To scoop out the concave front of the handles for the Dashing Dresser in Woodsmith 261, we used this router jig. The sides of the jig have rails to support a router attached to a wide base plate. A turntable set between the sides and base holds the workpiece.
To build the jig, start by cutting all pieces to size, then drill out the dust ports in the ends (detail ‘b’), the bit hole in the router base (detail ‘c’), and the holes for the dowel in the base and turntable. Next the sides need to be curved. After cutting them to size, I made my own beam compass out of scrap pieces to lay out a 26½" radius on one side. I cut the curve at the bandsaw, cleaning it up on the spindle sander (while being careful to keep the curve smooth). I then used the first side piece to lay out and trim the second side piece to match.
I assembled everything using #8 woodscrews. To scoop the handles, use double-sided tape to fix it to the turntable, then run the router along the concave rails, rotating the handle between passes.
Related: Best Measuring Tape
