Easy Router Jig for Flush-Trimming Plywood Edging
Plywood is a great material for building cabinets, shelves, and furniture. But exposed plywood edges don't always provide the finished look you're after. That's why I often cover them with strips of solid hardwood edging.
To make sure the plywood edge is completely covered, I start with edging that's slightly wider than the thickness of the panel. Once the glue dries, the excess edging can be trimmed flush with the plywood faces.
A hand-held router equipped with a flush-trim bit makes quick work of the job. The challenge is keeping the router steady while balancing it on the narrow edge of a plywood panel.
These simple shop-made panel supports make the process much easier.
Build Simple Supports for Plywood Panels
The supports are easy to make from scrap plywood. I used 3/4"-thick plywood for mine.
Each support consists of a long base, a center divider, and two shorter outside supports.
Start with a long plywood base that provides enough room to clamp the support securely to your workbench.
Next, glue together two layers of plywood to make the center divider. Attach this divider upright to the base.
The center divider separates the two panels being trimmed and provides a solid surface for clamping them in position.
Finally, add a shorter outside support on each side of the divider. These pieces hold the panels upright while you install the clamps.
Set Up the Panels for Flush-Trimming
Using the supports is straightforward.
Position the two supports near opposite ends of your workbench, align them with one another, and clamp both bases securely to the bench.
Slip a plywood panel between the center divider and an outside support on each side.
Then clamp both panels firmly against the center dividers at each end.
With the panels supported upright, their top edges provide a broader, more stable surface for the router to ride on.
This helps prevent the router from tipping as you trim the hardwood edging.
Trim the Hardwood Edging Flush
Once the panels are securely clamped, install a flush-trim bit in your router.
Adjust the bit so the bearing rides against the plywood face while the cutting edges remove the excess hardwood edging.
Before routing, make sure the clamps are clear of the router's path and that the bit won't contact the supports.
Keep the router base flat against the supported panel edges and move steadily along the workpiece.
Woodsmith Tip: Pay attention to the direction of cut. For the setup shown, rout around each panel in the clockwise direction as indicated in the drawing. Verify the correct feed direction for your router and bit, keeping the cut against the bit's rotation to maintain control and avoid climb cutting.
After routing, a little light sanding is usually all that's needed to blend the hardwood edging smoothly with the plywood faces.
A Handy Router Jig for Plywood Projects
These simple supports take the balancing act out of flush-trimming plywood edging.
By holding two panels upright and securely clamped, they provide better support for the router and make it easier to produce smooth, even results.
Best of all, the supports are inexpensive to build from plywood scraps and can be stored away when you're finished.
It's a practical jig worth having on hand whenever you're building cabinets or furniture from plywood.
More Ways to Flush-Trim with a Router
A flush-trim bit is one of the most useful router accessories for cabinetmaking and furniture projects. But when you're working with narrow edges or awkward surfaces, the right jig can make all the difference.
Learn another way to get precise results with our How to Flush Trim Wood with a Router Jig article.
LEARN MORE ROUTER FLUSH-TRIMMING TIPS → Get Cleaner, More Accurate Flush Cuts
