For the corners I use a piece of wood 1 3/4 x 1 3/4 and cut a 45 on the band saw up to where the birds mouth starts. I save the 2 triangular pieces cut off (2 sides) and i make a jig that will cradle the piece. After smoothing the surface i use a 3/16 fluting bit set up to be 3/8 apart. I plow out the flutes using the router until I bump into the birds mouth at which point I carve the last 3 inches by hand. This is the jig
For the fluting across the top I have another jig that will allow the piece to slide thru it. I mark off lines across the work piece 3/8 inch apart and slide the board up to a mark and again using the 3/16 inch fluting bit I cut across one by one. This part is time consuming because I cut a groove, turn router off, unclamp work piece, slide up to the next mark, clamp it down so it doesn't move, start the router and plunge in to cut groove. Repeat what seems like a million times. One mistake and its firewood and a do over.
A forum community dedicated to professional woodworkers and enthusiasts. Come join the discussion about shop safety, wood, carpentry, lumber, finishing, tools, machinery, woodworking related topics, styles, scales, reviews, accessories, classifieds, and more!