Reply by Bill_Steele

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Posted on Best way to flush trim lots of 3/4" plywood?

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636 posts in 2341 days

#1 posted 02-22-2017 06:14 PM

I think the bandsaw to pattern routing approach sounds viable—especially if you don’t need them in hurry AND you don’t mind the hours of repetition.

I used to get ShopNotes and remember a project in one of the magazines for a bandsaw pattern cutting jig—not sure if that will help. It does NOT flush trim, but if your template was a little bigger than your desired final dimensions—it might get you to where you need to be. I can get the issue number if you want.

I think I have seen flush sanding drums for the drill press. That might help.

I have had good luck with the Whiteside spiral flush trimming bits. I have both of these:

I would suggest getting a bit with a 1/2” shank and at least a 1” cutting length. If you decide to stack the parts you’ll need a longer cutting length. I like the compression bits, but the price is steep.

I often use pattern cutting in my projects. I typically use double stick tape (I like golf grip tape) to hold the template to the work piece. Here’s a good approach (works well for corners) The “wings” on the template make it self aligning and easy to apply the template with no tape. This approach does work well for a corner profile—not sure how well it can be adapted to a larger profile or odd shapes.

Whatever you decide, you must come up with an accurate, repeatable process. Please let us know what approach/process you decide on. Best of luck.

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