Forming Perfect Slots
Drilling end holes and sawing out the waste between them is one way to form a slot. Appearance 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.
Draw slot boundary lines on the part, extending the end lines to the edges.
Chuck a slot-size bit in the router. Position the fence to center the bit in the slot.
Align the slot left end line with the left edge of the bit. Position and secure the right stop.
Align the slot right end line with the right edge of the bit. Position and secure the stop.
Using the part width to gauge the distance, clamp an auxiliary guide parallel to the fence.
Note: The part should slide easily between the guide and fence without excess play.
Using a bit 1⁄8 " smaller than the slot width, drill overlapping holes inside the layout lines.
Note: Creating a slightly undersized rough slot with a drill bit lets you rout a clean finished size slot in one easy pass.
With the right end of the workpiece touching the right stop, lower it onto the spinning bit.
Feed the part to the left until it hits the stop. The auxiliary guide keeps the part in line.