I’ve been pretty productive over my holiday break. I received a new 3/8” up cut router bit and collet. I tried finishing up the mortise on the breadboard ends on my router table, but was still getting a lot of vibration and weird sounds from my router. I tried slowing the speed down even more, but that didn’t help.
I ended up going back to my plunge router base with guides to finish them up. I was concerned about using this setup, since I would be routing a pretty deep slot in the edge of a 4” wide board. In the end this worked out better and gave me a cleaner mortise. I still got some vibration when routing, so I’m wondering if the bearings I replaced a year or so ago have gone bad already. I don’t feel any play in the bottom bearing, but I do see a lot of electrical arcing from the motor brushes when the vibration happens. The vibration is more pronounced when cutting a full slot. When widening the slot with the bit only cutting on one side, the vibration is much less if at all. Not sure it this is a characteristic of the spiral bits grabbing the wood?
The original plans called for a 2” tenon into the breadboard ends. The $50 carbide bit only has a 1 1/4” cutting length, so I cut down the tenon to 1”. We’ll see if this is enough.
Next, I faceted the ends of the breadboards and routed a series of 1/4” deep slots on the outside edge for some walnut accent pieces. These pieces will cover the screw holes that mount the breadboard ends.
I used a 3/8” forstner bit to make counter sink for the mounting screws. I slotted the screw holes to allow for movement. I had some 2” screws with a hex head and wide washer surface left over from my deck. With all four screw snugged up, the breadboards are very solid. No glue used here.
The walnut accents match the ones on the drawer fronts and front apron. I milled a 3/8” strip, then ripped a 30 degree bevels on it, and finally cut them to length. They are just tapped into place with no glue in case I need to remove them later to access the screws.
With that, all the major construction is done. I have a couple of the wedges to repair where they broke when I was pounding them in. This left a ragged edge that I’ll fill with tinted epoxy and filler. Then it should be a final sanding and shop clean up before applying the finish.
It’s back to work on Monday.
Happy New Year to everyone!
-- -Jim, "Society is well governed when its people obey the magistrates, and the magistrates obey the law." -- Solon