router technique help from intermediate or expert craftsman

fr8train,

You can make a template out of hardboard (Masonite) with coping saw or saber saw and file it to the smoothness desired (you can test the smoothness by cutting some scrap pieces). Make sure that the template material is big enough so that the router base can remain flat and in contact with the template through your entire cut.

Cut the work piece with a coping saw, sabre saw, or band saw to remove all but about 1/8” inch of the material to make it easier to smooth it out with the template and router (less if you are using a 1/4” bit to reduce tear out).

Mount the template to the work piece with carpet tape … don’t use too much tape because you want to be able to remove the template after your cutting is done and not destroy the template.

Sorry I don’t have any graphics which would have made this description a lot easier!!!

If you have guide bushings then you can use a straight bit and with successive cuts remove the material. Remember, that there is an offset between a guide bushing and the bit which will effect the size of cut. To calculate the offset, subtract the diameter of the bit from the diameter of the bushing and divide by two; the router cut will be that distance from the template. You can mount the template as above.

NOTE:
By varying the combination of bushings and bits you can effectively change the size of the cut. I have some circle templates that, with varying the bushing and bit size, give me a quite a few different diameter circles.

I have used both of these methods and each work. The latter one takes more router cuts while the former one requires material removal before routing.

-- "I never met a board I didn't like!"

If you dont have a bandsaw cut it out with a jig saw . If you dont have a spindle sander go get some drum sanders for your drill press. They are pretty inexpensive.

http://www.harborfreight.com/4-piece-quick-change-sanding-drum-set-35455.html

Gentlemen.

I appreciate your assistance…. thanks for all of the advice. This is a better way to learn, rather than a trip to the hospital and the old “I wish I would have…..” method.

And, I got it done…. I applied physics and lessons learned from the past….. I used the bandsaw for the rough cut and then set the fence up on the routher table to take out the excess material in the straight cut…. For the edges, I carefully fed the piece from the front of the table (closest to me and(against the blade spin) with the fence on one side acting as my guide….. it came out perfect. Will snap some pics…... can’t say I wasn’t nervous, but I stayed careful…. all digits are still there!