how to make tray handles using router roundover bit

[tom coleman]

I am making trays that have end pieces 3/4" thick and measuring 4x15. I want to cut out handles on each end and expect to drill 1" holes 4 inches apart as the first step. Then I will connect the holes w straight lines and cut out most of waste w a jig saw cutting close to the line. I'd like to remove the rest of the waste and get a very straight line using a straight bit in the router table. Is this a risky operation? Once I have the straight lines cut, I intend to use a bearing guided round over bit to smooth the handles. Any suggestions appreciated.

[Mike Henderson]

That's close to what I do. I drill a hole at each end, draw a line along the top and bottom and use a jig saw to cut close to the line. Then I use a rasp to bring the cut down to the line. I use Nicholson #49 or #50 rasps. Then use a roundover bit (with a guide bearing) to round the wood. I have a tutorial on making a tray on my web site. The page that deals with making the handle is here (http://www.mikes-woodwork.com/RectangularTray6.htm).

Mike

[John TenEyck]

An alternative approach would be to use a straight bit in a plunge router with a collet and template to cut out the opening, then remove the collet and template and switch to a bearing guided round over bit. The advantage of this approach is that you don't have to worry about drilled holes being slightly out of alignment.

John

[Joe Scharle]

An alternative approach would be to use a straight bit in a plunge router with a collet and template to cut out the opening, then remove the collet and template and switch to a bearing guided round over bit. The advantage of this approach is that you don't have to worry about drilled holes being slightly out of alignment.

John

That's what I do. I use the size straight bit (1" in your case) of the slot I want to make. Set stop/start blocks to control the length of the slot.
Doing this in 1 pass instead of using a smaller bit and multiple passes, is quicker and less prone to funny looking ends. I follow this with a bearing mounted roundover bit.

[pat warner]

"very straight line using a straight bit in the router table. Is this a risky operation?"
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Very.