Killing Flies With an ICBM

Everyone should own a milling machine.

I had a problem with the guitar I’m making. I routed a cavity bigger than it should have been, and I had to make some 0.7″-thick inlays to fill it so I could start over. I was piddling around, trying to get my router table to work so I could put perfect 1/4″ corners on the inlays (to match the cavity cut by a 1/2″ router. I started thinking, “Man, I wish I had a 1/4″ roundover cutter for the milling machine.” Then I realized…I had a collet that would fit the router roundover bit.

Naturally, that put all thoughts of routers out of my head.

I started machining the inlays. Man, what a difference. I face-milled each one down to within 0.010″ of the correct thickness. I made the edges perfectly square. I used the band saw to cut them to length, but truthfully, and end mill works better. The cuts are virtually perfect, and the surfaces are glassy.

I stuck the router bit in the mill and made that corner. It probably took 15 minutes, because I had to sneak up on it on two axes. But by the time I was done, it was much better than anything I could have done on a woodworking machine.

Unfortunately, when I was using the band saw to rough-cut the pieces down close to the right size, I made a cut from the wrong end and ruined an edge adjoining the nice corner I made. So I have to make that corner all over again. Still, the mill is amazing. I should use it for face-jointing difficult pieces of wood.

I don’t know why more woodworkers don’t use mills. I know they cost a lot, but for precision joinery, they blow woodworking tools out of the water.