Pie Crust Table #4: Working on the inside edge

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Blog entry by GaryK posted 05-05-2009 09:51 PM 3294 reads 3 times favorited 15 comments Add to Favorites Watch
« Part 3: More work on the top. (Does it ever end?) Part 4 of Pie Crust Table series Part 5: The edge completed! »

Now I feel like David Marks with all the templates, but it was the only way I could think of that was fool proof. By fool proof I mean that you can’t wander with the router and cut off what you didn’t want to.

I needed to make three paper patterns. One for each of the cuts I will be making. Here are two of them taped to the template before cutting.


These were made from the corners of MDF like the one for the outside. I had to leave more material on the outside edge so that when I applied pressure with the router if didn’t flex away. They don’t look pretty but they turned out pretty good where they counted.

These gave me a chance to use my scroll saw which sits neglected in my shop most of the time. Then some sanding and filing and the edges were perfect (as far as I could make them anyway).

Then since I wouldn’t be able to see my lines in the top, once I starting removing material, to line things up I drilled a hole to allow me to see through. Then just extended my line into the hole. This is one of the reasons I am going to save cutting the outside radius until last. Otherwise it would remove my lines from the outside edge.

Here you can see part of the rough cut just to make clearance for the other bits. I just used the flat router bit with one of the wider templates. Now here I don’t want to remove too much material from the surface because I still want to use it to support the router base when I route the outside radius. That will be the last thing I do before removing all the material from the inside.

Here’s one of my 2 rarely used plunge routers, set up with my router guide insert and flat bit. You can also see why I left so much material on the templates. I have to have room for the clamp.

Now because of the diameter of the 1/4” radiusing bit I couldn’t use a router guide insert like a did above, so I had to do something different.

I had to add a bearing to the bit. Luckily the bearing from the other bit I am going to use would work. See the larger diameter shank on the blue bit? Well, that was because the inside diameter of the bearing was 5/16”. So to get it to work on my 1/4” shank red bit I had to make a sleeve to the shank to increase the diameter. Now I just happen to have a metal cutting lathe so I just made one.

The next time you see this I should have the entire inside edge done and show you how I remove the rest of the material from the inside.

-- Gary - Never pass up the opportunity to make a mistake look like you planned it that way - Tyler, TX

15 comments so far

View pommy's profile


1697 posts in 4107 days

#1 posted 05-05-2009 09:56 PM

outstanding gary as always but then i can only dream of being half as good as you thank you for the posts and please keep them up i’m learning so much for your work


-- cut it saw it scrap it SKPE: ANDREW.CARTER69

View PurpLev's profile


8551 posts in 4064 days

#2 posted 05-05-2009 09:58 PM

nice progress. templates ARE the safe way to go… make it once. and it’s good for a while

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View a1Jim's profile


117652 posts in 3993 days

#3 posted 05-05-2009 10:00 PM

Looking good Gary I can’t wait to see the finished top. Great work

View longgone's profile


5688 posts in 3724 days

#4 posted 05-05-2009 10:02 PM

Templates and jigs add so much versatility to using a router. Your table wil look so very unique and nice when completed.

View patron's profile


13649 posts in 3757 days

#5 posted 05-05-2009 10:29 PM

oh the things we learn through our ( and each others ) mistakes !
nice save .

cant wait !

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View Bob #2's profile

Bob #2

3810 posts in 4437 days

#6 posted 05-05-2009 10:39 PM

Looking good Gary.
How did you figure out the pattern fit for the circle diameter or do you have to fudge the edges a bit to get a fit?


-- A mind, like a home, is furnished by its owner

View TopamaxSurvivor's profile


18595 posts in 4092 days

#7 posted 05-05-2009 10:42 PM

Very interesting process. Nice to see a master in the act :-))

-- Bob in WW ~ "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence

View Rj's profile


1047 posts in 4047 days

#8 posted 05-05-2009 10:53 PM

I was wondering how you were going to do the recessed area of the top ? Looooking goood .
Thanks again for the step by step.

-- Rj's Woodworks,San Jose & Weed Ca,

View GaryK's profile


10262 posts in 4404 days

#9 posted 05-05-2009 10:58 PM

Bob – I always figure things out with AutoCAD first. Then I print one or more pages in 1:1 scale and tape them together as required.

-- Gary - Never pass up the opportunity to make a mistake look like you planned it that way - Tyler, TX

View Scott Bryan's profile

Scott Bryan

27250 posts in 4238 days

#10 posted 05-05-2009 11:16 PM

Gary, you have an innate ability to take a complex process and reduce it to a seemingly simple step wise approach. This has been an interesting series to follow.

-- Challenges are what make life interesting; overcoming them is what makes life meaningful- Joshua Marine

View lew's profile


12800 posts in 4171 days

#11 posted 05-05-2009 11:30 PM

Great Blog, Gary!!

The idea of leaving material on the outside edge of the template is something I will have to remember!! Now that you have the templates, you will have to make more than one table! (unless you’re like me and have a shop full of one-of-a-kinds)


-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View bluchz's profile


187 posts in 3789 days

#12 posted 05-06-2009 12:28 AM

Amazing Gary, thanks for posting the process.

-- flash=250,100][/flash]

View Russel's profile


2199 posts in 4355 days

#13 posted 05-06-2009 12:31 AM

Remarkable work. I wish I had your meticulous nature.

-- Working at Woodworking

View Les Hastings's profile

Les Hastings

1305 posts in 4189 days

#14 posted 05-06-2009 12:48 AM

Great project and blog Gary. Good to see your getting some quality time in.

-- Les, Wichita, Ks. (I'd rather be covered in saw dust!)

View Woodhacker's profile


1139 posts in 4139 days

#15 posted 05-06-2009 04:06 AM

Good stuff Gary. I actually have autocad software…just haven’t taken the time to learn to use it….This makes me rethink that. Going through this blog series, is providing fuel for various ideas for using these techniques.

Thanks for taking the time to post this series.

-- Martin, Kansas

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