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Discussion Starter · #1 ·
Here is the design that I have in mind
It will sit over a 3/4" subfloor edge on each side, flush with the floor
The North and South of the picture ends have been represented that way to give a clear picture of the cuts required but they will be 3/4" wide co properly visually balance the look of the register

I do not know how to safely route the long pieces, for the shorter ones I am building a jig
 

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Most reliable way to cut a straight opening would be by using two straight pieces to bracket the router base with the bit lined up to the cut line. Double stick tape to hold the pieces in place. Use a plunge router and make several passes, each a little deeper.

You could also use a bushing (Center the base first), and make a one time jig that allows for the offset of the bit from the edge of the bushing. Make many passes. I'd use a spiral bit for this, half inch or at least 3/8ths. If the grille has square edges that fit into the opening, trim the rounded corners with a jig saw or small hand saw. I'm assuming this is far enough from the wall that you can have enough room to cut the edge nearest the wall with your router. If it's too narrow, cut as much as you can with the router, then use a jig saw.

As a final resort if it's too tight for even a jig saw to fit, I'd visit a Harbor freight and get one of these. Cheap tool, not used often.
Sleeve Automotive design Knee Thigh Elbow
 

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Discussion Starter · #3 ·
Thank you Tom
I just realized that for the long pieces it could be much easier cut them with the table saw
I was thinking about a way to do it on the router table not with the plunge router
 

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Since I don't have a table saw, I'd use my jointer. Here's the how to.

As well, I actually have an attachment for my tracksaw that lets me run the plunge router along the track. Very nice and accurate. But I'd only attempt that with heavier pieces than what you have there.
 
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