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How to fix this tearout???

2796 Views 14 Replies 10 Participants Last post by  SCOTSMAN
Hi all…I'm building a box using Mahogany with Paduk accents. I was trimming the paduk spines flush with a flush trim bit on the router table and on the last one got a blowout (see pics below). What do you suggest is the best way to fix this corner? I am considering routing out the corner again to remove all the paduk then re-gluing a new piece in. But a question arises…would I have to take the slot deeper (ie bigger) to expose new mahogany or could I come right up to the glue interface between the two pieces and re-glue on top of that? THe other thought i had was to use a chamfer bit and take off just the corner then glue on a piece and trim it back into a square corner.

Any and all suggestions welcome.



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Cut it out completely and re-do.

You could just leave a very small sliver of paduk. I think you would be hard pressed to notice it.
Hey Greg
The best solution I can think of is to lay you box on it's side and run the corner though the table saw & flipping it so that you have cut the corner out being careful not to hit the side wood. and then re-glue another piece of your corner wood back in placing using tape on the inside and out to protect against glue squeeze out.

I guess was posting the same time GaryK was
You don't really have any other choice than to do what gary suggests it would never be right otherwise and not worth the effort of saving this bad piece Alistair
ditto on above ,
maybe check the grain on next piece first,
and think router cutting direction before glue up .
This is why I love woodworking. Learning how to fix the mistakes and the little problems that can arise in any project. It has given me some well needed patience and perseverence. I agree with Gary and would replace it all together.
I'm with Gary K and a1Jim.

It happens to all of us sooner or later.
Ok, thanks. Looks like cutting it out and regluing is the way to go.

Bentlyj, I had thought about that. But I decided that, since this is my first attempt at a box assembly like this, I would take the opportunity to learn how to make a fix when something like this happens…

I will definitely pick my next piece closely for grain.

Thanks everyone!

Greg - It's not so much a matter of choosing your grain, but cutting it using a method that won't cause it to split.

Since you are using a router table you want to cut it in the proper direction. Don't cut in the direction that makes the router bit "scoop" out against the grain, but "push" it down.

Basically cut with the grain.
Gary, What would you do it this case, run it through the router backwards very slowlY?
I've been in the shop…although not fixing the corner…I'll do that next weekend…I moved onto shaping some 1/8" thick paduk for some inlay on the lid. It is very delecate to work with. The grain seems not to be very strong. This is my first time working with Paduk and also working with stock this thin…is that typical of paduk?
Gary, it sounds like climb cutting is what you are describing…is that right? I will get a chance to fix the corner in a few days, Until then…I'll take all the help I can get.


Hi Greg,

Have you tried a solid carbide down-cut spiral router bit. It pushes the chip toward the work piece and produces a MUCH smoother cut. Just know that they don't clear chips as well as an up-cut spiral, and are not as good on deep cuts like mortises.

Like many of those suggestions above, I'd re-cut back to the glue line and replace the whole piece.

Good Luck.
For TopamaxSurvivor. All he has to do is turn the box around and over and run it through the router table the other direction….which will be with the grain. Making several shallower cuts would probably also work.
Another concern is if those Paduk pieces are just straight strips of wood, what is holding the box sides together besides glue? Which will work fine unless the box is dropped.
I suppose if the box ever gets dropped it's trouble anyway you look at it.You could also round of the four ends with a large disc sandet or belt sander but as said this might weaken the structure.Alistair
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