Using Plunge Or Table Mounted Router For Cutting Cove - Router Forums
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post #1 of 12 (permalink) Old 10-02-2018, 03:55 PM Thread Starter
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Default Using Plunge Or Table Mounted Router For Cutting Cove

I'm not keen on using the table saw method of cutting a cove. As the crown guard has to be removed, exposing the bare blade. I personally don't think that is very safe.

I want to make a guitar neck support caul, like in the photo. Would I be able to do this using a plunge or table mounted router, how?
Thanks.
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post #2 of 12 (permalink) Old 10-02-2018, 05:01 PM
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How large of a radius are you thinking about? From the picture it looks like it might be a 2 1/2"-3" radius.
Maybe a bit like this, take a lot of passes of 1/8" height til you reach max.
https://www.amazon.com/Router-EnPoin...ose+router+bit

I would use a table set up, set it to start at the center of board and cut 1/8" high. Then move the fence away to cut max width,( W/O changing height. Then turn end for end and run it through to cut the other side. Then raise the bit 1/8", move the fence forward 1/8", make a pass then end for end do the same , repeat til you as deep as you want.

Or take it to the TS and draw the profile on the oend of the board and set your fence and blade height the cut to the profile and it will be a stairstep halfmoon cut when you are done and you can sand out the stairstep the make a smooth radius.
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post #3 of 12 (permalink) Old 10-02-2018, 05:23 PM
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I found a core cutter of 2 inch width at Sommerfeld at about $45. I don't think that is wide enough for a guitar neck. I'm sure you can get larger, but couldn't locate one online just now.

I think that if you use a cove cutting jig, you can produce any width you want and the jig will allow you to make the cut with minimal risk. The Rockler jig has a place to mount a feather board over the blade itself, which means you can use a push stick at the end of the cut. And the price is about $100 at Amazon. https://www.amazon.com/Rockler-Cove-...ting+jig&psc=1

You can make your own for a few bucks using clamps to hold everything in place and push blocks to hold the workpiece down. It looks to be a 18 inch long piece at most, and a knot-free section of 2 by will cut easily.
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post #4 of 12 (permalink) Old 10-02-2018, 06:33 PM
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The problem is the radius Peter, as pointed out. This 2 1/4" by Amana is their widest and may not be big enough. https://www.amanatool.com/45949-carb...l?ff=1&fp=7269 The saw blade method goes much larger but if I remember right the more angled you are to the plane of the blade, the more elliptical the cut becomes in shape so you might want to use a smaller diameter blade on the saw like a small circular saw blade. I don't blame you for being intimidated by the cut but if you trap it as shown by Tom and use a pusher that covers it and has a hook at the back for positive engagement then it should work fine. You don't raise the blade much at a time.
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post #5 of 12 (permalink) Old 10-03-2018, 12:51 AM
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Can't think of anything I would have a use for a piece like that. When, and if, I ever finish my banjo I will be making a case for it and will just set it in the case.

However, if I did want a piece shaped like that it wouldn't be that hard. I'd cut the end profile wanted out of plywood, ether 1/2" or 3/4". I'd get it perfect, then glue it to a rough cut piece of plywood, then use the finished part as a master, and rout the rough cut piece. Then glue the two to another rough cut piece, and rout. Repeat until you get a length you want. It can be done, I've done similar. And when you put a finish on it, the plies will really pop. You could use solid wood also, but I like working with plywood. Just keep your fingers away from the whirly part.

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post #6 of 12 (permalink) Old 10-03-2018, 12:57 AM
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what is the real profile you are after...

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post #7 of 12 (permalink) Old 10-03-2018, 04:43 AM Thread Starter
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Thanks for the input people. I bought a guitar neck support caul almost same as one in photo, from China for $11.17 inc postage, takes about a month to arrive but I'm in no hurry.
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post #8 of 12 (permalink) Old 10-03-2018, 09:45 AM
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Quote:
Originally Posted by Gaia View Post
...I bought a guitar neck support caul almost same as one in photo, from China for $11.17 inc postage...
Good choice. You avoid doing something that spooks you and get what you want. I was going to make a box for my variety of teas until I found one for less than $12 on Amazon.
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post #9 of 12 (permalink) Old 10-04-2018, 08:43 AM
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If you end up needing to make one yourself, @DesertRatTom posted the way that I would do it. Gradually changing the angle of the jig relative to the blade will help determine the width. Raising the blade gradually with many passes will determine the depth, so you can sneak up on the perfect arc gradually to get the fit perfect. I have done this many times for making cove cuts and it works well, but the final passes should be made with very slow feed rates to get the cleanest cut. You will still need to do some sanding.

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post #10 of 12 (permalink) Old 10-04-2018, 09:37 AM
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Quote:
Originally Posted by DesertRatTom View Post
...The Rockler jig has a place to mount a feather board over the blade itself, which means you can use a push stick at the end of the cut. And the price is about $100 at Amazon. https://www.amazon.com/Rockler-Cove-...ting+jig&psc=1...
That's a nice looking jig, Tom. I really like the feather board idea. That would add a lot of confidence when doing a cove cut. Unfortunately it's pricey for how often I'd use it.
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