Hi Tim
Sounds like it needs a bit of inside support ,,,(so it can't flex) I would try some dowel rod down the PVC pipe then tape the ends up so the dowel can move out of the pipe..until you have the pass done also just a small cut say about 1/8" deep..
You can also use a pair of 3/32" slot cutters on the same shaft to get the 1/2" wide slot...( on the router table) but again only 1/8" deep...
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Last edited by bobj3; 04-17-2008 at 09:10 PM.
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