The router is a gateway to precision woodworking, transforming simple boards into functional and beautifully finished pieces. With the right collection of Router Cutters, you can move beyond basic cuts to create strong joints, elegant decorative edges, and custom mouldings. The possibilities are vast, even for a home workshop.
At Key Blades & Fixings, we’re passionate about empowering tradespeople and DIY enthusiasts with tools that deliver professional results. Our Router Cutters are designed for performance and durability. This guide showcases ten popular projects you can tackle at home to build your skills and create stunning work.
Foundational Projects for Every Woodworker
These first few projects are fundamental skills that form the basis of more complex work. Mastering them will open up a world of possibilities.
1. Cutting Clean Grooves and Dadoes for Shelving
A dado is a square-bottomed channel cut across the grain of the wood, while a groove is a channel cut with the grain. They are the strongest way to install shelves in a cabinet or bookcase.
Cutter Needed: A high-quality Straight Router Cutter. The diameter of the cutter should match the thickness of your shelf material for a snug fit.
Step-by-Step Guide:
- Measure and Mark: Carefully mark the positions for your shelves on the inside panels of your cabinet. Use a square to ensure the lines are perfectly perpendicular to the edge.
- Set Up a Guide: Clamp a straightedge or guide rail parallel to your marked line. The distance between the guide and the line should be equal to the distance from your router's base edge to the edge of the cutter.
- Set the Depth: Adjust the plunge depth on your router. For a strong joint, aim for a depth that is one-third to one-half the thickness of the side panel.
- Make the Cut: Place the router base against your straightedge guide. Make the cut in several shallow passes (around 3-4mm per pass) rather than one deep one. This prevents burning and gives a cleaner result. Slide the shelf into the dado to check for a tight fit.
2. Crafting Professional-Looking Rounded Edges
Softening sharp corners with a consistent, smooth radius instantly gives your projects a more refined and professional appearance. It also makes edges more durable and less prone to chipping.
Cutter Needed: A Rounding-Over Cutter. These are bearing-guided and come in various radii (e.g., 3mm, 6mm, 12mm) to control the amount of curve.
Step-by-Step Guide:
- Select Your Radius: Choose a cutter with a radius that complements your project. A smaller radius is subtle, while a larger one creates a more pronounced, softer look.
- Set the Cutting Depth: Adjust the router's depth so that the bottom of the cutter's curved profile is perfectly flush with the router's base plate. This ensures the bearing will guide the cut correctly.
- Rout the Edge: Move the router from left to right along the edge of the workpiece. Keep the bearing in firm contact with the wood to ensure a uniform curve.
- Handle Corners: When you reach a corner, continue the motion smoothly around it to create a seamless, rounded profile.
3. Adding Crisp Chamfered Edges
A chamfer is a flat, angled surface on an edge. It’s a classic decorative detail that adds a clean, geometric look to tabletops, posts, and beams.
Cutter Needed: A Chamfer Cutter, typically with a 45-degree angle. These are also bearing-guided.
Step-by-Step Guide:
- Set the Depth: The depth of a chamfer cut determines its width. Start with a shallow setting for a subtle chamfer and increase it for a more dramatic effect.
- Make the Cut: Just like with a rounding-over bit, move the router along the workpiece, keeping the bearing pressed against the edge.
- Check for Consistency: After the pass, check that the chamfer is even all the way along. If not, you may need to adjust your feed speed or pressure.
Intermediate Projects for Furniture and Joinery
Once you're comfortable with the basics, you can move on to creating strong, functional joints and more intricate decorative work.
4. Creating Rabbets for Cabinet Backs
A rabbet is an L-shaped groove cut along the edge of a board. It’s commonly used to recess cabinet backs, create shiplap joints, or join box corners.
Cutter Needed: A Straight Router Cutter used with a fence, or a specialised Rabbeting Cutter with interchangeable bearings to control the cut width.
Step-by-Step Guide (with a Straight Cutter):
- Set up the Fence: Attach your router's edge guide or use a router table with a fence.
- Position the Fence: Adjust the fence to set the width of the rabbet.
- Set the Depth: Adjust the cutting depth to determine how deep the rabbet will be.
- Rout the Joint: Make the cut in shallow passes until you reach the final depth.
5. Using a Flush-Trim Cutter for Perfect Templates
A flush-trim bit is a must-have for making multiple identical parts. It uses a bearing to follow a template, trimming the workpiece to an exact match.
Cutter Needed: A Flush-Trim Cutter. These have a bearing at the top or bottom of the cutting blades.
Step-by-Step Guide:
- Create Your Template: Make one master part from a stable material like MDF.
- Rough Cut Your Workpiece: Cut your final material so it is slightly oversized (1-2mm larger) than the template.
- Attach the Template: Fix the template securely to the workpiece using double-sided tape or clamps.
- Trim to Size: The bearing will follow your template while the blades trim the workpiece perfectly flush.
6. Making Tongue and Groove Joints
Tongue and groove joints are perfect for creating flat, strong panels for flooring, wall cladding, and tabletops.
Cutter Needed: A matched pair of Tongue and Groove Router Cutters.
Step-by-Step Guide:
- Cut the Groove: Set up the grooving bit in your router table. Adjust the height so the groove is centred on the board's thickness. Run all your boards through.
- Cut the Tongue: Switch to the tongue-cutting bit. Adjust its height so the tongue will align perfectly with the groove you just cut. Run the opposite edge of your boards through.
7. Routing Hinge Mortises for Doors
Cutting clean, perfectly-sized mortises for hinges is essential for hanging doors correctly. A router makes this job fast and accurate.
Cutter Needed: A Straight Router Cutter and a hinge mortise jig.
Step-by-Step Guide:
- Use a Jig: A commercial or shop-made hinge jig is the easiest way to get perfect results.
- Set the Depth: Place a hinge in the jig and set your router's depth to match the hinge leaf thickness.
- Rout the Mortise: Use the router to clear out the waste material within the boundaries of the jig.
Advanced Decorative and Finishing Touches
Take your projects to the next level with these decorative techniques.
8. Creating Decorative Mouldings
You don’t have to settle for off-the-shelf mouldings. With decorative Router Cutters, you can create your own custom profiles for skirting boards, picture frames, and architectural details.
Cutter Needed: An Ogee, Beading, or other Moulding Cutter.
Step-by-Step Guide:
- Use a Router Table: For safety and consistency, this work is best done on a router table.
- Take Multiple Passes: Complex profiles remove a lot of material. Make several shallow passes, raising the bit slightly each time, until you reveal the full profile.
9. Making Raised Panel Doors for Cabinets
Raised panel doors are a hallmark of quality cabinetry. This classic look is achievable with specialised Router Cutters.
Cutter Needed: A Raised Panel Router Cutter and a matching Rail and Stile Cutter set.
Step-by-Step Guide:
- Create the Frame: Use the rail and stile cutters to create the joinery for the door frame.
- Shape the Panel: Use the large-diameter raised panel bit to carefully shape the edges of the central panel. This must be done on a router table with a variable speed router set to a lower RPM.
- Assemble the Door: Fit the panel into the grooves of the frame and glue it together.
10. Cutting Precise Inlays
Inlays involve setting a thin piece of contrasting wood into a recess for a stunning decorative effect.
Cutter Needed: A fine-tipped Straight Router Cutter and a guide bushing set.
Step-by-Step Guide:
- Create the Recess: Rout out the shape of your inlay into the main workpiece.
- Cut the Inlay Piece: Use the same template but with a different guide bushing to cut the inlay piece itself, ensuring a perfect, tight fit.
By exploring these projects, you’ll not only improve your woodworking skills but also gain a deep appreciation for the versatility of the router. Investing in a solid range of quality Router Cutters is an investment in your craft.