I am trying to replicate the wooden arm that goes on an old metal patio chair. I can't figure out how to make the groove that the pipe arm fits into. See pictures. I have a 3/4 core box bit that seems to be the best fit. I have tried a couple different ramps and such, but I can't seem to get the tapered end looking right. Also, I haven't been able to keep the router perfectly straight, even with an edge guide.
Suggestions? Other ways of doing this besides a router? Would it be possible to do this on a router table, so I can use the fence for guidance?
This is for a friend, for his wife's birthday, so I'm up against a deadline in the next week or so.
Picture of the original, and one of the blanks I have ready for grooving:
the easy end:
the tapered end:
the groove is flat for the first 6", then rises a total of 0.42 inches from that point until the end of the taper. I've tried making a ramp from those numbers, but the taper is way too long. How do I figure out what slope of ramp and where to start it?
I'm so lost and frustrated right now. I'm willing to do it by hand, but I don't have any carving tools, other than normal chisels.