Replies

1. 
   user-1119429039 | Jul 30, 2008 06:24pm | #1

   Dear Luggage Guy,
   Before trying to assign your question to an expert, I want to be sure I understand the problem you're having. If I read your question correctly, you're trying to cut matching flutes in 4 sides of square stock, but for some reason, the cuts on opposing sides don't match.
   Is the stock you're using straight and square, or tapered? Are the flutes you're trying to cut stopped, or do they run the full length of the workpiece?

   Personally, I'd try this: Set up the router table, with the fence set to cut the first flute. Make that cut on all 4 sides. Then set the fence for the second cut. Make that cut on all 4 sides. Repeat for all the flutes you want to cut. As long as the height of the router bit stays constant (that is, it doesn't drop inadvertently), and as long as your stock is milled square and true, you should bet consistent results on all four faces of the board. It sounds as if it's almost the same as cutting grooves on a tablesaw: The blade is fixed, the rip fence is fixed, the only thing moving is the wood.

   Or am I missing something?

   David Heim
   Managing Editor
   FineWoodworking.com

1. 
   luggage guy | Jul 31, 2008 01:59am | #2

   David,

   Thanks for your response.. I failed to mention the flutes are on the corners and are stopped. All else with set up is ok.

2. 
   user-148830 | Aug 16, 2008 04:40am | #3

   Hi,
   My question to you is how are you holding your workpiece to run it past the cove bit? If you're not set perfectly at 45 degrees to the table then your cove won't be centered on the corner of the block. Not centered means that the remaining faces are unequal in size.

   I would make up a holder or jig that sets your block tipped at a 45 degree angle. Check my Complete Illustrated Guide to Joinery book for spline miter cuts in carcases. You can use a jig like the variation shown to hold your block at the right angle along with some kind of hold down clamp. Set your stops off the ends of the jig to get your stopped cuts. Good luck. Gary

1. 
   luggage guy | Sep 02, 2008 05:01pm | #4

   Gary,

   The illustrations on pg. 113 were very helpful.. great book!

   Thanks