Replies

1. 
   Bob_Van_Dyke | Jan 12, 2007 04:53am | #1

   Peter- A 3 wing slotting cutter would be the simplist. It is bearing guided and the router would sit on the face of the door and the cutter runs on the bottom of the door. The problem is the depth of cut. I do not know if there is a bit that will cut a groove as deep as you need.

   The other way- a bit harder, would be to turn the door on end-support the door vertically - one good way is to clamp the door to a set of open stairs (like you see frequently going into a basement -you will be working up high on the stairs) so make sure it is safe. The router will be running on the bottom edge of the door with a fence. You will need to build up the door thickness so that the router is steady.Clamp some thicker cauls flush with the bottom edge of the door to do that. You should be able to position the router wherever you need the groove by setting the fence to guide it. Make sure the fence is on the right side and that you are pushing away from you  (left to right) as you cut (feed direction is critical in any fence guided cut).

   I would use a plunge router and only cut about 1/4" depth at a time until you reach your final depth.

   A standard 2 flute bit should be fine for this . If you can buy the diameter bit you need- great- other wise use a bit between 3/8" - 1/2" cutting diameter and set the fence twice.

   hope that helps

   Bob

1. 
   Peter Charlesworth | Jan 12, 2007 06:06am | #2

   Dear Bob,

   Thanks very much for your comments and suggestions.  They have been most helpful.  Now I just need to find the right set of stairs!

   Kind regards,

   Peter