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Sandor Nagyszalanczy

INTRODUCTION

power

grooves

bit, a router

joinery

and

can cut basic

biscuits

shaping stair and

paneled

"With great

that

tool. That's

router

doors. But as the cartoon

cutting all those

a bit and switching

study,

what this booklet is designed

safely

tools

dados,

invented. Due in no

ever

decoratively

joinery,

like

(Fig

2). And fastened

bar railings, or even

power,

and a little

great

comes

impressive shapes and

the tool

practice

and effectively, so

shape edges.

like dovetails and

drawer

lipped

to

the duties

and movie

responsibility."

lt takes a bit

on.

doesn't

you'll get

joints

probably

simple

the right

(Fig.

1).

the most versatile

tasks, like

jig

cut

and

The router is

part

to the incredibly extensive line of bits and accessories that are available, a router

perform

can

When set up with
finger

With special bits, routers can cut all sorts of special shapes,

moldings,

classic

a router

table,

shaper does, including raising

traditional

ing

character

In the case of the router, it means

isn't always as easy as

understanding

get

to

the most from this versatile

Acquaint

you

resu/ts with the least

becomes

style

"Spider

(no pun

with how to

and slots

cope-and-stick

Man" once said'.

just

problems.

plate

for

a sort of mini-shaper, capable of many of

panels,

mounting

intended), a little

use a

small

pulls,

a router

that a

creat-

joints

of

hurt either,

to

do:

the

besf

Figure 1

The [,4ost From Your Router

Getting

Nagyszalanczy

I

Figure 2

SAFE

ROUTING

PRACTICES

Always Wear

At the

high speeds a router rotates

Eye

And

Ear Protection When Routing

it's

at,

all too easy for the spinning

splinters and wood dust with incredible velocity.

(and

irreplaceable)

glasses

with

it's important

run the

router.

Always

Plugging in

a wildcat loose;
across

Chech The

an router with it's switch

your

can result in

always check that the switch is in

(a

prudent practice

Always

A
created

Use A Firm

generates quite

router

by the motor and the force of the bit as it's

adopt a secure
bit into wood for

routing the length

Always

Wait For The Router Bit Tb

eyes with a

protectors.

side

to don a

pair

Router's

rotational

the

benchtop and onto the floor. Worse

serious injury if

with

Grip

grip

on both of

Keep

a cut.

long

of a

good pair

goggles,

of

Routers also create

of

sound-attenuating earplugs or earmuffs every time

Switch Before Plugging It ln

accidentally set in the

force of the router's motor can send the tool bouncing

you

come in contact with

"off" position

the

power

any

And

a bit of

tool).

Steady SUmce

force when it's running,

the router's handles,

your

legs in

plank,

a spread stance, and don't over reach

when routing

or

Stop Spinning

Before Setting The Router Down

you

Once

important to

is

not in contact with the workpiece or benchtop.

top

shut

only after

a router, it takes a few seconds for the bit to stop spinning.

off

continue

to hold the router

you

have made completely sure that the

securely, and make sure

to throw

bit

Hence, it's vital to

a safety

a substantial amount of noise, so

"on"

before

to

whirring

it's

plugging

still, trying

protect

face

shield or

position

grab

a runaway

bit.

in the tool's cord

is like

Therefore,

When Routing

the

both

cutting

especially when introducing

across a wide

the router down on the bench-

Set

has stopped.

bit

centrifugal

through the wood. Always

panel

(Fig

3).

that the

spinning bit

out

delicate

safety

you

turning

router

force

the

when

lt's

Figure

3

Getting

The Most From

Your Rouler I Nagyszalanczy

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Always UnplugThe

For

safety's sake, always disconnect a router's

make

bits or
should

remind

benchtop, in

Always

Powering

cord

be

gauge

below right),

adjustments. This

you

accidentally switch the tool

you

to

plain

The Right

Use

a router-or any

plugged

thick

enough

you'll

blowing a fuse). Just as

to

motor

damage and

Neuer Leave

When
(who

knows,

retract the
that the bit is

thing

One

you

time

A Bit Loose In The Router's

you're

done routing for the day,

maybe

bit above the

exposed

you

switch the router on, the loose

plug

sight

into

should

the

prevent

Router Before

practice

cord in afterwards,

(Fig

4).

Extension Cord

power

properly

a

tool-far from

sized extension

to handle the

overheating the

important,

premature

it'll

be

router's

to

damage.

never

failure.

the

one

subbase, or take

is

do

leave a bit loose in the router's collet-The next

amount of current the tool draws
you'll prevent

you

consequences.

Changing Bits

power

cord every

will save

on

you

considerable

during

bit changes and adjustments. To

the

set

electrical

an electrical outlet requires that

cord.

plug

By

choosing a cord

wire and tripping a circuit breaker

overheating

the tool, which

CoIIet

you

can leave the last bit

need the next time

care

can

bit

easily

not to

fly

you

out,

you

rout). lf

set

with

you

time

somewhere on the

pain

(see

and

with

the

change

grief,

a

chart,

(or

can lead

used in the router

you

do,

either

the router down

possibly

disastrous

it's

wire

so

Figure 4

Mucimum Extension

Cord Lengths

Getting The Most From Your Router

Nagyszalanczy

I

-For

1 2o-volt Dowertools

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Use Dust Collection Whenwer Possible

Besides

that

they

a router's
in either

being noisy,

throws

it

can

case can throw things

Ye

F

Z

*

* &

one of

out during routing.

pile

up on benchtops and shop floors, but

subbase and a

{;

Y Z

7**

*"

the downsides

Chips

jig,

or between

off and

can

ruin the

z"}V

#,*

another nuisance, since a rapidly rotating
and eyes, and worst

nose and lungs.
The

best way to

to fit the tool with

clear-plastic fitting
that keeps the lion's

(Fig.

5). Chips are sucked up

where they

collect until they're
works best when
ting mortises.
chips are

the routing

sucked away

process.

of all, stir up clouds of even finer

reduce

the amount of fine-wood waste that a router

a dust collection accessory connected to a shop vacuum.

attaches

share of chips and dust to

used

An added bonus of using dust collection in the latter application

to the router's

into

a flexible hose and transported to

safely and conveniently disposed of. Dust collection

for

surface-routing tasks, such as sign making or

before they

collect

of the router is

the fine dust and chips

all

become a nuisance, not only because

because

guide

edge

an

accuracy of

bit can throw tiny

they

the workpiece, which

and

your

particles

particles

base, forming a shroud around the bit

prevent

from being thrown outwards

in mortises,

where

they

get

can

between

cuts. Fine dust

your

into

that end up

generates

shop vacuum,

a

plunge

interfere with

can

in

The

is

face

your

is

cut-

is that

Figure

5

Getting The Most

From Your RoulF-r

Nagyszalanczy

I

SETTING UP

THE

Choosing the right bit

what makes

Part of
extensive

array of

a

bits

right router bit for any

often

are

for

TIP:

the

number of factors

a

job.

For the

smoothest, chatter-free cufs, use 1/2 in.-shank bits

ROUTER

router one of the most versatile tools in any

and cutters

given

that

are available.

task is a simple as choosing the

variables involved when choosino

and

lt would seem

desired

whenever

woodshop is

that selecting

profile.

But there

that's

a bit

possible.

the

the

best

Straight

Useful for a multitude of woodworking duties, from
recesses for

tile. In

choose a straight bit with the right style

but often leave a rough-cut surface; Twin-flute

the cutting

est cutting
routed

bits

inlays to

addition to choosing the right

cutting mortises and other

diameter

(Fig

edges are skewed; Spirally fluted bits don't

all

of

straight bits and are best for

edges need

to

be really clean and tearout-free.

plowing

joints,

straight

bit to suit the

6): Single-flute

bits cut

more cleanly,

cut as fast, but

inlay

other delicate

and

grooves

task,

bits cut material

Piloted bits

you

When

piloted

need to

bit is the right

the workpiece,
roundovers, rabbets,

panels

raised

and

that's

screwed

quickly

shape

the

choice. Guided by a small ball

piloted

bjts come in dozens and dozens

and

coves

(Fig

to a stud

7). Most

on

the

bevels,

piloted

end of

edge of a box,

to

shapely and

router

the

bit, but

bits

are

there

shelf, or cabinet
bearing

of

decorative

"end-piloted," with a bearing

also

are

that have a bearing on their shank secured with a locking collar.

The Most From Your Router I Nagyszalanczy

Getting

bits are

you'll

especially

riding on

profiles,

beads,

"shank

to creating

highly versa-

also want

quickly,

the

are

where

work

carcase, a

the edge of

from

basic

ogees

piloted"

to

when

clean-

bits,

Figure 6

Figure 7

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You can expand the range of

pilot

to

simple
can
pilot

dimensions of

cabinet,

bearing with a

a

roundover

with a smaller O.D. bearing and lowering

bit

rout a decorative beaded

bearing and setting it's height are

the

in a

stepped

picture

glass

shapes

different

outside diameter

profile

lip that this bit cuts

frame, etc.).

Flush-kim Bit

One of the handiest bits in

the

addition of a

pilot
flush-trim bit makes
to make the edge of a face

carcase. The height of the bit is set so

that

so

the cutter can

plywood

the
countertoo

Used in a

pattern

or

Pattern routing uses a

shape of
nails or screws

the

of

cabinet side.

laminate materials. like

router

table

parts

routing

the

desired

to

the

template,

thus trimming the workpiece

the

shop,

bearing

quick

trim the

fitted

on

work of trimming down one

frame that's been

slightly

Flush trim bits

Formica.

(see p5.27),

flush trim bits are extremely

to exact shape

template, made from MDF or

part,

that is temporarily attached with

workpiece. The flush trim bit's

a bit's capable of cutting by simply changing

on an edge. And changing

the

a Flush-Trim Bit is basically a straight

the end, below

that the bearing rides

overhanging edge of the

are

(see

(O.D.).

means by which

basic

(useful

for

its cutting flutes

part

glued

to the front edges of a cabinet

great

also

for cleaning up edges

the section on

For example, by

it's

cutting height,

a rabbetting bit's

you

recessing the

fitting a

change

back

bit with

(Fig

B).

relative to another, say

just

betow the

face frame flush with

useful for trimming

guide

bushings,

glue

pS.

the

on a

A

of

26).

hardboard cut to the exact

double-stick tape, small

guided

is

(Fig

by edge

9).

to

pilot

size and shape

exact

bearing

you

line,

Figure

8

The lvlost From Your Roubr

Getting

Nagyszalanczy

I

Figure

9

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loinery

ln

simple wood

designed specifically for

FINGER

You

and
cuts
or drawer,

Guided

dovetail
blanket

(7',9',14",

results,
using, as recommended in the

Bits

addition

to

using basic straight bits for cutting finger

joineries,

JOINTS AND DOVETAILS

there

cutting

wide variety

are

wood

can cut strong and decorative finger

guide

bushing, as shown

properly

are

fit

together snugly.

by a similar

joints

(Fig

spaced, so

jig,

11),

(Fig

that the two halves

a router

a strong

fitted

and traditional way of

10). A special

with a dovetail bit and

joints.

joints

chests and cabinet carcases. Dovetail bits come in a

etc.) and styles, including

choose the

particular

bit that's

jig's

piloted
designed

manual.

joints,

of specialized

router fitied with a straight bit

using a

joinery

template

joint,

the

of

joining

unpiloted bits.

and

to work with

mortises and other

sides

bushing

of drawers,

get

the best

bit

sets,

that

of a box

can

jig

you're

router bits and

assures

the

say

guide

the sides

variety of sizes, angles

To

the

dovetail

the

cut

Figure

10

Getting

The Most From

Your

Flouter

Naryszalanczy

I

Figure

11

SryLE AND RAIL CUTTERS

you're

lf

then
rout a

"cope"

matching
door
together to

around

edged central door
that accepts
set
come with a

Specialty

The
a basic assortment to
able

KEYHOLE
This

can

screw, so it supports the frame or

ambitious

you'll

need

matching

is

routed on the edges of

"stick"

frame members)

the

the

bits before use, so it's best to read through the

Bits

bits so far discussed represent

(all

are shown in the

bit routs

hang it

enough to want to make

a set of style and rail cutting bits.

"cope

and stick"

is routed

(Fig

the

form

inner edges of the frame, designed to hold

a wall.

panel.

'1l2

in. shank

set before

bit

keyhole-like

a

The

door frame,

give you

photo,

stepped cut

joint
the

door styles

the ends

on

12). In

addition to creating the corner

most

Besides a sturdy routertable,

to run style

bits

just

it,

buying

just

an idea of

Fig 13).

into the

shape

is

designed

plaque

your

own traditional-style

with a router table, these

Used

on the edges of the

(the

and

rail

rail

rail bits.

of each

style and

to make sure

the tip of the router-bit iceberg. Here are

the various

all

of a

back

to

slide over

securely.

door

vertical frame sides), while the

(the

horizontal top

bit sets also create a

either

you

need a heavy-duty

can be

Also,

particular

you're

specialty

picture

frame or

the head

cabinet

frame members. The

bottom

and

joints

that are

groove

plywood

a

up to the

or

complicated to

instructions

challenge.

bits that are avail-

plaque,

pan-head

of a

doors,

glued

raised-

router

that

so

just

you

bits

Figure 12

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The Most From Your Router

Getting

Nagyvalanczy

I

Figure 13

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KERF CUTTER
Like a saw blade

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W

on a short shank, a kerf cutter bits allows

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edge of a workpiece. By slotting the inner

panel

wood
different

in. wide kerf

parts

wood

DRAWER PULL

This ogee-like bit cuts a

for

useful

VEINING AND VEE BITS

their

With

signs, or for creating

piece

or

sized

of mirror or

ranging from 1/16

slots,

cutter to cut slots

to

build boxes, cabinets, and more.

profile

glass.

The

in. to 1/4 in. or more. You can even use a 5/32

plate

for

on an edge that forms a comfortable-to-grab

all-wood drawer fronts and doors.

pointed

sharply

ends, veining and vee bits are useful for routing custom

details in moldings

sharp

loinery

Taking Care Of Router Bits

quality

High

care of them in order to

foremost,

and

them loose in

is likely to result in

so

prevent

To

prevent-or

can

preventative,

shank,

Brite, and

carbide-tipped router bits don't exactly

get

the best life and

take care not to drop bits

a drawer or

rust

from degrading bit shanks, do not store bits

toolbox, where

in their

chips

brittle carbide cutting edges.

at least reduce-rust by wiping or spraying router bits

such as

put

a little light oil

lightly

Bullfrog

rub the

(such

rust

"Rust

Blocker." To remove a light coating of rust on a

as WD-40)

(Fig

away

(especially

14).

edge of a

frame,

cutters come

biscuits-a

parts.

and

grow

performance

cutting

not onto concrete floors!)

they can bump

piece

on

a

of fine steel wool or Scotch-

you

to cut a slot in the

you

can capture a

in various

powerful

on trees, so it

sizes, for cutting

way of

from them. First

against

each

in

damp locations. You

pays

other.

with

ply-

joining

pull,

to take

leave

or

Doing

a rust

Figure 14

The Most From Your Router

Getting

Nagyszalanczy

I