Reply by OSU55

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Posted on Repeated router kickback, Why?

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2155 posts in 2290 days

#1 posted 01-27-2017 08:04 PM

Ive made many totes with the same type bit. I made a combination pattern/clamp to hold them because a wood screw clamp didnt seem reliable enough, but I do use one with round over bits on the totes. I suspect you had the bit bearing riding the pattern and put it into a heavy cut. As mentioned, cut as close as possible with the bandsaw, and drill out the tight corners to remove excess material, but I still have areas that extend too far out of the pattern for one pass. I can feed the part into the bit and guide it through a light cut w/o being on the bearing. I just keep working the excess material down until the bearing rests on the pattern. I do several passes with the roundover bit, raising it some each pass. Gluing sandpaper to one or both faces of the screw clamp with hold the work more securely. Here is a blog entry, with modified drawings, you might make use of.

If you cut an end grain surface all the way through against bit rotation, i.e. in your pic the lower front of the tote toe, the wood will blow out. I leave that as clean up, and feed with bit rotation so the wood is removed ahead of the next cut. Its only an 1/8” or so in length, not enough for the bit to grab the piece and throw it. One of the reasons I made the pattern/clamp jig – to control the operation well.

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