Rout the Edges
5 Now chuck a 3/16" round-over bit into the table-mounted router, and relieve the edges of all four horseshoes, where shown in the Drawing 1.
6 Rip a 2x21" strip from the birch plywood to create the center cleats (B) and end cleats (C). (Though the cleats are small, the following operations will be much easier and safer if you start with an oversized piece.) Resaw the piece to 1/4" thick, then rip the resawn piece down to create a 1/4x1/4x21" strip.
7 Crosscut the strip to create four center cleats (B) and eight end cleats (C) at the sizes shown. To give the cleats their final shape, adhere a quarter-sheet of 80-grit sandpaper to a flat surface and sand 1/16" tapers on the edges and ends of all the cleats.
8 Glue one center cleat (B) and two end cleats (C) to one face of each horseshoe, where shown on the full-size horseshoe pattern.
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