Replies

1. 
   SawdustSteve | Feb 13, 2003 07:29am | #1

   The simplest way is to make a pattern that can be used with your (plunge) router and collar setup.  Design it to use a 1/4" bit as that is the width  of the tail of the design.  If you do it right the pattern will have two side guides that will slide snugly around the two sides of the baluster, register at the top of the baluster and can be held in place with one or two clamps.  Both the diameter of the through-hole and the width of the tail slot will be determined by the outside diameter of the  collar.  It takes a while to get the pattern correct, but once set up, it is very fast.

   SawdustSteve

1. 
   Boxduh | Feb 13, 2003 03:51pm | #2

   And shall I use a spiral bit?  If so, upcut or downcut?  I don't want any tearout when coming up or going through.  Should I place a fresh piece of sacrificial backer each time I cut one?

1. 
   SawdustSteve | Feb 13, 2003 07:00pm | #3

   Sacraficial board... DEFINITELY    As for the bit, any three woodworkers will give you four different answers.  It depends on the wood, the grain of the wood, the way the wood-gods feel that day...   Try using a nice new streight carbide bit.  You're not going to make THAT many pieces.   Just feed the cutter slowly and take a series of SHALLOW cuts.  Don't try to do the whole job in one pass.

   SawdustSteve

2. 
   LeeEschen | Feb 14, 2003 11:15am | #5

   Eagle America (I think) has spiral bits which combine upcut on the tip and downcut on the upper portion. They are designed to minimize tearout on through cuts.

   --

   Lee in Cave Junction, Oregon

   On the Redwood Highway

1. 
   AlanTurner | Feb 14, 2003 04:12pm | #6

   MLCS (or MCLS, I can never remember) has these as well.  Great mail order house; no shipping charges.  bits are inexpensive, and of pretty good quality.

2. 
   patternmaker | Feb 13, 2003 10:09pm | #4

   Mr Micro:

   As a suggestion, I advise to raise the routing fixture about 1/4" above the surface of the work piece.

   I use this system to cut mortises with the plunge router.

   The space allows the chips to be blown clear of the template slots.Saves the time required to stop and clean out the clogged guide slots in the routing fixture.

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