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Final Ogee over Bullnose Profile

 

All countertop fabricators have a set of edges and profiles that are used over and over.  Most have a bottom bearing that rides on the lower portion of the countertop to create a nice, smooth, consistent cut.  We rely on the bearing because cutting without one would make profiling an edge extremely time consuming.

However, there are those customers that want a something special.  You may have over twenty profile router bits, but the customer only wants a small portion of one bit as the profile.  Although it takes more time and setup, it is possible to cut without the bearing.

This concept requires the use of a standard bit with or without a bearing and a quality straight edge.

In this example, the top profile needed an o'gee cut on a countertop that was not quiet tall enough for the router bearing. We simple ran the router base against the straight edge as a guide.

 

Here's how it’s done:

 

Cutting the Profile
Profile Bit Cutting
Profile Bit 1
Finished Profile Bit

STEP 1:  Accurately measure from the center of the bit to the outside edge of the router base. Note this measurement. This can be done easily by adjusting the bottom of the bit to the bottom of the router base.

 

STEP 2:  Accurately measure from the center of the bit to the front of the router base. Note the measurement. The reason for the two different measurements is because you will want to run two separate straight edges to make a continuous cut into and away from the inside corner of the countertop.

 

QUICK NOTE: A round base can be used, but it must be perfectly centered on the router bit for accuracy.

 

STEP 3:  Measure from the edge of the countertop to the edge of the straight edge. Clamp or hot glue in place. Make sure the straight edge is parallel to the edge for best possible appearance.

 

If you are cutting a lot of edge, you may want to cut a guide to quickly duplicate the offset.

 

STEP 4:  Start the cutting from left to right or counter clockwise. This will help in case there is any blowout as you finish the cut.

 

With this particular edge profile, the bottom portion was created as a separate piece and attached later. The upper portion is the o’gee profile.

 

This edge may have been able to be cut with one, large bit, but is really too much for a 3HP router.

 

Hope this helps and good luck on your next project.

 

About the Author:  Andy Graves is the owner and operator of Olive Mill Manufacturing Inc. in Anaheim California.  Olive Mill specialized in residential and commercial countertop fabrication/installation.  Graves can be reached at olivemill@gmail.com   Visit his website:  www.olivemill.com

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