I’ve always cut/glued/pinned returns on my stool horns. However last week while installing an unusually wide stool, I found I couldn’t easily cut it with my miter saw and I began to rethink the idea of milled horns. I looked at my local dealers and couldn’t find an appropriate router bit so my question to you is what do you use to mill returns to match the stock profile on Lowe’s/HD stools. Thanks
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Replies
I've used this Eagle bit for years, it's a good performer. I'd now get the bearing model which would be a plus all around, but particularly for the mock returns.
Clamp your stock between start and end boards to insure that your bit doesn't get on the wrong side, the window side of the stool, and to prevent tearout on the end of the cut.
Once the ends are routed, sand, wet the stock, sand, prime, sand and prime again maybe to to get the ends as smooth as long grain.
For most uses I find that enough clear wood can be found from #2 5/4 pine. Flatness is imperative since you will be cutting the top and bottom profiles at the same time. Any movement up and down will ruin a cut. Or necessitate another pass. Don't rip until you have the clean profile you need on all three sides.
Maybe that's more remedial that you need.