Router work: learn from mistakes

Wizard

I ruined a tele body in the final stages yesterday when I messed up the neck pocket.
I had clamped down the body firmly at one point, but it still moved while routing.
I thought I was fine about it.
Woke up at 2am really annoyed and frustrated.

Decided to document all the many costly mistakes I've made while doing router work.
I've spotted many recurring patterns.
I then set about creating a check-list for next time I use my over-elaborate neck pocket jig.
(but which produces incredibly tight fits when it works).

Avoidable errors I've made:
- Failed clamping of template to wood. In this case clamping the body and bolting down all guides
- Doing an initial plunge which isn't deep enough, the router bit bearing doesn't engage & router eats template
- Forgetting that router has eaten template slightly and using same template again
- Router guide bearing not tightened
- Errors with setting plunge depth
- Lining things up properly

Interestingly I hardly ever make errors with lining things up; but worry about that the most.
My major errors are inadequate clamping and not engaging the bearing on the guide; things I seem to worry about the least.

I now have a picture with a checklist.
Hopefully this will lead to some learning.

Chocklit_Thunda

Dude!!! I feel your pain! :'( I hashed a beautiful Tele body just last week... Doing the control cavity, everything went smoothly using the template, but when I removed the template and used the previously cut section as a guide, the bit rose a fraction when I plunged and then ran along the top of the cavity instead of the side wall as it was supposed to.... This meant that the guide was running against nothing and the bit was freehand cutting toward the pickup cavity :'( :'( :'(

Routers aren't fun....

Stoffeltoo

Do you still have your fingers?
If so, it was a cheap lesson 8)

Chocklit_Thunda

Stoffeltoo wrote: Do you still have your fingers?
If so, it was a cheap lesson 8)

Still have all my fingers but lost a nice pair of shorts that day.... ☹

AlanRatcliffe

Make sure to check that the collet hasn't loosened between cuts. As a corollary, make sure to replace worn collets (and other worn parts) on well-used routers. :-[

Wizard

Good news.
My new military check list works beautifully.
It's actually really cool to follow a trusted list rather than worry that your 50+ brain has forgotten something again.

And I have "sort of" saved the body.
Cut the pocket oversized; glued in some wood and recut it accurately.
Luckily most of the drama is under the pickguard.

Sean

Stoffeltoo wrote: Do you still have your fingers?
If so, it was a cheap lesson 8)

+1!!

Shibbibilybob

Sean wrote:
Stoffeltoo wrote: Do you still have your fingers?
If so, it was a cheap lesson 8)
+1!!

This terrifies me. I have known a few very competent, capable and meticulous carpenters who have lost fingers to routers.
Jigs are useful, they help a lot. still terrifying.

AlanRatcliffe

The guy I (sort of) apprenticed to eventually lost two fingertips and thumb on his right hand to his table saw. The thought still gives me chills.

Wizard

Alan Ratcliffe wrote: The guy I (sort of) apprenticed to eventually lost two fingertips and thumb on his right hand to his table saw. The thought still gives me chills.

I've often been tempted to get a table saw because of the expected extra accuracy and repeatability.
But i'm just too scared of that exposed blade looking up at me.
I use a high-end spring loaded plunge circular saw on a rail on a table instead.
Like the idea of pushing the blade away from exposed fingers.

I dabbled with a router table for a while, then had a few scary moments with stuff biting and being thrown across the workshop. Packed it away.
Again - too scared of that exposed spinning bit looking up at me.

Having said that, I use my bandsaw very extensively.
And I just know it's the wolf in granny's clothing.
It's so innocent looking and quiet and easy to use.
I have to remind myself to fear it.

It's when you lose your fear that the trouble starts.

Chocklit_Thunda

Table saws are the best! Get a sturdy guard and plenty of tools to keep yer fingers away from the blade and you're pretty safe. Also lets you get good straight cuts if you use a guide.

But it's true, if you start getting complacent you're gonna have problems. I wrecked a few good templates lifting a router too early or cutting too close to (over) the line and even had a drill bit explode on me ???

I'm actually surprised I've made it to 20

Explorerlover

Wizard wrote:
Alan Ratcliffe wrote: The guy I (sort of) apprenticed to eventually lost two fingertips and thumb on his right hand to his table saw. The thought still gives me chills.
I've often been tempted to get a table saw because of the expected extra accuracy and repeatability.
But i'm just too scared of that exposed blade looking up at me.

I got past that fear, but also, when it's on, I make sure I stand next to it. Not ideal, but still, just that sound when it starts up is enough to make me think twice. On the router front, I have also bought one and just taken it out of the box to look at it. Too sh!tscared to use it.

G-Man

I think that the key to wood working with power tools is to never do anything in anger. Always think about your task and then set about it in a robotic and methodical manner, even if that is not your normal way of going about things in the workshop.

I had a few scary moments while working with my bass guitar build and all of them were from a lapse in concentration from not taking enough breaks in between tasks.

Still got all my fingers!! ?

Shibbibilybob

G-Man wrote: I think that the key to wood working with power tools is to never do anything in anger.

Yeah man. If you feel yourself getting frustrated, then it is time for a break.

lapdawg

Last year I came home from work, feeling tired & went straight into my workshop. I inexplicably put my hand into the table saw whilst my eyes were fixed on the spinning blade. I cut through the plane of my left index finger nail and put a 5mm slot in my index finger. The nail was virtually gone & some flesh underneath. Fortunately I it all grew back - somehow.

I was really angry with myself. I now have a slight fear when putting my hands near any power tools. I was lucky & learnt a good lesson.
If you find yourself getting too casual, then you are in danger.

Wizard wrote: I now have a picture with a checklist.
Hopefully this will lead to some learning.

I now also have this pic & checklist. Thanks Wizard. These things must be familiar to anyone who has done this sort of work. I understand the frustration - only too well. I have found that good, broad roll of double sided tape works brilliantly. I always use it when clamping templates now. It works so well that you can hold back on how tight you clamp. Also, where possible, I prefer to use a template guide ring in the router for the first cut. This leaves a lip a few mm. Its a good dry run for checking template stability and also makes the final bearing guide cut much easier.