How do I router out a small, shallow pocket? - Router Forums
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post #1 of 22 (permalink) Old 09-16-2016, 06:10 PM Thread Starter
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Default How do I router out a small, shallow pocket?

Hi guys,
I am new to the forum, and hopeful that you can help me with a project. I am doing some custom knife handles, and the knives are spring assisted, so I need to put the spring pocket in the one side of one of the handles. I have to do this for 10 knives. I was thinking of building a small router table, and that I could put a matching pocket in a piece of aluminum or something as a guide, but the smallest corner is only going to fit a 1/8" cutter. I am new to using a router as well, so ANY advice will be hugely appreciated. There will 5 done in micarta, and 5 done in stabilized walnut. The handle blanks will be 4.5x1.5" and the pocket needs to be .082" deep. Because of the precision of these knives, and the action of the spring, these pockets need to be quite precise. I attached a photo of the stock handle, as reference.
Cheers,
Dustin
You can see my work on Facebook and Instagram @Tocherdesigns
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Last edited by Dustin Tocher; 09-16-2016 at 06:12 PM.
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post #2 of 22 (permalink) Old 09-16-2016, 06:29 PM
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Welcome to the forum Dustin. I can't help with your inquiry but I'm sure someone will be along to give some advice.

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post #3 of 22 (permalink) Old 09-16-2016, 06:32 PM
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Hello Dustin and welcome to the forums...

see if this helps..
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post #4 of 22 (permalink) Old 09-16-2016, 07:31 PM
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Welcome Dustin. To build a bunch and get them accurate and all the same you need a pattern or template or you need to farm them out to someone with a CNC router which you might want to check out. To rout the entire cavity with a 1/8" bit will be slow. I would rout most of it out with a larger bit and switch to 1/8" to finish the tight spots. You need a fairly short bit with a top bearing such as a small mortising bit to do the major cutout. The next problem is that there are no top bearing 1/8" bits so you would have to switch to a template guide and probably a different template for the last cuts or just chisel the last bit out instead which could be a lot faster than it may sound to you.
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Last edited by Cherryville Chuck; 09-17-2016 at 02:14 PM.
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post #5 of 22 (permalink) Old 09-16-2016, 07:43 PM
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Way too spooky on the router table.
In my view, has to be done with hand routers.
& you're asking a lot from ground zero.
An understanding of the whole megillah is paramount.
You can see how many templets it takes to get to the work here.
And there were other templets to make these.
I'd be thinkin' laser templet routing, (have it done x a pro).
Complimentary template routing (CTR) is the end game in this art.
Not the beginning.
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post #6 of 22 (permalink) Old 09-17-2016, 10:52 AM
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Make a template that you can use with a router collar and 1/8" bit. This post may help http://www.routerforums.com/guide-bu...beginners.html

You might see if you can find someone local with a CNC that could do the work at a reasonable cost and they could cut all the pockets and drill all the holes. They could even do 2 sided carving and contour the grip.
Or you could have them make a template for you to use with a router collar to cut the pocket that you could use over and over.
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post #7 of 22 (permalink) Old 09-17-2016, 01:58 PM
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Quote:
Originally Posted by MEBCWD View Post
Make a template that you can use with a router collar and 1/8" bit. This post may help http://www.routerforums.com/guide-bu...beginners.html

You might see if you can find someone local with a CNC that could do the work at a reasonable cost and they could cut all the pockets and drill all the holes. They could even do 2 sided carving and contour the grip.
Or you could have them make a template for you to use with a router collar to cut the pocket that you could use over and over.
I'm with you Mike , as soon as I seen it cnc came to mind . I'd like to see it done with a plunge router , but the template would be a pita too make IMO
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post #8 of 22 (permalink) Old 09-17-2016, 02:43 PM
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I see 2 pockets, and 3 recessed holes... too much for a simple template in my opinion AND what about the other side of the knife scale? There may be more pockets and holes on that one. A CNC is the way to go , and if you don't own one, you can buy one or rent time on one, OR farm out the entire project. Once programmed, the rest will be a 5 minute routing job, no limit to the number of pieces you can make.
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post #9 of 22 (permalink) Old 09-17-2016, 02:50 PM
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Welcome to the forum !




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post #10 of 22 (permalink) Old 09-17-2016, 03:40 PM
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That project just screams for a CNC router. I can do it on my table, but you are in Canada, so ...

If you will be making more of these types of cuts, you might want to invst in an X-carve CNC machine or something like the Piranha or Laguna CNC router machines.

Joe

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Laguna CNC machine

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Last edited by The Hobbyist; 09-17-2016 at 03:45 PM.
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