Step 1
Cut a Chamfer
On a table saw, rip the stock to the appropriate size. Next, cut a chamfer into the edge of the wood to give it a finished look. To cut the chamfer, first set the blade angle to 45 degrees and cut a sliver of wood off of the edge. Be sure to use a stock throat plate, because it may not be possible to use a zero clearance throat without binding. Add chamfers to as many edges as needed.
Step 2
Cut a Groove Into the Wood
On a router table, cut a groove the size of the bar stock into the wood, using a bit that corresponds to the size of the bar stock. Use a featherboard on the router table to hold the wood against the fence to get as accurate and clean a cut as possible.
Step 3
Sand the Groove and Insert the Bar Stock
Before putting the aluminum bar into place in the groove, use a random orbit sander to polish it first. Use a high-grit sandpaper to achieve a glossy finish. Placing a rubber pad underneath the bar stock will prevent it from shifting while sanding. Place the bar stock into the groove. A rubber mallet may be necessary to coach it into place.
Step 4
Adhere the Bar Stock to the Wood
Use contact adhesive, white glue or screws to hold the bar stock in place. If screwing the aluminum bar stock to the wood, first cut clearance holes for the screws into the bar stock using a drill press. Use a bit that makes it possible to countersink the screws.
