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Routing perfect slots

For arrow-straight slots with crisp, clean ends and edges,
let your router table, a few shop-made accessories, and
a little know-how help you produce on-target results.

Submitted by WOOD community member WOOD Magazine StaffSubmit a Shop Guide
  • Perfect slots

    Drilling end holes and sawing out the waste between them is one way to form a slot. But success depends on your unwavering ability to follow the straight cutlines connecting the end holes with a scrollsaw or jigsaw. Here's a better method that eliminates the risk of wandering off course.

  • 1. Lay out the slot

    Draw slot boundary lines on the part, extending the end lines to the edges.

  • 2. Position the fence

    Chuck a slot-size bit in the router. Place the fence to center the bit in the slot.

  • 3. Set the right stop

    Align the slot left end line with the left edge of the bit. Position and secure the right stop.

  • 4. Set the left stop

    Align the slot right end line with the right edge of the bit. Position and secure the stop.

  • 5. Add an auxiliary guide

    Using the part width to gauge the distance, clamp an auxiliary guide parallel to the fence so the part slides easily between the guide and fence.

  • 6. Drill out the waste

    Using a bit 1/8" smaller than the slot width, drill overlapping holes inside the layout lines. Drilling an undersized rough slot lets you rout a clean finished-size slot in one easy pass.

  • 7. Make a plunge cut

    With the right end of the workpiece touching the right stop, lower it onto the spinning bit.

  • 8 Rout the slot

    Feed the part to the left until it hits the stop. The auxiliary guide keeps the part in line.

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