago
Can you take the chips back gary and ask for your money back. Tell them it was not needed.
Great job on the flattening. and removing.
-- What happens in the workshop stays in the workshop. No wait that doesn't sound right. Karson Southern Delaware karson_morrison@bigfoot.com †
Lee A. Jesberger
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3710 posts in 876 days
posted 199 days ago
Hi Gary;
I’ve been watching with interest in how you did the top. As usual, your work is Masterful.
Hollowing out the center is a scary process, huh?
A suggestion if you don’t mind. If you are going for an 18th century look, the outside or “crust” looks a little on the bulky side.
That has a lot to do with our decision to carve the edges, when we were building one:
http://lumberjocks.com/LeeJ/blog/1628
Great work!
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
CanadianWoodChuck
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164 posts in 810 days
posted 199 days ago
Excellent progress report Gary – it will be beautiful. I love your flattening jig. Thanks
-- Canadian Wood Chuck (Bruce)
Gary Fixler
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648 posts in 278 days
posted 199 days ago
Did you use any blocks or sanders with that 40-grit?
Now is the time when I would lock that thing in a vault, away from dropped chisels and natural disasters! It is perfect!
-- Gary, Los Angeles, video game animator
GaryK
home | projects | blog
9533 posts in 884 days
posted 199 days ago
Thanks for all your kind comments.
Napaman – That 1/2 hour was the total time for the last method I settled with. It took me a few days to get my method down.
Lee – Believe it or not but I’m going for more of a 12th century look. You will know what I mean when you see the base I’m working on.
Gary – Just a quick sanding with a ROS.
-- Gary, East TX -- The longest journey begins with a single step.
ND2ELK
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6209 posts in 670 days
posted 199 days ago
Hi Gary
Very impressive on how you came up with ways to build this beautiful table top. Looking forward to the finished project. Thanks for posting.
god Bless
tom
-- Mc Bridge Cabinets, Iowa
Lee A. Jesberger
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3710 posts in 876 days
posted 199 days ago
Hey Gary,
I’m anxious to see it. I know it will be great!
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
PG_Zac
home | projects | blog
154 posts in 285 days
posted 199 days ago
Gary,
I’m sure I speak for many LJ’s when I say “Thank you”
It’s always good to see projects coming to life, and to see the finished products, BUT ... ...
What I thank you for is showing the process. As Tim stated, many of us file away the methods and adapt them to future projects. Not only do your projects inspire, but your processes and methods help us improve our skills.
Cheers.
-- I may be schizophrenic, but at least I have each other.
Tony
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812 posts in 926 days
posted 199 days ago
Turned out nice so far – thanks for showing the different methods you considered to remove the bulk material from the center.
-- Tony - All things are possible, just some things are more difficult than others! - SKYPE: Heron2005 (http://www.poydatjatuolit.fi)
Russel
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2061 posts in 835 days
posted 199 days ago
I keep coming back to look and it keeps looking good. This is an impressive piece of furniture and you haven’t even got to the stand yet. Your work is a constant “Wow!”
-- Working at Woodworking www.VillageLaneFurniture.com
Woodhacker
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1145 posts in 619 days
posted 198 days ago
Gary, once again…great job. I was wondering how you were going to do this. Thanks for sharing your thought processes. Nice photos too.
Thanks for posting it.
-- Martin, Kansas
DAN
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6450 posts in 879 days
posted 198 days ago
12th CENTURY !!!! .... This is really getting GOOD !! >grinzzz<<
-- work from your heart and your spirit will live forever