• An actual woodworking question - routing a deep slot

    From Theo@21:1/5 to All on Sat Feb 24 20:28:05 2024
    Suppose I have a roughly 100x100mm post of (green) oak, that I want to route
    a 1m long slot out of the back for cables - let's say 20mm wide by 20mm
    deep. I have a 1/4" trim router but nothing bigger. I also have a 65mm cutting depth circular saw.

    Is that something I can do with the trim router, in which case what kind of router bit would I need? Or should I do depth cuts with the circular saw
    and then try to chisel out the remains? Or some combination of the two
    tools?

    Once this is done, I'm thinking of drilling a hole at the end of the slot
    and having the cables turn to go through to the other side of the post. To
    do that they will have some kind of turn radius, so how could I make the end
    of the slot gradually deeper to meet the hole? Drilling a series of
    holes of increasing depth and chiselling them out is one option I suppose.
    I don't really want to make a huge hole to accommodate the bend inside the
    hole itself.

    Any better ideas?

    Thanks
    Theo

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  • From Bill@21:1/5 to Theo on Sat Feb 24 16:41:10 2024
    On 2/24/2024 3:28 PM, Theo wrote:
    Suppose I have a roughly 100x100mm post of (green) oak, that I want to route a 1m long slot out of the back for cables - let's say 20mm wide by 20mm
    deep. I have a 1/4" trim router but nothing bigger. I also have a 65mm cutting depth circular saw.

    Is that something I can do with the trim router, in which case what kind of router bit would I need? Or should I do depth cuts with the circular saw
    and then try to chisel out the remains? Or some combination of the two tools?

    I don't think a trim router is designed for this sort of work. I would
    make multiple passes with your circular saw and then it should be very
    easy to chisel out what you want. I'm assuming your post is square,
    otherwise I think you would require a fancier set up, or it could be
    dangerous (IMO, but lots of folks here know more than I do).




    Once this is done, I'm thinking of drilling a hole at the end of the slot
    and having the cables turn to go through to the other side of the post. To do that they will have some kind of turn radius, so how could I make the end of the slot gradually deeper to meet the hole? Drilling a series of
    holes of increasing depth and chiselling them out is one option I suppose.
    I don't really want to make a huge hole to accommodate the bend inside the hole itself.

    Any better ideas?

    Thanks
    Theo

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  • From pyotr filipivich@21:1/5 to All on Sun Feb 25 08:15:13 2024
    Theo <theom+news@chiark.greenend.org.uk> on 24 Feb 2024 20:28:05 +0000
    (GMT) typed in rec.woodworking the following:

    Suppose I have a roughly 100x100mm post of (green) oak, that I want to route >a 1m long slot out of the back for cables - let's say 20mm wide by 20mm
    deep. I have a 1/4" trim router but nothing bigger. I also have a 65mm >cutting depth circular saw.

    Is that something I can do with the trim router, in which case what kind of >router bit would I need? Or should I do depth cuts with the circular saw
    and then try to chisel out the remains? Or some combination of the two >tools?

    Use the saw, chisel out the remains. One issue is that you will
    not have a "square" end to the slot because of the saw blade curve.
    But it is in back, so who will see it?

    Once this is done, I'm thinking of drilling a hole at the end of the slot
    and having the cables turn to go through to the other side of the post. To >do that they will have some kind of turn radius, so how could I make the end >of the slot gradually deeper to meet the hole? Drilling a series of
    holes of increasing depth and chiselling them out is one option I suppose.

    Depends on how deep the slot is, and can you just let the cables
    "rise up" to point out the hole.
    Other wise, drilling a series of holes is pretty much the
    "easiest" solution. Could drill that hole first, the cut to it with
    the saw. "Like this {Insert sketch}!"

    Alternately, you could work the sides down with a chisel and
    chisel out the middle, much as you would for a mortise and tendon.
    I don't really want to make a huge hole to accommodate the bend inside the >hole itself.

    Any better ideas?

    Thanks
    Theo
    --
    pyotr filipivich
    "With Age comes Wisdom. Although far too often, Age travels alone."

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  • From Scott Lurndal@21:1/5 to Theo on Sun Feb 25 18:51:52 2024
    Theo <theom+news@chiark.greenend.org.uk> writes:

    Suppose I have a roughly 100x100mm post of (green) oak, that I want to route >a 1m long slot out of the back for cables - let's say 20mm wide by 20mm
    deep. I have a 1/4" trim router but nothing bigger. I also have a 65mm >cutting depth circular saw.

    Is that something I can do with the trim router, in which case what kind of >router bit would I need? Or should I do depth cuts with the circular saw
    and then try to chisel out the remains? Or some combination of the two >tools?

    With your tools, I'd go for the latter. Note that it will be tough
    going for a 8mm trim router (I saw that switch in units, above)
    to route a 3/4" x 3/4" x 39" slot.

    Set the saw for a 3/4" deep cut and build a jig to guide the saw,
    don't try to freehand it.

    If you have a drill press, you can hog out the waste with a 3/4"
    forstner bit, then trim with a chisel.


    Once this is done, I'm thinking of drilling a hole at the end of the slot
    and having the cables turn to go through to the other side of the post. To >do that they will have some kind of turn radius, so how could I make the end >of the slot gradually deeper to meet the hole? Drilling a series of
    holes of increasing depth and chiselling them out is one option I suppose.

    Again, that's probably your best option.

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  • From Theo@21:1/5 to Scott Lurndal on Mon Feb 26 22:36:08 2024
    Scott Lurndal <scott@slp53.sl.home> wrote:
    With your tools, I'd go for the latter. Note that it will be tough
    going for a 8mm trim router (I saw that switch in units, above)
    to route a 3/4" x 3/4" x 39" slot.

    Set the saw for a 3/4" deep cut and build a jig to guide the saw,
    don't try to freehand it.

    Thanks, that makes sense. Alas it's not a track saw which would make it easier, but can probably jig something up.

    If you have a drill press, you can hog out the waste with a 3/4"
    forstner bit, then trim with a chisel.

    That's a good thought, rather than trying to chisel out big chunks of
    material. I don't have a drill press but I suppose doing it by hand might
    be safe enough (then tidy up the edges).

    Once this is done, I'm thinking of drilling a hole at the end of the slot >and having the cables turn to go through to the other side of the post.
    To do that they will have some kind of turn radius, so how could I make
    the end of the slot gradually deeper to meet the hole? Drilling a series >of holes of increasing depth and chiselling them out is one option I >suppose.

    Again, that's probably your best option.

    A forstner bit to make stepped depth holes might work too. I should have a play...

    Thanks all,
    Theo

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  • From Bill@21:1/5 to Theo on Tue Feb 27 10:12:41 2024
    On 2/26/2024 5:36 PM, Theo wrote:
    Scott Lurndal <scott@slp53.sl.home> wrote:
    With your tools, I'd go for the latter. Note that it will be tough
    going for a 8mm trim router (I saw that switch in units, above)
    to route a 3/4" x 3/4" x 39" slot.

    Set the saw for a 3/4" deep cut and build a jig to guide the saw,
    don't try to freehand it.

    Thanks, that makes sense. Alas it's not a track saw which would make it easier, but can probably jig something up.

    If you have a drill press, you can hog out the waste with a 3/4"
    forstner bit, then trim with a chisel.

    That's a good thought, rather than trying to chisel out big chunks of material.

    Note: If you run the circular saw, having an 1/8" inch blade (!)--not a
    thin one, multiple times up the post, there won't be any big chunks to
    chisel out. If you can put the post on a sturdy table or bench, a
    clamped 2-by-4 ought to give you an ample jig to support the circular
    saw. Clearly the post should also be clamped/secured. I used this
    technique (on an admittedly smaller scale) once, and was really
    impressed with it! I do not take any credit for it.


    I don't have a drill press but I suppose doing it by hand might
    be safe enough (then tidy up the edges).

    Once this is done, I'm thinking of drilling a hole at the end of the slot >>> and having the cables turn to go through to the other side of the post.
    To do that they will have some kind of turn radius, so how could I make
    the end of the slot gradually deeper to meet the hole? Drilling a series >>> of holes of increasing depth and chiselling them out is one option I
    suppose.

    Again, that's probably your best option.

    A forstner bit to make stepped depth holes might work too. I should have a play...

    Thanks all,
    Theo

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