Reply by Rich

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Posted on Router Question

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6169 posts in 1509 days

#1 posted 01-18-2018 05:32 PM

What John is suggesting is ideal. If you make the template such that the cross fits into it snugly, then with a 1/2” OD bushing and a 1/4” bit (round bead or 45º depending on the profile you want down in the groove), you will get a 1/8” shoulder between the edge of the groove and the outer edge of the cross. Go with a larger bushing if you wish that to be wider, or alternatively you can cut a shallower groove which will also result in a wider shoulder.

Of course the template has to be taller than the cross. If they are both 3/4” thick, then you can put some 1/4” thick blocks on the back of the template to raise it up. I’d also use some double stick tape to hold the cross down to the work surface for stability.

Rather than messing with spray paint for giving the groove color, I’d use glaze. Based on the color in your photo, some van dyke brown would do nicely.

-- Half of what we read or hear about finishing is right. We just don’t know which half! — Bob Flexner

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