I'm building an English garden bench out of redwood. To cut the curved pieces (legs and arms) I do the following:
- created clean templates of curved pieces out of 1/4" tempered hardboard,
- traced the pattern outline on the piece,
- rough cut to within 1/8" of the outline using a jigsaw (do not own a BS)
- attach template using double face tape to top of rough cut piece.
- Use 2" flush trim bit (top pilot) on router table to trim to pattern.
The problem I am having is that when I do the flush trimming, it trims
95% of the time OK but occasionally, I get chipout and chunks are taken out of the piece along the edge I am routing flush to the template.The lumber is kiln dried clear all heart (CAH) redwood that is dimensioned lumber (1 1/2" thick). It is beautiful wood (but expensive), very soft, and seems very dry and splinters easily.
I take the trimming operation very slowly but still get the problem. The bit is a 1/2" shank, dual flute, 2" flush trim bit Rockler house brand. I've even tried climb cutting but the operation is very difficult.
Either it is my technique or just a result of this wood species. Maybe kiln dried redwood heartwood is just too frail for this type of operation. The plans called for using a bandsaw to cut to shape -- using the pattern and flush trim bit is my idea.
Any suggestions?