- Safety should be the first thing you think of when operating power tools. A router cuts very fine shavings, so inspect the dust collection system prior to use and wear a dust mask or respirator during operation. In addition, you should wear safety glasses or a face shield to protect your eyes from flying debris. Wear close-fitting sleeves and keep the power cord draped over your shoulder if you are not using a router table. Unplug the router before changing the bit to prevent accidental engagement. Finally, routers make a loud, high-pitched whine when they are running, so you will need ear protection as well.
- Use a router table with a fence to cut molding, especially long strips of molding. Hold the blank firmly against the fence as you push it through. Use several different designs on different strips to build up a more complex cornice piece. Use different designs to make elegant picture frames. If your cut removes wood from the entire side it is cutting, use a two-piece fence to support the strip evenly on both sides of the cut.
- Build a jig for times when you are doing the same cut repeatedly, as with a dovetail joint, when you require accuracy or when the cut is difficult. Use a material like high-density fiberboard for your jigs, especially when you will use them frequently. Bits used in a jig should have a guide bearing to use against the jig to guide the router as you push it. Clamp the jig firmly to the work piece and clamp the work piece firmly to the bench or table you are working on.
- Routers are designed for finesse rather than force. If you are cutting a deep cut that will require the removal of a lot of material, try removing as much as possible by some other means first. Coping saws, scroll saws or band saws are common tools to remove excess material. If a large amount of material remains, make multiple passes with the router, removing about one-fourth to half of the material in the cut with each pass, adjusting your fence as necessary between each cut. Listen to your bit--you will still hear it through your ear protection--to determine how hard it is working. If it slows down considerably, try backing the piece off and making an extra pass. Always use a test scrap when trying out new jigs or new setups. This will prevent frustration later when you are working on your project.
