Curved Router Carriage
I recently made a pair of stools and wanted to put a curved “saddle” in the seat to cradle the butt and also to make sure that no one mistook the stools for end tables. After considering several different ways I decided to make a router carriage set-up using two barrel staves for the curve. The pictures tell the story.
Here is the basic carriage. Note that I chose to use my laminate trimmer with a cove cutting bit. Also, the router is boxed into the carriage to eliminate unwanted movement.
This shows the curved part of the jig. The curve of the stave is somewhat adjustable with the screw at the middle of the curve.
Now by moving the router back and forth I cut the curve into the seat. I toyed with the idea of indexing the slide with screws into the stave but that would have taken too much time. I can vary the dept of cut by adjusting the router or by inserting shims under the piece being shaped.
After the final pass with the router I removed any high spots with a spoke shave and scraper and started sanding. As I rarely make the same thing I'll probably put the jig in the corner of my shop and it will sit there until I need the materials for something else. I'll post the finished pub table and stools in the Readers Gallery.