Replies

1. 
   seajai | Nov 30, 2006 07:54am | #1

   You can make floor registers by using the same style and rail router bits used to make cabinet doors.  Run the style bit on your sides, then take a wide piece of stock and run the rail bit on each side, then simply crosscut off pieces to whatever width you choose. I made a couple of cold-air  return grilles a few years ago and it worked out perfect.. I cut the ends to 1/2" and a 1-1/2 " center section and about 1/4" for the "slats". You can even cut the slats at an angle to direct the air flow.A crosscut sled or a jig on the miter box will work well for cutting the thin slats.

   Saftey glasses?......Nah!, I'm wearing saftey contacts
2. 
   BobMc | Nov 30, 2006 09:39am | #2

   Attached are a few (crappy) pics of a heat register I made.  You can probably get the idea. 

   On the stiles I cut an 1/8" by 1/8" rabbet and then cut a plough 1/4" wide by 1/8" deep that is one saw kerf below the rabbet.  (I didn't want to fool with the dado stack, so I worked in saw kerfs.)

   For the fins I machined a block of wood that was the width of the fins and long enough to make all the fins, the center divider, and the rails, plus wastage for the blade, and a half-foot for clearance for my hands.  The block was the same thickness as the rails.

   Machine each long side of the fin block to fit the rabbet and groove on the stiles.  Set the saw-blade angle to the fin angle.  Make the first cut to form one end rail.  Then cut all of the fins.  Flip the (now short) fin block upside down to cut the middle (fat) fin.  Finally, turn the remaining block to the only remaining square end, and cut the other rail.

   I recommend you apply any finish to the fins before gluing the assembly.

   Make a bunch of spacers to keep the fins at the proper distance (I cut several plastic drinking straws into one-inch lengths). 

   I'm sorry I don't have any plans, I just made a rough sketch, figured the dimensions, and gave it a go.  I had to make several, and it was pretty easy.  I also don't know of any articles or plans on the web.

   HTH