Pattern Routing

[Jerry Solomon]

I'm using my table-mounted router with a hardboard pattern to cut the tops on cedar pickets for a new fence. Is there a "best" way to temporarily mount the pattern to the workpiece. On a test piece today I used masking tape and it worked pretty good for that one try. What about double-sided tape, hot glue, ???.

[Todd Burch]

Personally, I would use a miter saw with a stop clamped to the fence - bingo-bango - as fast as you can flip the board for the second cut, and you're done.

However, here's how to pattern route without any glue, screws, tape or any other aid. Make a sled out of 1/2" ply wider than your fence boards, as shown in the drawing. Notch the corner, as in the drawing (I love Sketchup!!) and hold you fence board to the sled fence and cut away. The gif shows one corner of the fence board already cut.

(I would have drawn in the router bit too, but my pizza is getting cold for dinner!)

I used this type of jig for corner round-overs and such. Got several of them.

[Bob_Hammond]

Todd's reply is so cool, I'm embarrassed to add mine. I would use double sided carpet tape. I keep a roll or 2 on hand all the time for just this purpose.

Bob

[Mike Sweat]

Sounds like Todd has the answer for what you are doing. On other patterns I have used two faced tape and it works great for me.

<img src="http://www.mandswoodworks.com/assets/images/db_images/db_pic_0451.jpg">

[Keith Starosta]

Personally, I would use a miter saw with a stop clamped to the fence - bingo-bango - as fast as you can flip the board for the second cut, and you're done.

However, here's how to pattern route without any glue, screws, tape or any other aid. Make a sled out of 1/2" ply wider than your fence boards, as shown in the drawing. Notch the corner, as in the drawing (I love Sketchup!!) and hold you fence board to the sled fence and cut away. The gif shows one corner of the fence board already cut.

(I would have drawn in the router bit too, but my pizza is getting cold for dinner!)

I used this type of jig for corner round-overs and such. Got several of them.

Todd, looks like you're getting the hang of that software! I made the plunge and picked up a copy myself. Very, very cool...

Keith

[Tom Hintz]

If your picket has a shape other than the plain angle cuts I would make a sled much like shown in other responses but with one half of the desired shape at the end to use as a pattern. You can route one side, flip the piece over in the sled and route the other side.
Routing the sides individually helps so you can always be routing down the grain, not up it on one side.

[John Scarpa]

Sketchup huh? That looks too cool. Does it take long to put out a sketch like that. Wow talk about a communication enhancer!

[Keith Starosta]

Sketchup huh? That looks too cool. Does it take long to put out a sketch like that. Wow talk about a communication enhancer!

John,
Once you get even a little proficient using the tool, it takes no time at all. A very cool "non-CAD" drawing tool, indeed. You can download a trial version of the application for free. Check out their website.

Jerry, sorry to have highjacked your thread with an ad for SketchUp! :D

Keith

[Jim Guy]

Mike, your PIC shows some router patterns. At least I think thats what they are. Do you make them yourself or purchase? If so - where?

[Jerry Solomon]

Thanks to everyone for the feedback.

I guess I should have been more specific about what I was doing. These are not standard square cut fence boards with clipped corners ("dog-ear"). These are 4" wide boards x 4 ft. long for a picket fence. They have a curved top (I think the style may be called "Gothic"). I attached a photo to clarify.

Todd - I was very impressed by your graphics. I'll have to take a look at that program. Thanks again.

[Jerry Solomon]

I changed the resolution of the photo. Hopefully it will fit in the frame now. Sorry!!

[Mike Sweat]

Jim, the orange templates for arched doors I bought here

http://www.sommerfeldtools.com/products.asp?ID=74

the other template for the swing arm I made with 1/4" hardboard.