My friend Casey asked if I could make his vision come to lift as a gift for his wife Maggie. Here’s his sketch.
He picked up a nice piece of maple, which I cut and glued up. I’d never made recessed cuts in wood before, so that was a fun challenge to tackle. I bought a piece of acrylic and made a large base for my palm router.
Then I made a 4″ circle template in some scrap plywood by cutting a large hole with a forstner bit, getting close to the line with the router, and finishing up on the oscillating spindle sander.
I attaching the template to the maple by using blue tape on each surface and then some CA glue with activator in between the taped surfaces. I used a flush trim bit with a top bearing in the router to copy the template. It was much easier than I expected.
To cut a slot for an iPad I clamped down some scrap wood to create a border for the palm router and it’s original base. I didn’t have the iPad so I cut thin plywood to a similar size for testing, while also making sure the slot would work for future iPad sizes.
I cut and attached runners, rounded all of the corners and edges, and gave everything a thorough sanding.
My work was done at this point, since Casey was taking care of the finish to match their bathroom cabinets. It turned out great and we had a happy recipient!