I'm making some parts using a router template. But I'm having trouble going around some tight curves on end grain - the diameter of the end semi-circles is 1 inch. The routed surface is very good on the parts when everything goes well, but it's far too easy to get tearout in specific places - and by tearout I mean big, honkin' chunks gouged out of the workpiece. I've figured out I have to saw very close to the final line, leaving very little for the router bit to remove when routing the final shape to the template. So far, I'm doing this on the router table, hand-holding the workpiece. Do I need to change fixturing? Would a shear or spiral bit - with guide bearing - work better? Should I use a spindle sander instead of a router? Any other suggestions?
Parts.JPGTemplate.JPGTearout.JPG
Thanks!