Need advice about raised panel routing
As a relatively new and inexperienced router user, I experience new adventures daily. Maybe you can help with the latest:
I am using a new Bosch 1617 router mounted on a Bosch RA1171 table. I started using straight and rabbeting bits and it went well, until the latest...
I decided to built some cabinet doors with raised panels. The huge diameter (3.5") cutters concerned me, so I decided on a smaller Freud 2.75" Quadra-cut bit, with no back cutter, following many recommendations. I installed the bit into the router (with the 1/2" collet) and examined it spinning. No wobbling or uneven spin could be detected with the naked eye.
For my first shot, I used a 3/4" poplar board and set the fence so the first pass was limited to just 1/2". Using 2 featherboards, and a pushstick and the board secured against the fence, I carefully pushed forward.
Then the problems started: it made a weird noise and wood chips started flying. When the whole table began vibrating, I turned it off immediately. The partly routed raised panel was not straight, but wavy. Chips had been torn in a few places.
What could be the cause? (I am working by the book, after watching many youtube clips).
Then I thought maybe there is a problem with the aluminum plate insert. I was not sure it is leveled perfectly (very annoying process) and when I checked with my ruler some light is passing, indicating sagging in the middle. It is not severe but still noticeable. I also feel a small bump when the wood passes from the MDF table, to the aluminum plate. Could these cause my problem?
I reinstalled the bit in the collet at a different level, and tried again with another board. The results however, were similar.