I'm working on a product for a class and have a question regarding the process for one of the steps.
You start with a 4'' x 4 3/8'' x 2'' block of oak.
Said block needs a recess 1'' deep 3'' long centered 1/2'' thick, 1/4'' away from the face, in the endgrain.
our current set up is a router table with a sled, you slide the block into a slot, the sled is moved from stop block to stop block till the cut is at full depth. a comment was made that this could possibly be unsafe, but I fail to see how as the wood cannot be thrown, and the user is not exposed to the cutter at all.
Use of multiple handheld routers was discussed, but a mention of failed accuracy was mentioned and more possible danger.
also the use of a mortise then a router was talked about.
any other methods that are missing? Any input on how to do it safely and quickly?
This process will need to be completed 51 times by a student who will not necessarily have strong experience with the equipment but will be taught before the use of it. Every single piece must be the same as they will be sold to the public.