Wanted to throw out something here to see if it makes sense or not among the more experienced woodworkers.
I purchased the Adirondack chair plans from LV as I want to make a couple for the lake. Now I expect that I will be making more than one or two at some point so I figured I would make templates of the parts using 1/4 hardboard. I glued the entire plan on a 4x4 sheet of board, then cut them out on the BS. My thinking on this was that I would have patterns that would last longer than paper alone, and that I could rough cut the parts out of cedar, then screw the hardboard templates on and trim on the router table with a flush cut bit with hopes of eliminating as much sanding as I can. (I hate sanding). For the most part the routered pieces are smooth except for some of the opposite grain sections
Found two problems with this plan so far:
1. It appears as though my BS blade might be dull as I seem to have had a bit of a rough finish on the hardboard. Enough so that the bearing would reproduce the surface ever so slightly. I then lighty sanded (ugh) that hardboard so that it would be smooth.
Lesson learned - a flush cut bit will reproduce even the smallest ridges so get a new BS blade to see if that makes cuts smoother.
2. while executing the router flush trim plan I encountered a slightly scary scenario that basically tore the half of the piece from the part I was holding. Granted, I was on the end grain portion however I am only taking 1/6 at most from the parts and I had done a few already, so this was a bit suprising.
I am using the posts incorporated into the table to brace the work, and I am feeding the material correctly.
Can I assume that the trim bit is just dull and subsequently scrap metal (not sure if they can be sharpened and still be used for flush cut being undersized to the bearing). It is cedar and I don't expect that this would happen with hardwood but it's a bit of a scary event when half of the part goes flying; but at least the finger count was positive.
Am I complicating this more than I have to and maybe just cut them all out on the BS with a new blade, then sand? Does this mean I need another tool!
Thoughts would be appreciated!