Save time by pattern-routing duplicate parts
Jigsawing and sanding duplicate parts to size gets the job done—eventually. Using a pattern bit, far left, in a handheld router, however, you'll get perfectly matched parts in less time.
First cut and sand one part to shape to serve as your template. Rough-cut duplicate parts within 1⁄16 " of the pattern lines. Center the sanded part on a rough-cut part, and clamp or double-face-tape the two together on pieces of scrap that lift both above your workbench.
Install a 1⁄2 " pattern bit in your router and adjust its depth so the bearing rides against the sanded part and the cutter extends just beyond the full thickness of the rough-cut part below.
Rout in a clockwise motion around the pattern. To avoid tear-out on the end grain, grip the router firmly and "climb-cut" by moving the router the opposite direction. To decide where to climb-cut, practice routing curves on scraps.
—from the WOOD® shop