I'm really hoping someone can help me out because I'm feeling a bit overwhelmed with my woodworking side-gig. I recently made an MCM lounge chair using a purchased template, and while I had a great time following the design, I hit a snag when it came to routing the rough-cut side frames to match the template. Using double-sided tape, I affixed the template and set up my biggest template routing bit into my router. It's an impressive bit—1/2" collet, 3/4" diameter, and about 2" long—mounted in a full-sized Dewalt router, ideal for routing 8/4 walnut stock. I already cut away as much wood as possible with a bandsaw, so there was really only a small amount to remove, maxing out at about 1/8". However, this was the most terrifying experience in the shop! I ended up with several large chunks torn away from both the template and the wood itself, forcing me to reshape by hand afterward. At one point, the piece actually kicked upward toward me, and thankfully I was using work-holding paddles for safety. I can't believe the bit is dull, as it's only been used once...so I must be doing something wrong. Any wisdom?
5 Answers
Definitely check if you're using a straight bit instead of a spiral one. Straight bits can tear out wood more easily, especially on end grain. If you can, switch to a spiral bit for a smoother cut. They’re a bit pricier but are worth it for this type of work, plus they give you peace of mind about fewer mess-ups. And always make sure you're aware of the grain direction to minimize tear-out.
I think you're on the right track, but it's concerning that you had major tear-outs. The template should glide against the router bit's bearing, not touch the blades. Maybe the bearing is set too low? Also, ensure your workpiece is secured well—if it’s shifting, you'll get poor cuts. I use push pads for stability, and that keeps my hands further away, too. And don’t forget about grain direction; cutting against the grain can give you tear-out. If you're routing tricky grain, consider flipping your piece and routing from the top instead.
Step one, definitely switch to a spiral bit if possible! It’ll make a big difference. Step two, consider making a thicker template out of MDF taped to your main template to get better control. And as you mentioned, it's so crucial to take your cuts in smaller passes, especially with walnut's grain acting up. Also, if you're going to be template routing that thick of lumber often, a dedicated router table setup might be a real game-changer for you.
It sounds like you're routing around corners, which can make things tricky with changing grain direction. A spiral bit would probably help. And when routing, I would suggest removing as much excess as you can with a bandsaw first, then template routing in multiple passes instead of trying to do it all at once. That way, you lessen the chance of tearing out chunks of your work!
It sounds like you might be trying to take off too much material in one go! With a bit that size, it's usually better to make several passes, like 3/8" at a time, instead of trying to tackle 1/8" or more all at once. That could help prevent those nasty tear-outs you've experienced!
Totally agree, grain direction is key! When I encounter challenging grain, I also make sure to carefully plan my cuts to avoid those bad spots.