: I need to cut a slot in my hull 1/2" wide and about 14" long using
: an awkward router. My thinking was to cut two 1/2" thick plywood
: strips and glue 1/2" spacers betreen them at each end making a
: 1/2" slot. Then fasten this slot pattern over the area I want to cut
: out and plunge a 1/4" router bit through the boat and let part of the
: smooth bit shank guide against the pattern slot sides. It seems like this
: would work.

: John

John, it may go just fine routing the full depth at one pass, but you may want to consider taking 2 passes and only routing 1/2 the depth on the 1st path. It depends on the power of your router and the bit you are using. I would also suggest using a bushing guide on the router base plate or use a router bit with a top bearing guide to go along your plywood pattern. In both cases you 1/2" spacer would have to be a little wider to compensate for the dia of the bushing or bearing.

Using the strait shaft of the bit to guide you may be iffy. The spinning shaft may cut into your plywood guide and you will not get a straight cut.

If you are planning on doing it full depth at one shot, I would highly recomend getting a down spiral bit. It will push the debris to the underside and you wont take any chances of spintering the top side. If your planning on using a straight flush bit and do the job in one pass, it will take a little more muscle on both your part and the routers. You may end up with burnt edges.

What ever route you choose, practice on some scrap 1st. If your in the process of striping, then maybe you can do a test run over the cockpit cutout area.

Let us know how it goes.

Tom