Not sure if what I'm trying to do is crazy or not. Trying to make some wooden cars, buses, etc, for the toddler and kids of the family/friends. I created a template out of 1/4 MDF, maybe 1/8". Prepped the blanks, in this case 1.25+" thick hard maple. Carpet taped the template to the blank and roughed it out on the band saw. Took the blank with the template to the router table with a 2" flush trim bit. Router is 2hp. Had the speed set almost as fast as the router will go. A lot of kickback, but got the hang of it or so I thought. Reached the end grain and kicked the template right off the blank. A couple screws through the template into "windows" secured the template to the blank. Managed to get one end of the bus cut out and the bottom. However when I got to the other end, going cross grain, the kick back was absolutely uncontrollable. I tried slowing the router down which may have helped but not much. Tried going the opposite direction which didn't help at all.
Am I crazy for trying to cut 1.25" thick maple in this manner? Is that why I see a lot if not all of this type of toy made out of pine or douglas fir? The other alternative is to get a sanding drum that has a guide on it, available in a catalog somewhere so I know they exist, and sand the blank down to the template, but I bought the 2" flush trim bit especially for this process.
Why we're on the topic of maple, I have 6/4 rough and tried planing it down to 5/4. I'm seeing quite a bit of chip out. Is that typical of maple?
Thomas