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Nov 8, 2015 at 9:12 vote accept LeFauve
Nov 7, 2015 at 7:04 comment added Jack The router does not need to be cut full depth of the recess. If you cut in 1/2" max, that will give enough surface for glue bonding and enough thickness for durability. The edge looks like it is about 1/2" away from the edge, cutting with in a 1/4" with a SHARP bit will work. I like the idea that the dummies book presents, with the 2 different size collars, you could make the patch the shape of an amoeba with limitations of course and the fit will still work. The idea was with the patch was to have round corners as it was, even if it is only a 1/8" radius.
Nov 6, 2015 at 23:41 comment added LeFauve Now that I know the proper name of this method, I found this video: youtube.com/watch?v=Ld6HI7g_U6Q . It sounds like what the article on dummies.com describes, however I noticed the issue with corners that of course cannot be made by a router bit; Wouldn't it be easier to use a "round rectangle shape", so there won't be any straight corner and the router will cut the perfect shape without any need of using a wood chisel?
Nov 6, 2015 at 23:24 comment added LeFauve Thanks, I heard about this method but never find a detailed way to do it. I'm very tempted to give it a try; especially since from what I understood if it goes wrong I can make a slightly bigger template and try again; my only concern is those holes are very close to the edge of the board and I'm afraid using the router to enlarge the hole may break the outer edge. Also the holes are pretty deep. Can I put some epoxy glue in the bottom of the holes as suggested by ojait? I'll try to find one of those "router inlay kits".
Nov 6, 2015 at 16:49 comment added Jack You could choose to find a matching piece of wood to make the dutchman. It will help it blend in.
Nov 6, 2015 at 5:28 history edited Jack CC BY-SA 3.0
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Nov 6, 2015 at 5:07 history answered Jack CC BY-SA 3.0