I'm trying to figure out how to make the following cut -
I'm making a lid for a rectangular box. Normally, I'd just rabbet the edges
of the lid so it fits inside the opening of the box. This is what I want to
do but my problem is the piece of wood that will become the lid. It is not a
rectangle, it's edge is just a freeform shape, like a blob. One face of the
piece is flat, the other is rough and uneven. I want to have the FLAT
surface on top, which means I need to rabbet the rough surface. I have no
reference side and can't seem to figure out how to make the cut.
I have a router, a router table, table and band saw and assorted other
tools. A radial arm saw with it's top cutting action would seem ideal but I
don't have access to one.
Of course, I may be wrong, I thought I was wrong once but I was mistaken.
1. Rig a surfacing jig (search google) for your router, and surface the
rough face of the blob so its parallel to the other face. Then cut the
2. Use a hand plane to thickness/smooth the blob (its a GREAT reason to buy
a good bench plane). Then cut the rabbets.
3. Call around town and find a lumber yard, hardwood dealer, etc., who will
thickness plane the blob for you. Then cut the rabbets.
I assume you want to keep the rough surface on the bottom of the lid.
Fashion a fixture that you could mount your router to that would suspend the
router slightly above the table, making it an overhead router. Use a bottom
bearing piloted bit to cut the rabbet.
Buffalo, NY - USA
(Remove "SPAM" from email address to reply)
Use a slot cutter in the router table, with a bearing on the shaft. Run
it with the flat side down, edge against the bearing. The width of the
rabbet (in from the edge) is determined by the size of the bearing. The
depth of the rabbet is determined by the height of the bit above the
It may take more than one pass, if your slot cutter is narrower than the
desired depth of the rabbet. Be sure to cut the end grain first.
If you can't put a bearing on your slot cutter, you can use a template
bushing in the router baseplate instead. It's harder to be as accurate
that way, though. If your router table does not accommodate a template
bushing, you could clamp the lid down to a piece of scrap at the edge of
your bench and use the same technique with a freehand router, but I would
recommend modifying your router table to accept a template bushing
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