Router and bit question in regards to material removal then flush trimming.

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Forum topic by InstantSiv posted 05-29-2014 07:48 PM 889 views 0 times favorited 3 replies Add to Favorites Watch
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262 posts in 1588 days

05-29-2014 07:48 PM

I attach a frame to an oversized piece of plywood. Remove most of the material with a table saw and flush trim it. Problem is I get tear out(can’t do zero clearance insert due to design.

How much material can you safely remove in a single pass with a router? I get anywhere from 1/8 to 5/8 overhang? edit It would still be a two step process. First pass to remove bulk of material. 2nd pass to do the flush trimming.

What kind of router and bits would be best suited to this kind of operation?

3 replies so far

View rrww's profile


263 posts in 2106 days

#1 posted 05-29-2014 08:45 PM

Router table, large flush trim bit should be able to do a single clean pass on 1/8. The bigger the overhang the more you risk tearout. There are up shear and down shear bits that will cut clean on the top or bottom, but not typically both. So if there is a side that isn’t real critical you can get by with those. You can pick a compression bit for zero tearout but they are $$. Anything more than 1/8 is kind of pushing it to get a perfect cut even with a compression bit. I don’t think a any router combo is going to do a good job with a single 5/8 pass. You may need to look into shapers & tooling to deal with cuts like that in a single pass.

If you can keep your rough cut plywood closer (~1/16) to the finished dimension the bits will last longer, the router will last longer and you will get a better product with less labor.

View InstantSiv's profile


262 posts in 1588 days

#2 posted 05-29-2014 08:48 PM

Oops sorry I meant to say that it would still be a two step process. 1st pass would remove the bulk of the material and the 2nd pass would do the flush trim.

The question being what’s realistic on how much material I can safely remove on the first pass.

I don’t have the equipment/space to size the plywood closer.

View NiteWalker's profile


2737 posts in 2570 days

#3 posted 05-29-2014 09:17 PM

No more than 1/8” at a time for the cleanest cut.
For the final pass, even less would be ideal.

Also, a climb cut when hand routing can eliminate tearout and still be a safe cut so long as you firmly hold the router.

-- He who dies with the most tools... dies with the emptiest wallet.

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