Routing curved stock for a historic door

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Forum topic by willhime posted 12-06-2018 04:27 PM 570 views 0 times favorited 6 replies Add to Favorites Watch
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156 posts in 2311 days

12-06-2018 04:27 PM

Topic tags/keywords: jig question resource tip trick mahogany router

I’m recreating historic doors to a town theatre. Because they’re ‘historic’ everything has to be a copy. I’m concerned about the arched part of the door glass trim. I’ve recreated the profile and everything is great for the straight sections but sending a curved piece of stock through the sam multiple bit process seems that pretty dicey. Is there a safe way or jig to ensure I finish with 10 fingers intact and stock that’s not torn out ?

-- Burn your fire for no witness

6 replies so far

View Aj2's profile


3080 posts in 2570 days

#1 posted 12-06-2018 05:56 PM

Yeah that’s tricky, I’m not a big fan of routers but I have to do curved pieces sometimes, so here’s my guess.
You mention what wood your going with and how you layout the grain on the curve that makes a difference with short grain.
The one on the left I would try with a template and handheld.
The one on the right also a template with bearing in a table.
Cut with the grain and you will still be able to count to ten.:)

-- Aj

View DBDesigns's profile


232 posts in 770 days

#2 posted 12-06-2018 06:03 PM

Not sure about the steps of your process but I would say that it would make sense to use the router on wider stock then cut it down to its finished dimension after the profile is cut. “Wider stock=more control and distant fingers.”

Then just cut the curve with the band saw.

Another approach would be to rout straight stock and then steam bend it. More work but more toys to play with!

-- I remember when Grateful wasn't Dead

View bmerrill's profile


104 posts in 846 days

#3 posted 12-06-2018 06:11 PM

First thought is to cut the curve section out of stock with a band saw and touch up with the sander.
Then using a router table cut the profile with a guide bearing.

-- You are not told the truth, you have to learn the truth.

View willhime's profile


156 posts in 2311 days

#4 posted 12-07-2018 12:15 AM

I’m using sapale mahogany. I can’t sand the curves because they have to be too exact. The inner diameter is 15.75” and outer is 17”. Exact. I’m gonna rough cut the curves with my bandsaw then flush template them. The hard part is the profile which consists of 4 separate router bits. The straight parts are easy on the router table but I’m just anxious about having to feed them through the same setup.

-- Burn your fire for no witness

View 000's profile


2859 posts in 1671 days

#5 posted 12-07-2018 12:38 AM

Make a sled and use toggle clamps.

Make an inside curve sled for the opposite side.

View a1Jim's profile


118065 posts in 4349 days

#6 posted 12-07-2018 01:38 AM

J like Jbay’s approach+ ordering a shaper cutter or router bit to make all the cuts of the detail all at once done by sneaking up on it making light cuts.


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