How do I do this?
I am trying to cut two pieces of wood to fit together with joinery integral to the seam. For example, I want to cut a wave patten on the edge of one board, and then make a negative of that cut on another board, so they fit together perfectly without the need for extra joinery.
I can't use a router bit to do this easily, as the bit cuts the positive of the form with the inside radius of the bit, and the negative of the form with the outside radius resulting in different shapes.
I also cant get the perfect fit I need for a good glue joint by using a jig saw and a spindle sander. It looks perfect, but I can still see light through the seam in places.
I have also tried a template, router, and collar in an attempt to use a small collar and the outside radius of a bit to cut one side, and a large collar and the inside radius to cut the other. This works for smooth curves, but when the curve gets tight or comes to a point, I don't think this method will work anymore (although I have not tried it on anything other than a smooth curve).
Am I missing something, or is this just incredibly difficult to do?