Step 1

Use an oddment of 8mm ply to make a circle jig, mark a line down the centre. At one end, bore a 25mm hole for the router cutter and two smaller holes to bolt it to the base of the router.

Top Tip!

Don’t over tighten the bolts as there’s a possibility of stripping the threads in the router base.

Step 2

The radius of the finger pull was set to 250mm by drilling a small hole for a pivot screw at the correct distance.

Setting the radius for routing

Step 3

Insert the 19mm cutter into the router and screw the circle jig into the template material. The router will now cut a curve with a radius of 250mm. Plunge the router several times into the template to form a curved shape of the required length. The last cut should pass completely through the material. Unscrew the circle jig from the template material.

Step 4

Remove the 19mm cutter and insert the 8mm bit. Install the 12mm bush into the router, giving a 2mm offset (12-8÷2=2mm).

Want to brush up on fitting Router Bushes?

Read this How To article which includes a chart guide to the offset.

Go to article

Bush and cutter inserted’

Step 5

Clamp the template to the project such that the curved finger pull will be routed in the correct location. The final width is 15mm (19-2-2=15mm) as the cutter is worked firstly along one side of the template and then the other.

Step 6

Remove the cutter and bush, replace them with a bottom bearing chamfer cutter. The hard edge of the finger pull is softened by machining a small chamfer all the way around.