David, The router bit needs to be slightly wider than the widest key, but not so you can cut in one pass. It takes a single round-trip pass, but that is OK. In fact, it is what keeps the wood from splintering at the edges. By moving clockwise from front to tail across the bass side of the key, then back on the treble side of the key, the cutter is always spinning toward the center of the wood (a climb cut), rather than tearing off the edge. By stopping at the tail end on the bass side, then sliding to the treble side while against the stops, the cut is nice and square and can be set to match the keytop length exactly. If the bit is just slightly larger than the key width, the maximum diameter of the bit covers the key completely. That's the theory, anyway. I use a 5/8th inch straight bit, and make a second pass up the middle with the router base catycorner. It goes quickly. I'm still thinking about getting a 1 inch bit. Just being cheap, I guess. Very rigid jig, very smooth and repeatable results. The only touchy part of building the jig was getting the vice bottom and jaws square to the router bit. Once set, it has been very reliable. Greg Graham >Keytop Jigs >David Ilvedson ilvey@sbcglobal.net >Mon, 24 Oct 2005 7:32:04 -0700 >Greg, >Is the router bit big enough for the entire width of >the key, i.e. one pass... >David Ilvedson, RPT >Pacifica, California __________________________________________________ Do You Yahoo!? Tired of spam? Yahoo! Mail has the best spam protection around http://mail.yahoo.com
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