How to Cut Smooth, Accurate Slots with a Router
Whether you're making handholds for a tool tote, openings in a cabinet, or slots for another woodworking project, getting smooth, even edges can be a challenge. Cutting the opening is only part of the job. The real trick is making sure the sides are straight and the rounded ends look clean.
Fortunately, you can create professional-looking slots using a Forstner bit, jigsaw, and flush-trim router bit, along with a couple of simple guide blocks.
Drill the Rounded Ends of the Slot
Start by laying out the slot on your workpiece, marking both ends and the straight edges.
At the drill press, use a Forstner bit that matches the desired width of the slot. Drill a hole at each end to establish smooth, consistent curves.
Next, use a jigsaw to remove the waste between the holes. Stay slightly inside the layout lines so there's a small amount of material left for the router to remove.
Use Guide Blocks for Straight, Smooth Edges
The secret to getting clean, even sides is a flush-trim router bit and a pair of straight guide blocks.
Apply double-sided tape to the guide blocks and position them along the layout lines on opposite sides of the slot. These guides provide a straight reference surface for the bearing on the flush-trim bit.
At the router table, adjust the bit so the bearing rides against the guide blocks while the cutting edges remove the remaining waste.
Carefully rout both straight edges, using the guides to produce a smooth, consistent opening.
Clean, Professional-Looking Slots Every Time
Once the routing is complete, remove the guide blocks to reveal a neatly shaped slot with straight sides and smoothly rounded ends.
This simple technique is especially useful for creating handholds in tool totes, shop storage projects, and other woodworking assemblies. Best of all, the same approach can be repeated to make multiple matching slots without complicated jigs.
Featured Project: Utility Tool Tote
Put this slot-cutting technique to work with our versatile Utility Tool Tote. This hardworking shop project combines portable tool storage with a sturdy step stool, featuring a sliding tray, open cubbies, and plenty of room for everyday tools. Large cutouts provide easy access to the storage compartments while giving you an opportunity to practice making smooth, accurate openings. Get the step-by-step plans and build a handy workshop accessory you'll reach for again and again.
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