Notching wood with a router is an essential woodworking technique for joining pieces of wood. This comprehensive guide will teach you everything you need to know about using a router to cut notches, from choosing the right bit to calculating the notch depth. With just a few tools and these easy steps, you'll be notching like a pro in no time!
Notching is the process of slicing into a piece of wood and making a groove or indentation. Notches provide structural support and allow two pieces of wood to intersect perpendicularly. When done correctly, they form a tight joint that helps strengthen the overall wood framework.
In this must-read guide, we'll cover when you need to notch, how to choose the notching position and depth, the notching process step-by-step, and tips for perfect notches every time. With over 10 years of experience in the woodworking industry, I'll share everything you need to become an expert at using a router for wood notching. Let's get started!
When Do You Need to Notch Wood?
Notching is necessary when you want to join two pieces of wood at a 90 degree angle. Common examples include:
- Building a wood frame for a shed, fence, deck, or other structure
- Constructing wood furniture with right angles like beds, chairs, tables, etc.
- Assembling cabinetry and enclosures
- Creating wood frameworks for doors and windows
Without proper notching, the perpendicular wooden pieces won't join tightly. This weak joint will cause the wood structure to be unstable and can lead to breakage as the framework grows under the weight of heavy objects.
Proper notching helps strengthen the joints by increasing the surface area for gluing/screwing. The notches also provide mechanical support to prevent lateral movement or twisting. So notching is a must for rigid, long-lasting wood structures.
Choosing the Notching Position
When notching wood, the first step is deciding where on each piece of wood the notches should go. This notching position will depend on the type of joint you are creating.
Consider the cross-sectional dimension of the wood pieces as well as the layout of the overall project. Generally, the notches should be made half-way through the thickness of each piece of wood.
For example, if joining two 2x4s with 3 1⁄2” thickness, the notches should be 1 3⁄4” deep. Mark the measurement carefully on both pieces using a marking knife, pencil or awl. This will be the notching position.
How Deep Should the Notch Be?
The depth of the notch is one of the most important factors for a secure joint. If the notch is too shallow, the wood pieces won't fit together snugly and the joint will be weak. If you notch too deep, you risk cutting through the entire thickness of the wood.
As a general rule of thumb, the depth of the notch should be half the thickness of the wood piece. For example, for 3/4" plywood, cut a 3/8” deep notch. For 2x4s, aim for a notch depth around 1 3⁄4”.
For heavier projects, you may need to notch deeper to provide adequate structural support. The ultimate notch depth depends on the joint type, wood thickness, and dimensions of your project. Do some mathematical calculations to determine the required notch depth for each joint.
Step-by-Step Wood Notching Process
Now let’s walk through the wood notching process from start to finish:
Gather Your Materials
- Router with straight cutting bit
- Safety glasses & ear protection
- Wood pieces for notching
- Pencil or marker
- Measuring tape
- Clamps & scrap wood to secure piece
Mark the Notches
- Mark the center point of where your notch will go with a pencil or awl.
- Use a measuring tape and mark out the total length and depth of the notch.
Secure the Wood Piece
- Use C-clamps to firmly secure the wood to a work table or sawhorses.
- Position so notch mark is unobstructed and router will have room to move.
- Place scrap wood under the notch area to protect from tear-out.
Cut the Notch
- Equip your router with an appropriate straight cutting bit. Insert into the router collet.
- Position the router over your notch mark, lining up the bit with pencil lines.
- Make several shallow passes to slowly cut the notch to the desired depth.
- Rout in one direction until desired depth is reached.
- Repeat on the second wood piece, using the first notch as a template.
Smooth and Complete the Joint
- Use a chisel to square and smooth the curves of the notch.
- Test fit the two wood pieces together and check for tightness.
- Make additional passes with the router or trim with a chisel if the fit is too loose.
- Once the perfect fit is achieved, glue and/or screw the pieces together.
Tips for Perfect Wood Notches
Follow these best practices and you’ll be notching wood like an expert carpenter in no time:
- Always review router safety before attempting any project. Keep hands away from spinning bit!
- Work slowly and make several shallow passes rather than gouging out too much wood initially.
- Position your body and hands safely throughout the process and maintain control.
- Use sharp router bits specifically designed for notching. Multi-flute straight bits work well.
- Cut perpendicular to the wood grain for cleanest edge. Cutting across the grain can splinter the wood.
- Clamp wood securely and check for movement before starting. Use scrap wood to reduce tear-out.
- Visually inspect progress frequently. Stop to reposition if necessary.
- Make small final trimming cuts with a sharp chisel for perfect fit.
- Practice on scrap wood first to master the technique before notching your final project.
Conclusion
Notching wood is a vital joint-making skill for both hobbyists and professionals. By following this step-by-step guide, you can become proficient at using a router to cleanly and accurately notch wood.
Keep these key tips in mind:
- Notch halfway into the thickness of each piece
- Calculate the required notch depth for sturdy joints
- Cut notches precisely with a router and straight bit
- Work slowly and safely
- Smooth and perfect notches with a chisel
- Practice on scrap wood to build expertise
With the right techniques, you’ll be ready to incorporate secure notched joints into all sorts of woodworking projects. So grab your router and let’s start notching!