Email Support about the Router…

Today’s post is about an email that I received from Robert another router enthusiast. I have collected our email correspondence and have included them into this post about my personal router uses coaching.

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First email:

Rick,

I was using a 3/8″ up-cut spiral bit and cutting 3/8″ grooves in solid maple 1×4 and maple plywood. after making the first cut and placing the groove over the guide rail, I noticed that the wood did not slide as easily as I thought it should. Is there a problem.

One other thing I noticed was that the bit I was using (brand new MLCS #7467) was leaving a lot of “fuzz” at the bottom of the cut. Even after clearing most of the fuzz, the wood did not seem to slide as easily as I anticipated.

Thanks for your help.

Robert.

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Second email:

Robert,

Can you provide a photo of the results of your cuts?

Rick

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Third email:

Rick

Here are my photos of me experimenting with the box joint.

Robert,

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Fourth email:

Robert,

I have noticed that you have been cutting against the grain and not with the grain. In order to make the box joint with the maximum strength you need to make the box joint cuts with the grain or on the ends and not the edges. May I ask why you have chosen to cut the joint on the edges instead of the ends of the boards? If you cut on the ends you will eliminate the fuzz and the broken fingers…

Rick

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Fifth email:

Rick

I was experimenting with joining wood in that manner to see if it would be feasible to use this to join different types of wood together, such as maple and walnut. Trying to make wider pieces of contrasting wood and the box joint giving additional “personality” to the piece. The pieces would be used as a box lid or sides.

Using this joint on end grain may leave a cleaner cut and if I continue to use it this manner (against the grain) I may be subject to having to clean it up after the cuts are complete. Would a dovetail bit give the same result? I may have to simply glue it up straight without the joints at all.

Do you feel this would not be a strong joint? These pieces would not be “load bearing”.The broken off piece happened after the cuts when I was putting the pieces together and taking them apart.

Thanks. Robert

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Sixth email:

Robert,

It is nice to hear that you are experimenting with the box joint.

In my opinion: It is very tough to put a wood joint on the edge of the piece and use it to glue the pieces together. I personally would use the box joint to joint pieces together that create the 90 degree assembly of the project. Things like assembly of the box sides, box top and drawers remembering that the joints are made with the grain.

The dovetail will yield the same results maybe a bit worst because the spiral router bit cuts on the angle and creates a clean cut. With the dovetail bit it will enter and exit the material at the same angle all at once, which will break out the material. To stop this you need to clamp a backer material on either sides and move the blow out process onto the backer material and not the good pieces.

Rick

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Seventh email:

Rick,

Thanks for the info. I suppose I will just do glue-ups if I decide to join the pieces on edge. Or maybe I’ll continue to play with it and see what happens. Thanks again for your help.

Robert.