How to use a 2 hp router for a precision carving...

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Project by HalDougherty posted 1833 days ago 20981 views 20 times favorited 15 comments Add to Favorites Watch

This is a short tutorial showing the steps of carving a rifle stock. The first photo shows the stock to be duplicated being set up. I use a laser to make sure everything is straight by putting a 3’ rod in the rear bolt hole. The laser line on the rod helps get the top of the stock 90 degrees to the action. At the top of a 3’ rod you can see if the stock is tilted just a few thousands of an inch. It’s hard to put a level on the side of a curved surface.

The second photo shows the blank being lined up as well. This stock is for a Winchester Model 70 and the blank is made from ambrosia maple, black cherry and walnut. The stylus is shaped to match the cutter and it follows the pattern stock while everything that’s not a stock is cut away from the blank. The duplicator isn’t the crutch you’d think. The stock still has to be carved. Notice the guard on the router! I’d like to install one, but so far I haven’t found a way to fit one that will let me see everything I need to see. A dust collection system would be great too. I traveled all the way from Tennessee to South Dakota to the factory to see how they handle dust control. Yep, they put the machine in a room, close the door and the operator wears a respirator. Then clean up after the job is finished. Another stockmaker I visited only has 2 walls on his shop, the ends are open and he blows a huge fan while he carves. It’s ok in the summer, but it has to be freezing in the winter.

The third photo shows the stock just before it’s removed from the duplicator. IT takes 1 to 1 1/2 hours to carve a stock, then it takes about an hour of sanding to result in a stock that’s ready to fit to an action. The final sanding, bedding and finishing can take days.

The fourth photo is to show how close the dimensions can be duplicated. The bottom inlet is .007 smaller than the pattern. That gives some room to allow for variations in factory actions. You can always remove wood, but it’s hard to add any if you cut the opening too big.

The final two photos show the finished stock.

-- Hal, Tennessee

15 comments so far

View a1Jim's profile


111999 posts in 2174 days

#1 posted 1833 days ago

Wow very interesting . I was wondering the brand name of the duplactor is. thanks for sharing.

-- Custom furniture

View blockhead's profile


1450 posts in 1905 days

#2 posted 1833 days ago

Beautiful rifle stock Hal. Nicely done!!

-- Brad, Oregon- The things that come to those who wait, may be the things left by those who got there first.

View cabinetmaster's profile


10874 posts in 2155 days

#3 posted 1833 days ago

Nice wormy maple stock. Have never seen one made from wormy maple before but it looks fantastic. And to have a natural finish like that looks like camo for desert operations.

-- Jerry--A man can never have enough tools or clamps

View SnowyRiver's profile


51451 posts in 2077 days

#4 posted 1833 days ago

Great job…very nice!

-- Wayne - Plymouth MN

View kiwi1969's profile


609 posts in 2039 days

#5 posted 1833 days ago

Dust collection on CNC,s is hopeless and the speed the chips fly off the cutter at destroy most gaurds pretty quick anyway. I used to make disposable ones out of thick cardboard even if it just meant the dust and chips stayed in the vicinity of the machine rather than get thrown across the room. Maybe just give a kid an after school job cleaning up the mess!

-- if the hand is not working it is not a pure hand

View Kent Shepherd's profile

Kent Shepherd

2697 posts in 1883 days

#6 posted 1832 days ago

Cool—- I am always fasinated to see how things are done

-- She thought I hung the moon--now she just thinks I did it wrong

View tomakazi's profile


644 posts in 1880 days

#7 posted 1832 days ago

Wow great job. Like Jim, I would also be interested in the brand name of the duplicator. Thanks


-- I didn't go to college, I was too busy learning stuff - Ted Nugent

View Dan Hux's profile

Dan Hux

576 posts in 1971 days

#8 posted 1832 days ago

great thumb-hole stock..I have a sweet bull barrel 25-06 that would look great on one of those stocks..great job..

-- Dan Hux,,,,Raleigh, NC

View HalDougherty's profile


1820 posts in 1834 days

#9 posted 1832 days ago

The duplicator is made by Dakota Arms in Sturgis, SD. Here’s a link to their website:

Just click on “Duplicating Machines”

-- Hal, Tennessee

View BTKS's profile


1967 posts in 2061 days

#10 posted 1832 days ago

Wow, I would love to ditch my synthetic stocks for something like this but the time and cost are a real consideration. Ammo is going so high, I barely shoot in comparison to what I used to. Even reloading components are hard to find and expensive when you do. Keep up the good work and remember, aim small, miss small. BTKS

-- "Man's ingenuity has outrun his intelligence" (Joseph Wood Krutch)

View jockmike2's profile


10635 posts in 2844 days

#11 posted 1831 days ago

Gorgeous rifle stocks. Looks like they fit like a glove.

-- (You just have to please the man in the Mirror) Mike from Michigan -

View BlueStingrayBoots's profile


722 posts in 2599 days

#12 posted 1784 days ago

Wow! That looks very fun. Thanks

View Swede's profile


191 posts in 1615 days

#13 posted 1615 days ago

Very nice looking stocks you have made.
May I ask what Type/Brand of Glue are you using?

-- Swede -- time to make some sawdust

View EMVarona's profile


436 posts in 1433 days

#14 posted 1110 days ago

Awesome! Real professional!

-- Ed "Real happiness is one that you share."

View stefang's profile


12560 posts in 1931 days

#15 posted 930 days ago

Interesting machine and a fine result. I hope you find a good dust solution.

-- Mike, an American living in Norway.

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