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Project by Alvarez posted 02-10-2010 08:51 PM 2261 views 1 time favorited 15 comments Add to Favorites Watch

I am cutting rails, many of them, usually I use a table saw, it takes a while though, my table saw will not accept a dado blade and I dont have a bandsaw. I have a question, I need to make these rails. They are made of 1x Pine stock, is there a router bit I can use, a procedure in which to use the bit or any ideas to cut this. The overall size of this template is 11” tall x 5-1/2” wide. I need to cut the stock as shown on the picture. The second picture illustrates the rails.

-- Alvarez

15 comments so far

View BreakingBoardom's profile


615 posts in 3044 days

#1 posted 02-10-2010 08:57 PM

What are the widths and depths of the hatched area? You couuse some straight bits to cut this but depending on the dimensions, there may be an easier way. Can you post the dimensions?

-- Matt -

View Enthalpy's profile


44 posts in 3004 days

#2 posted 02-10-2010 08:59 PM

What is the purpose of the rails? Finished size??? (DBeener, finished size would be 2 words)

View DaddyZ's profile


2475 posts in 3003 days

#3 posted 02-10-2010 09:03 PM

I would lay the rails on the 3/4”/1” Side Clamped together, Route the 1st groove, Then after done with 1st Groove Route the second groove, All with a straight edge. But I am just a hobbiest NOT professional

Straight cutting bit 1/2” or Bigger

-- Pat - Worker of Wood, Collector of Tools, Father of one

View Rick  Dennington's profile

Rick Dennington

5802 posts in 3157 days

#4 posted 02-10-2010 09:14 PM

Greetings Alvarez: You can cut these out using a router. I would use a 3/8” or 1/2” up-cut spiral bit, or a straight cutting bit of the same size with a bearing on top to follow the template. If you don’t have that size, then drop down and use the size you have….. just go slower if necessary. Good luck.

-- " At my age, happy hour is a crap and a nap".....

View mikedrums's profile


102 posts in 2998 days

#5 posted 02-10-2010 09:16 PM

Do you have a drill press? You could make one as a template and use a guide bit in the router for the rest. The sharp corners would cut, first, using the mortise bit in a drill press.

If you don’t have a drill press, you could cut each of those steps on the table saw…
Make a sled or attach a tall sacrificial fence to your miter gauge.
Set a 1×6 (or several clamped together) on its 1” side, against the fence.
Set the blade height at the depth of the first step and make a pass for each of the four steps (2 per side).
Set the blade height at the depth of the second step and make a pass for each of those four steps.
Use a router with a pattern bit and your template to finish the cuts.

View Jim Jakosh's profile

Jim Jakosh

20270 posts in 3068 days

#6 posted 02-10-2010 09:51 PM

I always like to think outsdid the box when approaching a job like this. My first thought was to make two top and bottom pieces with just one step on them and a groove in the middle and insert a flat piece to make the final rail.

You can cut this shape on a router table with a straight router bit as others have suggested but you will be hogging out a lot of wood and with pine, it could warp when a lot is taken out of one side making it hard to hold parallel for the second side cut. If you do decide to do it, make one cut on one side and flip it over for the seconod cut on the other side before changing the fence location.
This shape reminds me of the I-beam sections they sell for floor beams. They are laminated particle board , but when glued up in the shape, they are very strong.
I hope this helps…....Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View Alvarez's profile


170 posts in 3025 days

#7 posted 02-10-2010 10:10 PM

Thank you all for the info, it will help me…..

-- Alvarez

View a1Jim's profile


117060 posts in 3540 days

#8 posted 02-10-2010 10:22 PM

Why not just do a glue up of the rails.

-- wood crafting & woodworking classes

View JAGWAH's profile


929 posts in 3047 days

#9 posted 02-10-2010 10:49 PM

What Jim said or plunge cut on the tablesaw and then use a handsaw. You could set up stops to limit the length of cut and doo quite a few very quickly.

-- ~Just A Guy With A Hammer~

View WistysWoodWorkingWonders's profile


12758 posts in 3119 days

#10 posted 02-11-2010 12:54 AM

I think Norm Abram would build 4 jigs and use 6 routers to accomplish this task… Am I right?
As for me, I would simply clamp them together and use the router table to start cutting through the waste areas.. just take your time and raise the bit 1/8” after each pass to prevent over heating and tearout. I would use the largest diameter router bit that I have for that application…
Either way you do it, best of luck to you and be safe… Don’t take any shortcuts – they lead to disaster…

-- New Project = New Tool... it's just the way it is, don't fight it... :)

View Ben's profile


273 posts in 3676 days

#11 posted 02-11-2010 01:18 AM

I would gang the peices and use the table saw and a miter gauge to cut to depth on each of the pieces. Put the edge face on the table saw and take an 1/8th of an inch at a time. Since they are symetrical you should do one cut at a certain distance and depth, then flip the ganged pieces around and do the same cut on the other side, and then flip it over and do it again. Then move the fence and repeat till all of the work is hogged away. This way you’ll have a bigger piece of wood to work with and it should be safer that way. Plus, this should result in less tear out on all of the pieces except the last one, unless you have a scrap piece ganged in the back. It my be slow going but I believe this will get you the best and most reprodceable results in the quickest time frame. Just be sure you sand all the edges smooth before you degang them to clean them up.
I hope this helps and was clear enough

-- Do something nice for somebody

View SgtSnafu's profile


960 posts in 3234 days

#12 posted 02-11-2010 03:42 AM

If they are to be painted I would glue them up from strips as Jim suggested, there would be far less waste. Otherwise I would stack them up with some long clamps. I would then cut the shoulders on the table saw, then I would hog out the rest with my router and the largest straight bit I had with a straight guide…

-- Scotty - aka... SgtSnafu - Randleman NC

View Alvarez's profile


170 posts in 3025 days

#13 posted 02-11-2010 04:45 AM

Thanks for all of your expertise!!

-- Alvarez

View Tango's profile


76 posts in 3516 days

#14 posted 02-11-2010 11:52 PM

I agree with the glued parts suggestion. More efficient way in terms of material waste. Just my 2 cents.

View Smiley's profile


39 posts in 3143 days

#15 posted 02-13-2010 06:53 AM

Ganging them together seems to be the best idea as far as a time saver but if you only gang say 3 or 4 you might be able to use a Jig Saw (if you have one of course) to remove most of the wast saving you time with the final cuts of the router.

-- No matter how good or bad a day your having a smile always makes it better!

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