To extend a routed rabbet to the inside corners of a cabinet door or frame, you can follow these steps:
Assess the rabbet: Determine the depth and width of the existing routed rabbet on the cabinet door or frame. This will help you understand how much extension you need to create.
Mark the extension lines: Use a pencil and a square to mark the extension lines on the inside corners of the rabbet. Extend the lines to the desired depth and width of the rabbet extension.
Prepare the router: Install a straight bit with a bearing guide on your router. The diameter of the bit should match the desired width of the rabbet extension.
Set the depth: Adjust the depth of the router bit to match the desired depth of the rabbet extension. Ensure that the depth is set accurately to avoid cutting too deep or too shallow.
Secure the workpiece: Place the cabinet door or frame on a stable work surface. Use clamps or a vise to secure it firmly, ensuring that it won't move during the routing process.
Rout the extension: Position the router over one of the marked extension lines, aligning the bearing guide against the edge of the workpiece. Turn on the router and carefully move it along the extension line to rout out the extension. Keep the router base flat against the workpiece to maintain a consistent depth.
Repeat for other corners: Once you've completed routing the extension on one corner, move on to the next corner and repeat the process. Take your time and work slowly and steadily to ensure accuracy.
Test the fit: Once you have routed the extensions on all the corners, test the fit of the cabinet door or frame to ensure that the extensions align properly with the existing rabbet. Make any necessary adjustments if the fit is not satisfactory.
Sand and finish: Sand the routed edges to smooth out any roughness. Apply any desired finish or paint to match the existing surface of the cabinet door or frame.
Remember to prioritize safety while working with power tools. Wear appropriate protective gear, follow the manufacturer's instructions for your tools, and exercise caution throughout the process.