Replies

1. 
   user-1119429039 | Jan 08, 2008 09:35pm | #1

   Dear Teton,

   If I were making wood switch plate covers, I'd first resaw the stock on the bandsaw, probably aiming for pieces no more than 1/8 in. thick, although that dimension is totally up to you.

   Next, I'd use a standard metal or plastic switch plate as a template to locate the cutouts precisely. Drill the hole for the mounting screw and (if it's for a light switch and not a wall outlet), drill out most of the waste for the rectangular hole for the switch. Then I'd use chisels to clean up the hole and pare it to size. If you're making a cover for a wall outlet, you might want to use a small router and a straight bit to clear out most of the waste for the two holes; and, because those are curved on two sides, you may want to use a carving chisel with a shallow sweep to pare those curves; or, you could nibble away with straight chisels and do some sanding.

   Finally, I'd round over the sides of the cover. You can do that with a block plane and sandpaper, with a rasp and sandpaper, or with a roundover bit and a router mounted in a router table.

   That should work. Please let us know how the covers turn out.

   Best,

   David Heim
   Managing Editor
   Fine Woodworking.Com