This project is a few months old, but I’m just now getting around to writing this blog. I came up with a novel method of carving intricate shapes with a router, and I thought it was worth sharing. I’m probably not the first to come up with this technique, but I came up with it on my own without really seeing it anywhere else.
The background: My wife wanted to make a large chalkboard to hang in our dining area, so I cut a large piece of cheap hardboard (30” square) and we painted it with chalkboard paint. I knew she would want me to make a frame of some sort, but when she asked me to make it “as fancy as you can” it got my mind working. I knew I could cut a curvy outside profile with my bandsaw and clean it up with a sanding drum. But I wanted to give it a nice moulding profile. I thought about it a lot and experimented in CAD with a few designs I thought I could pull off.
Here’s where the design ended up:
I was pretty sure I could pull this off with mainly just a router and bandsaw, but I knew I would need to make some specialized jigs first; that’ll come later in this series.