Obviously if you're afraid of the technique you shouldn't use it. I do a lot of template routing using climb cuts. But, there are rules to make it safe. First, and most impoortant, I cut a bare minimum with the router. I use a pattern guide on the band saw with the same template as I'm going to route to, to get the initial cut as close as possible to the final shape - rarely would I ever leave more than 1/16", and I shoot for and generally achieve less. Second, I use either a spiral flush trim bit, or an angles/shear cutting flush trim bit on the router. Third, I make sure I have plenty of mass in my template/workpiece combination, and good holds. Kickback when routing climb cuts is all about how much force the cutting bit develops relative to the mass and stability of the workpiece. These three things (minimum cut depth, shear cut, mass) put the equation in your favor.
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Originally Posted by James Jayko
