How to Make Decorative Cuts in Wood Beams

Lay the beam down onto several carpenters horses. It must be firmly supported along its entire length. Use wood clamps to attach the beam securely to each wooden horse.

Trace a pattern onto the beam, if so desired. Letters, designs, animals or whatever your fancy, can all be obtained from the Internet and printed out. Pressing hard on the lines of the design as it is placed over the beam will make a slight indentation into the wood. This indentation can then be highlighted by going over it with a permanent marker.

Select the correct bit to use for the router. Various types will work such as V-shaped router bits for lettering, plunge router bits for decorative cuts, panel pilot router bits for designs and several other types for the decorative cut you need. Always choose a router bit that does not have a pilot bearing on the bottom.

Put on safety glasses, a long-sleeve shirt and use ear protection before cutting.

Adjust the router bit for depth. The less depth you choose, the easier it will be to make the cut. Always begin cutting in the opposite direction that the bit is turning. If the bit is revolving to the left, make your cuts moving to the right.

Begin cutting at the edge of your design. This is a freehand cutting project, so always cut slowly and let the router do the work. Don't force the router bit to cut faster than it wants to, or you will burn the wood. Follow the design to the best of your ability. It doesn't have to be perfect because the beam will be mounted several feet overhead and slight imperfections will not be seen at that distance.