|Forum topic by Vulture||posted 10-01-2009 07:36 AM||4313 views||0 times favorited||7 replies|
10-01-2009 07:36 AM
I could use some advice with respect to complementary template routing. I’m working on a project where I have the sides of a box designed with, essentially, an ess curve centered around the mid-line of the height of the box.
I have been using a book authored by Carol Reed, “The Router Lady”, in which she describes the complementary template routing process that she uses. I have followed her steps religiously, but I still am not getting a perfect match in the templates (she refers to them as the left and right templates). So, the complementary curves aren’t really complementary.
I am using 3/4” MDF stock for the master pattern, the master template and the left and right templates (Carol uses 1/2” MDF, but my local Lowe’s only carries 3/4”). To create the left and right templates from the master pattern I am using a 1/4” spiral upcut bit with a 3/4” bearing and 1/4” stop collar just as she recommends.
The bearing follows the curve of the master pattern beautifully. When I’m finished with the cut I can align the left (or lower) template with the master template and the curves are a perfect match. However, when I take the supposedly complementary right (or upper template) and set it against either the master template or the left template, there are very noticeable gaps between them!
This is extremely frustrating as I have cut at least three sets of templates, always with the same results. In one case, I had better luck tracing the left template pattern on a fresh piece of MDF, band sawing it and free-form sanding it on a drill press mounted sanding spindle!
Does anyone have suggestions for what I may be doing wrong? Thanks!
-- Kevin, Vancouver, WA