I’m trying to build a sort-of trophy/ momento that requires a small blind slot be cut into a chunk of maple, which serves as a stand. The slot has to accept a piece of 1/16″ thin x 3/4″ wide aluminum bar stock (which then bends up and forward to hold the “trophy”, and the slot for the bar needs to be about 1″ deep for the bar to be secure in the base.
I’ve tried an oscillating multi-tool (oof) and drilling (1/16″ bits bend on contact with the maple). I’m now trying some thin Pfeil straight chisels, which might work, but it will be laborious to gouge out the wood.
I’ve also ordered a 1/16″ router bit, but my experience with the 1/16″ drill bit suggests that won’t work, either.
Suggestions? Thanks!
Replies
Mount your router in a router table and set a fence with stops to limit the length of the cut to 3/4". Set the bit to about 1/8" above the table and plunge the part while holding it to the fence and one side stop, then slide it along the fence to the other stop. Remove it, raise the bit and repeat until it is how feep you want it.
For safety use a nice long pc of stock to keep your hands clear & give you a firm hold. Cut it to size after the slot is finished. An upcut spiral bit would be my choice.
Love it, thanks!
Hey there - couldn't answer this earlier as I was all caught up in that email reset business... So this may be too late...
Anyways, agree with MJ, only problem you may have is finding a 1/16" router bit with 1" cutting length. I have a few and max for mine are 3/4".
Other option if you cannot find that bit is to do as I show in the attached picture. Basically rip the board into three "slices" and plane/drum sand the center to the 1/16" thickness, notch out the desired mortise size and glue back together. The straighter the grain the better you can hide the glue joints. Or better yet, make the 1/16" "slice" out of a contrasting wood or even that aluminum!
Good luck - let us know how it goes!
Makes sense, and you're right about the difficulty of finding a 1" bit!
And yes, I see the picture; thanks!
Truth be told I never even considered the depth of the slot... nice catch. Maybe cut the slot as deep as the router will allow and then take it to the drill press. Wandering should be minimal with a 1/2" deep slot guiding the drill bit.
Great idea, makes total sense, thanks!
Oops = not sure the pic uploaded!
How about using a Dremel tool with one of their tiny bits? I've done 1/8" one inch deep with those, but not 1/16".
Worth a shot, thanks!
Another approach is to make the slot with a wider bit and glue in a shim to get the slot width needed. This should be faster and safer. Good luck.
Great idea, thanks!
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