How To use a router to make crown moulding - DIY Chatroom

Leah Frances · 08-14-2009, 10:50 PM

Problem: my historic house has crown moulding that is unique - store bought moulding has wrong proportions and shallow spring angles.

Here's the three piece unit I need to recreate. The right side is the 'low run'.

1. I glued up some 2x2x36 poplar stock so it would be easier to run through the router.

2. I marked the stock with the original pattern:

3. Using my table saw I eased the waste corner of the stock so the router will have less work to do:

Leah Frances · 08-14-2009, 10:55 PM

4. Using the bit for the lowest cut I make the first pass:

5. Using the bit for the next cut I make the second pass

6. Using the table saw I make an angle cut and a straight cut to separate the moulding from the stock.

Here is the original with the recreation:

It's not a perfect match, but it's in the ballpark

Leah Frances · 08-14-2009, 10:59 PM

For the top run I used some bigger stock to start:

1. Marked the pattern on the stock

2. Eased the corner with the table saw:

3. My first bit required more than one pass. I started with the bit in a low position and slowly increased it's height for successive passes:

Leah Frances · 08-14-2009, 11:03 PM

4. I changed bits for the second pass - I had to slow down the router for the bigger bit:

5. Pass 3 also required changing the height of the bit some.

Here's the almost final product with the original:

It still needs some fine tuning - but this procedure yielded me a finished product in my test runs that I will be happy using. Next step is to go into mass production.

***Nathan*** · 08-15-2009, 02:09 AM

Great walk through... thanks for adding that!

**thekctermite** · 08-17-2009, 12:11 AM

Glad it worked out for you Leah, I have to admit my previous skepticism! You did well.

Question...How are you going to cut the back of the crown from the patterned piece you show in the last picture. I'd be really concerned with the safety of doing it on the tablesaw. That would be a kickback waiting to happen.

Or with the overall projection of the three piece crown do you have enough room to basically leave it as it is and hang it?

Leah Frances · 08-18-2009, 02:16 PM

Termite - allay your fears. I'll post the pics of cutting the moulding free. I assure you - it's Team Safety First at my house.

DIYtestdummy · 08-18-2009, 07:48 PM

SWEET!

I've been thinking about doing the same for my base molding, since nowhere local has anything I want. Now that I am back on my feet (sprained foot), I have a new router plate that fits in my saw table and I've been planning jigs and sleds and bits...OH MY!

Leah Frances · 08-19-2009, 09:44 PM

Here are the next steps:
6. Using a slightly canted angle (I used 7 degrees) and set the desired depth, I make the first cut to separate the top of the moulding from the stock:

7. Using a 45 degree angle and setting a deeper depth I make a second cut for the 'back' of the moulding:

8. Using the same 7 degree angle I separate the moulding from the stock with the final cut:

Doing it in this order allowed me work both sides of the stock without ever making any risky cuts.

I ran 56 feet of one pattern today. I have a 'helper', an 11 yo who lives on my street. Tomorrow, her job is to do some light sanding and prime the moulding I made today!

hightlow · 09-04-2009, 12:33 AM

I’ll be sure to keep everyone posted.
Thank you very much for the lesson. I knew that I can do this in better way.
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