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Thread: how to make tray handles using router roundover bit

  1. #1
    Join Date
    Nov 2005
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    Englewood, Florida
    Posts
    189

    how to make tray handles using router roundover bit

    I am making trays that have end pieces 3/4" thick and measuring 4x15. I want to cut out handles on each end and expect to drill 1" holes 4 inches apart as the first step. Then I will connect the holes w straight lines and cut out most of waste w a jig saw cutting close to the line. I'd like to remove the rest of the waste and get a very straight line using a straight bit in the router table. Is this a risky operation? Once I have the straight lines cut, I intend to use a bearing guided round over bit to smooth the handles. Any suggestions appreciated.

  2. #2
    That's close to what I do. I drill a hole at each end, draw a line along the top and bottom and use a jig saw to cut close to the line. Then I use a rasp to bring the cut down to the line. I use Nicholson #49 or #50 rasps. Then use a roundover bit (with a guide bearing) to round the wood. I have a tutorial on making a tray on my web site. The page that deals with making the handle is here.

    Mike
    Last edited by Mike Henderson; 04-18-2013 at 1:47 PM.
    Go into the world and do well. But more importantly, go into the world and do good.

  3. #3
    Join Date
    Dec 2010
    Location
    WNY
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    9,647
    An alternative approach would be to use a straight bit in a plunge router with a collet and template to cut out the opening, then remove the collet and template and switch to a bearing guided round over bit. The advantage of this approach is that you don't have to worry about drilled holes being slightly out of alignment.

    John

  4. #4
    Join Date
    Mar 2005
    Location
    Raleigh, NC
    Posts
    888
    Quote Originally Posted by John TenEyck View Post
    An alternative approach would be to use a straight bit in a plunge router with a collet and template to cut out the opening, then remove the collet and template and switch to a bearing guided round over bit. The advantage of this approach is that you don't have to worry about drilled holes being slightly out of alignment.

    John
    That's what I do. I use the size straight bit (1" in your case) of the slot I want to make. Set stop/start blocks to control the length of the slot.
    Doing this in 1 pass instead of using a smaller bit and multiple passes, is quicker and less prone to funny looking ends. I follow this with a bearing mounted roundover bit.

  5. #5
    "very straight line using a straight bit in the router table. Is this a risky operation?"
    **************************
    Very.

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