How to Route a Bullnose

Edge treatment is an important factor in finished woodworking. A tabletop in a heavily trafficked area needs to have a soft edge that will not injure someone bumping into it. Designers of office furniture often incorporate soft edges into their designs. The bullnose router bit offers a quick method for creating this soft or rounded edge. Route a bullnose with a few professional shop techniques to achieving an edge treatment that reduces the chance of injury.

Router
Bullnose router bit
Scrap lumber
Clamps

Instructions

- 1
  
  Measure the material carefully before purchasing the router bit.
  
  Select the correct router bit. Bullnose router bits have a "U" shaped blade profile. The bit comes in a number of sizes based on cutting radius. Choose a blade size whose radius is half of the material's thickness. If a 1-inch thick piece of material is being used, choose a bullnose bit with a ½-inch radius. Match the bit's shank size to the router's collar size.
- 2
  Insert the bullnose bit. Loosen the router's collar with either the wrench that came with the router or a small crescent wrench. The collar holds the router bit's shank to the router. Insert the bullnose bit, shank first, into the collar. Make sure the bit's shank is inserted all the way into the collar's cavity. Tighten the collar and the router is ready.
- 3
  Prepare the router guide. To ensure an even cut, a cutting guide must be created. The router will travel along the guide. Measure the distance between the center of the bit and the outer edge of the router's faceplate. Transfer that measurement onto the material being routed. Mark the distance in two places along the section of material being shaped.
- 4
  
  Always clamp the guide to the material being routed.
  
  Set up the guide. Lay a piece of scrap lumber, equal in length to the edge being routed, on top of the material being shaped. Lay the long edge of the lumber parallel with the edge being routed. Line up the edge of the scrap lumber with the two marks previously created. Hold the lumber in place with two clamps.
- 5
  
  Ensure that the material is clamped to a work bench.
  
  Clamp the material down. Hold the material to the work bench with a pair of clamps. Allow the material being routed to hang over the edge of the bench by at least 3 inches. Push on the clamped material to ensure it is held firmly in place.
- 6
  Route the material. Turn the router on. Allow it to reach its maximum speed. Position the router against the guide at the point where the material and guide meet. Slowly push the router along the guide until it reaches the other side. Gently pull it away from the guide. Turn the router off and check the cut. If the cut is rough, make another pass with the router.

How to Build an Under-the-Counter Wood Wine Rack

How to Make a Handle for a Rod

Woodworking