I am looking for a flush cut router bit for making a one piece form. Like the article described in Bowyers journal. Problem is I have a router with a 1/4" shank and I can't find a bit that cuts deep enough to get all the way through the form in a single pass. Does anyone make one or am I going to have to buy a router with a 1/2" shank to get the 2" cutting depth? Also , what type of bit is reccomended? Double flute, triple flute, spiral cut etc? Thanks Steve

Steve,

If you can find a bit with the bearing at the top that is over 1" depth, you can follow your form and make the first pass.  Then turn the form over and use another with the bearing at the bottom that has over 1" depth.

Good answer Bullofthewoods.  I would keep it simple and go slow with a good double flute.

Steve, I have a router with the small shank also. I bought the longest straight cut bit I could find. I think it was a little over 2" total length. When I make my forms, I make several passes cutting only 1/8" to 1/4" at a time and lowering the depth each time. I have to pull the bit out of the arbor a little to make it cut completley through with the last few passes but I just go slow and it seems to work fine. Mike

I have a 2 in. pattern bit set up on a router table (two horse power). I bandsaw the form as close to the line as possible. Then you have maybe a 1/16 or less to take off with the router.

Steve
Amana makes a 2-flute top bearing router bit that has 1 1/4" cutting surface and a 1/4" shaft. Use this bit on you pattern to cut the first 1" of your form and then remove your pattern and lower your bit so the bearing is know running on the smooth part of your form you already shaped with your first pass. I would definatly cut down close to your line with a bandsaw like Crooked Stic advised. The Amana Part number on the bit is 45461.