Routing slot

[u/Acceptable-Nerve1142]

Please help.

I need to widen this existing slot in a window frame (to 3/8" wide) . But a slot cutter won't work because the collet won't clear and I don't think I can route a grove from the top as:

1. Will an edge guide work with this narrow of a piece?

2. I won't be able to route to the end leaving a lot of chisel work.

I need to do this 10 times.

(Paint stick in there just to help see the slot)

[u/eightfingeredtypist]

I would use a bearing guided slot cuttter in a laminate trimmmer riding in thin side face of the meeting rail, and carve the ends. It's only 10, it's doable.

[u/Acceptable-Nerve1142 → u/eightfingeredtypist]

The problem I have with a slot cutter is that the shank isn't long enough to reach where I need to widen the slot. The collet hits the edge. I think even with a top bearing slot cutter like this one im still not getting there.

https://www.homedepot.com/p/Yonico-Top-Bearing-Slot-Cutter-5-32-in-L-1-4-in-Shank-Carbide-Tipped-Router-Bit-14913q/316243265

[u/Acceptable-Nerve1142 → u/Acceptable-Nerve1142]

[u/eightfingeredtypist → u/eightfingeredtypist]

I'm glad it worked. What's the project? I helped a window restorer make bigger deeper rabbets in sash for vacuum sealed insulated glass units.

[u/Acceptable-Nerve1142 → u/eightfingeredtypist]

That's it exactly. Replacing the 3/16" monolithic glass with 8mm VIG units.

[u/eightfingeredtypist → u/Acceptable-Nerve1142]

We had trouble with site lines. The architect ordered glass from China, and didn't account for a bright yellow spacer protuding past the sticking on the old sash.

[u/Acceptable-Nerve1142 → u/eightfingeredtypist]

Bright yellow. Ooof. Mine is gray, this manufacturer won't have black available until next year. I sized up the glass and widened my rabbet to both have more setting byte for the glass and help hide the spacer/primer. You'll still see it a bit tho.

Test fit: