How to Duplicate a Shape with a Router

Wood routers can be amazing tools if you know how to use them properly. One of the many things that a wood router can do is make exact duplicate copies of almost any flat object, even if the pattern is relatively complex. Fortunately, with the right router bit, duplicating a shape with a router is relatively simple.

Instructions

Difficulty: Moderately Easy

Things You’ll Need:

• Flush trim router bit
• Template
• Carpenter's pencil
• Jigsaw
• C-clamps

1. Load a flush trim router bit into your wood router following the manufacturer's instructions for installing a new bit.
2. Lay the piece that you want to copy onto a sheet of wood and trace around it with a carpenter's pencil. Set aside the original piece (also called your template) for the moment.
3. Trim away most of the excess wood around your tracing with your jigsaw. Cut away as much material as possible.
4. Lay your traced piece over the original piece such that the pencil lines of the traced piece correspond to the position of the original piece underneath. Use a C-clamp to attach the two pieces firmly together; use small blocks of wood to prevent the clamps from marring your original template piece and the new traced piece.
5. Trim away all further excess wood using your router with its flush trim bit. The flush trim bit has a bearing that will ride against the template, allowing the cutting bit to trim away all excess wood from the copy, producing an exact duplicate of the original piece.

Tips & Warnings

• When making the final cut with your trim flush router bit, make certain that the two pieces of wood remain firmly clamped together. Any movement between the two pieces means your copy will not be exact.
• Follow all safety precautions suggested by the router's manufacturer, including wearing protective eye and nose coverings.