Tool Tip #25: Making Architrave Corner Blocks

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Blog entry by robscastle posted 06-03-2016 05:29 AM 1586 reads 0 times favorited 7 comments Add to Favorites Watch
« Part 24: Hollow Chisel Morticer chisel sharpening angles found! Part 25 of Tool Tip series Part 26: HDPE in the Planer Thicknesser »

I needed to see if I could make some door trim Corner Blocks for a house
The job has been on the back burner for some time as I couldnt figure out how to do it.

The router bit I have is called a Dragon Ball and its 2” or 50 mm diameter not some thing you could put in a hand held router.
I initally tried my drill press but it was an outright all round fail, not enough RPM, not enough power, so that idea was scrapped almost as quickly as it started.

I then decided to mount it in my shaper/moulder and try again. As this was almost the opposite setup from before I didnt hold too much hope on it.

Well it actually worked albeit I could not see what I was doing
I checked the Shaper manual to see if there was any reference to the amount of rise and fall of the spindle in relation to the handle rotation, nil and expected as I am using the machine outside its primary design.

With a series of mount ups, cuts and then dismounts and checks I eventually came up with a satisfactory result.

This is the test piece I lashed up as I was concerned about not having enough bulk I had clamps holding it to the fence,and a massive block at the end.

I marked the handle of the moulder with some masking tape as an index and then selected some scrap to do a production run on.

This is the second run setup.
I spaced the material off the top so I could see the setup before turning the machine on

The scrap timber was originally longer and as I cut the profile I cut the completed individual corners off with the saw.

The final result

So I cut a set

The process worked well for soft wood and didnt require too much setting up.
Tearout, looks like I will have to factor in some rejects due to tearout and chattering in the final production run.

-- Regards Rob

7 comments so far

View Joe Lyddon's profile

Joe Lyddon

10898 posts in 4688 days

#1 posted 06-03-2016 05:50 AM


-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: ... My Small Gallery:

View crowie's profile


3426 posts in 2587 days

#2 posted 06-03-2016 06:23 AM

Look like plain-ish Rosette, Bob….how would they go with so beaut Aussie hardwood??

-- Lifes good, Enjoy each new day...... Cheers from "On Top DownUnder" Crowie

View robscastle's profile


6734 posts in 2840 days

#3 posted 06-03-2016 08:27 AM

Agree the profile do not do much for me either so I have been looking a various “interesting” other rosette sets.

-- Regards Rob

View Boxguy's profile


2868 posts in 2903 days

#4 posted 06-03-2016 09:42 AM

Rob, as always you are reaching just at the edge of what your tools will do. Be careful and good luck on your other rosette searches. Keep pushing and keep posting. Could you add to the design by mounting them in your lathe and adding a circle or two?

-- Big Al in IN

View Mark Wilson's profile

Mark Wilson

2705 posts in 1699 days

#5 posted 06-03-2016 10:17 AM

I a little dumbstruck as to why you didn’t initially go to the shaper/moulder. That’s what they’re for, innit? All the tea in China won’t make a router bit and a drill press play well together. And, B) Those rosettes aren’t all that expensive, at HD or Lowe’s.

-- Mark

View robscastle's profile


6734 posts in 2840 days

#6 posted 06-03-2016 10:32 AM

Thanks for rubbing it it I thought the same thing as well!
then add the fact I have only just got off ebay and seen blocks there going for about AUD2.00.

Add up the cost of an more attractive looking set of rosette bits and then the time, along with knowing there will be some rejects.
In all honesty I dont think I will persue the activity, oh well we learn something new every day.

Now I know the reason why there were no posts in LJs on them!!

-- Regards Rob

View stefang's profile


17039 posts in 3970 days

#7 posted 06-03-2016 01:04 PM

Curiosity often leads us to strange places. You got a good result for your efforts with this Robert, but as often happens we find that we are a step behind modern production methods and quantities that affords such low prices for store bought products that it isn’t worth making some things at home.

-- Mike, an American living in Norway.

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