DIY Network

Creating a Rabbet Learn how to create an inset for the cocktail table using a hand-held router. From "Freeform Furniture" episode DFFF-213

Host Amy Devers cuts a rabbet (or inset) to allow for a secure hold on the tabletop glass. She uses a hand-held router with a rabbet-cutting router bit to cut the rabbet's. Then she squares up all the corners and flips the table over to glue on the legs.

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	Room: Before
	Room: After
	Host Amy Devers creates this modern contemporary...
	cocktail table that defines Freeform Furniture.
	Amy makes the recess cut in the table to hold the glass.
	Figure A
	Figure B
	Figure C
	Figure D

Materials:

white oak wood
stop block
straight edge ruler
pencil
clamp
pipe clamps
bar clamps
yellow wood glue
small synthetic brush
cauls
cotton rags
marking gauges
glass insert
scrap blocks of wood
oil-based wipe-on polyurethane
cup
respirator
rubber gloves
prefabricated feet
felt pads

Tools:

combination square
table saw
cross cut sled
tenoning jig
hand plane
bench top mortise
1/2" mortise bit
chisel
mallet
handheld router
random orbital sander
drill
soft, rubber mallet

Creating a Rabbet

1. The tabletop won't hold a piece of glass in place as is, so you need to cut an inset around the inside edge — called a rabbet. A rabbet is just a recess cut for a panel insert.

2. Cut the rabbet with a hand-held router fitted with a rabbet-cutting router bit (figure A).

3. Set the depth to a 1/4" depth and just dig in.

4. With the tabletop clamped down, move the router carefully around the inside edge.

   Note: When routing inside edges, it is always better to move the router in a clockwise motion.

5. Once you make one pass with the rabbet bit, change out to a smaller bearing. The reason for this is because it isn't a large enough rabbet and you can only take off so much material at one time with the router without burning out the motor.

6. By putting on a smaller bearing, move the cut over by another 1/4" and make the rabbet just the size you want it to be.

7. Do another pass on inset with the hand held router.

   Note: Always pull the router toward your body as you work around the piece. This will help you maintain better control as you shape the groove.

8. Once the recess is in, the glass should fit nicely in there. The glass is square so you need to take a mallet and chisel and square up the corners that were left rounded by the router bit (figure B).

9. Use the combination square and mark some lines so you will know where you need to position the chisel.

10. Using the mallet, chip the excess wood out of each corner with the mallet.

11. Once all the corners are squared up, flip it over so you can glue on the legs. You need to do a dry clamp first so you can make sure that all the legs are lined up nice and square and perpendicular to the top.

12. Elevate the tabletop with scrap blocks of wood to give yourself enough space for the clamps (figure C).

13. Insert each of the tenon joints you made for the legs into the mortise holes of the table.

14. Get out four pipe clamps and clamp the legs to see how it all fits together.

15. Use the combination square to make sure the legs are fit at a perfect 90-degree angle.

16. After you take the dry clamp apart, put yellow wood glue inside the mortise hole and along the tenon (figure D).

17. Once the glue is on the joints, attach the legs.

18. Clamp them into place and use the combination square again to double check that the legs bond tightly to the frame at 90 degrees.

19. Use a cotton rag to wipe away the excess glue and wait for about four hours for the legs to dry.

RESOURCES :

Festool
Website: www.festoolusa.com

Stanley Tools Product Group
Website: www.stanleytools.com

Lie-Nielsen Toolworks, Inc.
Website: www.lie-nielsen.com

WMH Tool Group
Website: www.wmhtoolgroup.com

Adhesives, Abrasives and Safety Equipment
3M
The 3M Company
Website: www.3m.com

Power Tools
Porter Cable Power Tools
Website: www.deltaportercable.com

Gladiator GarageWorks
Website: gladiatorgarageworks.com

Hand Tools
Garrett Wade Co., Inc.
Website: www.garrettwade.com

The Peck Tool Company
Website: www.pecktool.com

Biesemeyer
Website: www.biesemeyer.com

Saw Blades
Forrest Manufacturing Company
Website: www.vacupress.com

Jogensen Adjustable Clamp Company
Website: www.adjustableclamp.com

Klein Tools
Website: www.kleintools.com

Power Tool Accessories
Woodcraft
Website: www.woodcraft.com

Ulmia GmbH
Website: www.ulmia.de

Shop Equipment
Eagle Manufacturing Company
Website: www.eagle-mfg.com

Delta Power Tools
Website: www.deltaportercable.com

MacBeath Hardwood
Website: www.macbeath.com

IMS Metal
Industrial Metal Supply Company
Website: www.imsmetals.com