Jigsawing and sanding duplicate parts to size gets the job done—eventually.

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DuplicateParts

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 116 " 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 12 " 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