I was making my second to final pass on an ogee edge routing in poplar earlier when the bit tore out a chunk of the wood. Not sure what I could have done differently. I used a scrap backing block anywhere I could but this happened as the bit came off of the end grain side where it meets the edge grain. Since the piece was routed all the way around a little at a time and then the bit raised slightly for each consecutive pass the front edge had already been routed so no backing board would have helped this. Fortunately I didn't panic and thought through a few solutions before attempting a fix. My fix ended up being to finish routing the piece and then glue the chunk back in and blend it in with the router a micro cut at a time. I used an artist paint brush to fill the void with a thin layer of glue, pressed the piece into place and waited about 15 minutes for it to set. It was well proud of the surface since I had finished the route before starting the repair. I maybe should have glued it in first and then finished the route but in the end all came out well and I'm very pleased with the results. It looks so good I'd never know it happened.
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