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Routing deep mortise

This is a discussion on Routing deep mortise within the Portable Routing forums, part of the Routers category; I am in the process of building a workbench and have eight 2-1/4" x 1-1/2" ...


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Old 08-31-2010, 09:42 AM   #1 (permalink)
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I am in the process of building a workbench and have eight 2-1/4" x 1-1/2" x 3" deep mortises I need to cut. Of the many ways I could go about producing these mortises, it seems using my plunge router would result in cleaner and more accurate mortises.

How would you recommend I go about routing a deep mortise: process?, type of bit (most plunge bits I have seen don't have the length to cut that deep)? and where to get such a bit if one were available?

Thanks,

Dalec

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Old 08-31-2010, 09:53 AM   #2 (permalink)
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Hi Dalec

I would suggest using a spade bit to hog out most of the wood and then use the bits below to clean up the hole with a template and/or brass guide on your plunge router base plate.

1 pc 1/2"SH 2-1/2" Blade Top Bearing Trim Router Bit - eBay (item 130425183413 end time Sep-25-10 15:53:21 PDT)

1 pc 1/2" SH 3" Blade Extra Long Straight Router Bit - eBay (item 130426568658 end time Sep-29-10 16:37:46 PDT)

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I am in the process of building a workbench and have eight 2-1/4" x 1-1/2" x 3" deep mortises I need to cut. Of the many ways I could go about producing these mortises, it seems using my plunge router would result in cleaner and more accurate mortises.

How would you recommend I go about routing a deep mortise: process?, type of bit (most plunge bits I have seen don't have the length to cut that deep)? and where to get such a bit if one were available?

Thanks,

Dalec
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Old 08-31-2010, 10:03 AM   #3 (permalink)
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Hi dalec

3" bits are available, but you will probably find they exceed the travel of the plunge so would make using them for such deep mortising complicated. Ones like 1 pc 1/2" SH 3" Extra Long Flush Trim Router Bit - eBay (item 130426115276 end time Sep-05-10 11:23:34 PDT) with the bearing removed might do. Better still
1 pc 1/2" SH 3" Blade Extra Long Straight Router Bit - eBay (item 130426568658 end time Sep-29-10 16:37:46 PDT)

I must stop looking on that web site. There are too many temptations !

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Old 08-31-2010, 10:04 AM   #4 (permalink)
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Thanks Bobj3.

I got stuck in routing out the entire mortise. Had not even thought about drilling out most of the waste before using a trim bit to clean up the mortise.

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Old 08-31-2010, 10:05 AM   #5 (permalink)
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Snap ! I was looking while you were writing, Bob !

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Old 08-31-2010, 10:13 AM   #6 (permalink)
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Peter,

Thinking with bearing guided trim bits, that I could gain some additional depth by using two different length trim bits so I can step my way down to a deeper mortise or use differing thickness template material and step down that way. Don't know if this would gain me much more depth however.

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Old 08-31-2010, 11:18 AM   #7 (permalink)
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Hi Dalec

Once you clean out the hole down ,than route the hole out to say 1 1/2" the rim of the hole will give you a nice edge to ride on with the bearing or the brass guide template..I have push my bit to 3 1/2" deep without any error..

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Peter,

Thinking with bearing guided trim bits, that I could gain some additional depth by using two different length trim bits so I can step my way down to a deeper mortise or use differing thickness template material and step down that way. Don't know if this would gain me much more depth however.

Dalec
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Old 08-31-2010, 03:46 PM   #8 (permalink)
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Thanks Bobj3 and Peter.

I appreciate the suggestions and can see the solution.

Dalec
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Old 09-06-2010, 12:00 PM   #9 (permalink)
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Key here is good and repeatable/indexable fixturing; without it , forget my proposal.
Indeed drill out most of the waste. Then rout all mortices with with generic HSS cutter maybe 1/2 x 2-1/2 long. Stay inside of the net dimensions x ~1/16" all around.
Now change to long (4-5" OAL) SC up-spiral or another longer HSS straight bit to waste to depth and width. All stock most go back into the fixturing just the way it came out in step one. Note this longer cutter will already have an inch or so of projection whence the motor head is all the way up the tubes. So take these first, tho modest cuts, with care.
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Old 09-13-2010, 08:01 AM   #10 (permalink)
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Thanks Quillman.

I really appreciate the responses I have gotten. It is like talking over a problem with a number of people in person and as the discussion continues suggestions begin to form into a process that will work for me. Quillman, even when I thought I had it figured out, your description of how to go about it, added to my thinking about what is now my approach.

Thanks everyone who had contributed your suggestions.

Dalec
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