Carving Mantels With a Router

Place the mantel board on a work bench with one 8-by-48-inch side resting flat. Clamp the board to the bench at each end with bench clamps. Tighten the clamps so that the board will not move.

Insert a 1 3/8-inch Roman Ogee bit into the router. Rout the profile of the bit along one 48-inch edge of the board in a smooth, steady motion until the cut is complete. This is the front top edge of the mantel.

Remove the bench clamps and stand the board with the 4-by-48-inch side flat on the bench with the front top edge up. Clamp the board in place. Rout the 4-inch side top edges of the mantel in the same manner as you did in Step 2.

Unclamp the board and place it back flat like it was in Step 1. Clamp the board to the bench. Insert a 1/2-inch roundover bit. Rout along the bottom 48-inch edge of the mantel board in a smooth, even motion until the cut is complete. Remove the clamps.

Rest the top 4-by-48-inch side of the board flat on the bench and clamp it down. Rout the 4-inch side bottom edges with the router equipped with the 1/2-inch roundover bit. The 48-inch routed side of the board is the front of the mantel. The 4-inch sides are the ends. Remove the clamps from the mantel board.